NEDO PROJECT COURSE 50
Technology Development for Environmentally Harmonized Steelmaking Process
Workshop on Delivering Green Growth
Seoul Korea March 4, 2010
P 1 COURSE 50
P 2 Drastic CO2 emissions reduction in steel industry ・Basic idea –1) Decrease of reduction amount (increased use of scrap) : Outside the scope –2) Iron ore reduction (adopted) Alternative reducing agents Reduction by carbon
Steps for (1) Utilization of hydrogen (1)CO2 capture radical ① Natural gas ① CO2 capture from BFG reduction ② By-product gas ・ Chemical absorption ・ Physical adsorption
Scenario 2 Scenario 1 1) Maximum use of waste heat 1) Further improvement of COG reforming 2) Expanded use of waste heat efficiency by the use of waste heat through CO2 absorbent 2) Verification of best solution for reformed development COG utilization 3) Utilization of external energy (2) Direct use of electricity sources
① Hydrometallurgy ② CO2 capture from other reduction processes (3) Use of C-Neutral agents ・ Coal-based Smelting Reduction ① Biomass ・ Coal-based Direct reduction ・Charcoal reduction, waste use P 3 Innovative Technology Development - Innovative Steelmaking Process
• Even with enhanced energy-saving, emission of CO2 is unavoidable. • COURSE 50 aims at developing technologies to decrease CO2 emissions by approximately 30% through reduction of iron ore by hydrogen as well as capture – separation and recovery – of CO2 from blast furnace gas. • The initiative targets establishing the technologies by ca. 2030 with the final goal of industrializing and transferring them by 2050, taking advantage of renewing blast furnaces and relevant facilities.
Outline of COURSE 50 1. Total budget: approximately 10 billion yen (planned) 2. Term for R&D: Step 1 of Phase 1 for 5 years (Fy 2008 – Fy 2012) 3. R&D targets:
(1) Development of technologies to reduce CO2 emissions from blast furnace
(2) Development of technologies to capture - separate and recover - CO2 from blast furnace gas (BFG)
P 4 Project targets
(1) Development of technologies to reduce CO2 emissions from blast furnace ・ Develop technologies to control reactions for reducing iron ore with reducing agents such as hydrogen with a view to decreasing coke consumption in blast furnaces. ・Develop technologies to reform coke oven gas aiming at amplifying its hydrogen content by utilizing unused waste heat with the temperature of 800℃ generated at coke ovens. ・Develop technologies to produce high-strength & high reactivity coke for reduction with hydrogen.
(2) Development of technologies to capture - separate and recover - CO2 from blast furnace gas (BFG) ・Develop techniques for chemical absorption and physical adsorption to capture - separate and
recover - CO2 from blast furnace gas (BFG). ・ Develop technologies contributing to reduction in energy for capture - separation and
recovery - of CO2 through enhanced utilization of unused waste heat from steel plants.
Time Table of Technology Development 2010 2020 2030 2040 2050
Phase 1 Phase 1 Phase 2 Industrialization & Transfer Step 1 Step 2 (2008～12） (2013-17）
NEDO Project 2008 2009 2010 2011 2012 Phase 1 Step 1 0.6 2 – 3 2 – 3 2 – 3 2 – 3 (billion yen) (2008～12）
P 5 R&D Organization
Kobe Steel, Ltd. JFE Steel Corporation Nippon Steel Corporation Contract research NEDO Nippon Steel Engineering Co., Ltd. Sumitomo Metal Industries, Ltd. COURSE 50 Committee Nisshin Steel Co., Ltd.
* COURSE 50 Committee at the Japan Iron and Steel Federation (JISF) supports the 6 companies’ R&D activities. Sub Projects 1. Development of technologies to utilize hydrogen for the reduction of iron ore. 2. Development of technologies to reform coke oven gas (COG) through the amplification of hydrogen. 3. Development of technologies to produce coke for hydrogen reduction of iron ore.
4. Development of technologies to capture – separate and recover – CO2 from blast furnace gas (BFG). 5. Development of technologies to recover unused sensible heat. 6. Development of holistic evaluation technologies for the processes.
P 6 Project Management Organization JISF NEDO COURSE 50 Committee Chairman: Keisuke KUROKI (Nippon Steel) Vice Chairman: Takashi SEKITA (JFE Steel)
Project Management Project Leader: Takashi MIWA (Nippon Steel) Deputy Project Leader: Haruji OKUDA (JFE Steel)
Assistant Project Leaders
Secretaries Project Management Meeting
Total Systems WG
Intellectual Property Meeting
6 Sub Projects
P 7 Development of Technologies for Environmentally Harmonized Steelmaking Process
(1) Technologies to reduce CO2 emissions from blast furnace (2) Technologies for CO2 capture
Reduction of coke ・Chemical absorption ・ Iron ore Physical adsorption Coke production technology Coke BFG H2 amplification for BF hydrogen reduction CO-rich gas CO2 storage Shaft furnace technology COG reformer Regeneration Coking plant BF Tower
High strength & high reactivity coke Reboiler H2
Iron ore Absorption pre-reduction Tower technology Coke substitution Reaction control technology Other project reducing agent production technology for BF hydrogen reduction CO2 capture technology Sensible heat recovery from slag (example) Waste heat recovery boiler Hot air Steam Slag Cold air Kalina Electricity cycle Power generation Hot metal Technology for utilization of unused waste heat BOF
COURSE50 ／ CO2 Ultimate Reduction in Steelmaking Process by Innovative Technology for Cool Earth 50
P 8 ・Identification of issues to be solved ・Identification of feeding Sub Projects 1 & 3 by reviewing past knowledge conditions of preheated gas, regarding blast furnace operations aiming at controlling with higher hydrogen feeding. increase of ore degradation • Quantification of results of by reduction associated with Pre-heated reduction in carbon supply. gas (N , etc.) enhanced reduction by 2 *FY2010 onwards hydrogen. Gas Flow ・Development of an operation design ・ model for reformed COG usage based Quantification of improved on the heat & mass balance model. reducivity of iron ore when *FY2010 onwards feeding reformed COG. ・Evaluation of effects of ・Clarification of accompanying reactions under optimal feeding hydrogen-co-existent gas conditions of reformed conditions. COG. Reformed ・ COG Model ・Combustion simulation of experiments ・ tuyere raceways under Simulation hydrogen-co-existence.
・Development of high strength ・Evaluation of balances of coke to deal with feeding of energy and CO2 for an reformed COG. entire steelworks. P 9 BIS: Blast furnace Inner reaction Simulator
Adiabatic[ controlAdiabatic ]
Characteristics of BIS furnace ・ Pseudo-counter flow moving bed ・ Possible to simulate endothermic reaction associated with gasification and hydrogen reduction, as well as heat exchange.
BoshBosh gasgas Sinter SinterSinter Experiment under bosh gas Half equivalent of conditionscarbon was adjusted replaced to CokeCoke hydrogen supply conditions Normal Coke C50% SinterSinter + Iron- coke C50% Evaluation of thermal reserve zone CokeCoke Heating at 100 oC to prevent condensation of water
P 10 Changes in rate of iron ore reduction estimated by gas analysis - BIS experiment - 80
base 80 60 200 Nm3/tp 300 Nm3/tp ～1050℃ 40 70 3 Rate(%) 300 Nm /tp
Total Reduction Total Reduction 20 60 200 Nm3 /tp 0 30 200 400 600 800 1000 1200 50 温度 (℃)
Total Reduction RateTotal Reduction (%) 0 base 100 Nm3 /tp 20 200 Nm3/tp 40 300 Nm3/tp
(%) 0 5 10 15
Hydrogen 10 Hydrogen Reduction Rate (%) Reduction Rate Reduction Supply gas composition: 60% H2, 30% CO, 10% N2. 0 0.04200 400 600 800 1000 1200 2 base 温度 (℃) 0.03 200 Nm3/tp Total Reduction Rate increases with 300 Nm3/tp hydrogen supply; presumably by 0.02 (NL/min) ・ enhanced hydrogen reduction in thermal 0.01 Formed CO+CO reserve zone and upper cohesive zone, and
0 ・ increased CO + CO2 due to the gasification 200 400 600 800 1000 1200 of carbon by H2O. Temperature (℃)
P 11 Summary Results 2) Supplying reformed COG into shaft
Findings Improved reduction clearly observed by holistic process evaluation （ BIS, BIS+Test of high temperature properties under load）. Desirable supplying conditions; Reformed COG feeding rate >200 Nm3/tp and Interior Distribution Ratio* >20%) Interior Distribution Ratio* found low in preliminary testing. *Interior Distribution Ratio: gas distribution ratio inside the furnace
Issues Measures to improve Interior Distribution Ratio; Supplying height, velocity, nozzle shape and injection angle. 1) Supplying reformed COG through tuyeres
Findings
Possibility to reduce CO2 emissions by 10% at feeding rate of 200 Nm3/t. Determination of testing conditions for combustions experiments. Issues Adequate supplying conditions (feeding rate and gas analysis) Hydrogen behavior in raceways. P 12 Energy balance at a steelworks with the introduction of reformed COG process. Changes in energy input into ironmaking system being studied associated with supplying reformed COG to BF. Substitution with ; １、 Coke ＋ Supplying r. COG through tuyeres ２、Sensible heat of hot air Supplying r. COG into lower shaft ３、Pulverized coal
Energy input COG Assemblage & Gas calorie distribution Downstream Coal of gases M&H balance model Steam COG r. process Power H&M balance model BFG Coke Ovens r. COG Heat & Mass Energy subtraction Coke Balance Model BF tar,oil Rist model ＋ Hot stove Sintering plant H&M balance model H&M balance Sintered ore model
Heat for dry Heat for ignition Heat for hot stove distillation burner
P 13 Development of coke-making technology by utilizing high performance caking additive (HPC)
Blended coal HPC Strong coke
Melting Coking
HPC starts softening and melting at low temperatures below 300 oC, packing together coal particles effectively by filling gaps in between them, consequently realizing increased coke strength.
•Possible to increase coke strength without relying on blending centered on coking coal, thus realizing diversified use of coal. •Enhanced compatibility with raw materials at the time when hydrogen Experimentally produced coke with HPC (300 kg) reductionP 14 is put in practical use. HPC manufacturing test with high ash content Overflow
Set suitable conditions for slurry extraction from settling tank to overflow part of residual coal (RC) to include in HPC. 6 [wt%] 4 HPC in 2 Ash
0 10 20 30 40 50 Underflow UF flow rate [% on total slurry] Ash in HPC v.s. underflow flow rate RC Ash RC-org. Extract
HPC-0
HPC-1
HPC-3 0.1t/d HPC continuous manufacturing HPC-7 test plant （BSU） Ash combined with residual organic components 0 20 40 60 80 100 Content in HPC sample [wt%]
Components of sample HPC P 15 Coke strength when blended with high-ash HPC
86 90 Industrially feasible 85 range ] - [
15 88 84 15 150 DI base 150 Base 83 HPC-0 DI HPC-0 HPC-1 HPC-3 86 HPC-3 82 0 5 10 15 HPC blending ratio [wt%]
Coke strength when blended with high-ash HPC 84 for 8 different coals under simulated industrial 700 800 900 1000 1100 conditions. 3 （50kg furnace，B.D. 720kg/m3） Bulk Density [kg/m ]
High strength coke produced with high-ash HPC （320kg furnace）
P 16 COG Reforming Technology NSC •Steam reforming technology for tar etc. in COG, using COG thermal energy (part of results of past national project) • Newly developed catalyst
P 17 Development of chemical absorbents (Collaborative Research with RITE)
1.Development of chemical absorbent to reduce energy consumption for CO2 capture ① Identification of reaction mechanisms of chemical absorbents using quantum chemistry and molecular dynamics, as well as component designing. ② Designing of high-performance amine compounds by chemoinformatics (analysis by multivariable regression model) with the existing amine database. ③ Examination of synthesis technologies for mass production of high-performance amines. ④ Exploration of absorbents other than amines. ⑤ Evaluation of chemical absorbents by laboratory experiments and process models.
2.Testing of new chemical absorbents for industrial application ① Evaluation of new absorbents in terms of corrosivity and long-term stability. ② Support for experiments with real gas by model simulations.
P 18 Development of chemical absorbents (Collaborative Research with RITE)
Apparatus for gas-liquid equilibrium Measuring device for absorption and diffusion
・Synthesis of new amines
Carbon Hydrogen Nitrogen Oxygen Bromine
P 19 Development of the chemical absorption process
Strategy for the Cost Reduction
CO2 Separation Cost 2004Fy
（JP￥/t-CO2） 6000
Waste heat recovery 5000 Development of the chemical absorbent 4000 Optimization of the chemical Present absorption process
3000 Optimization of the entire system (with the improvement of steel-making process) Goal 2000 Heat Unit Consumption 3.0 2.5 2.0 （GJ/t-CO2） 20 Development of the chemical absorption process Test Plants Construction & Research Schedule
年月 2009 4 5 6 7 8 9 10 11 12 2010 2 3 4 5 6 3 1 1t/D Transfer, Assembly, and Adjustment Bench Plant Solvent A MEA Solvent B Test new Solvents
30t/D Construction Process Trial Run Evaluation Solvent A Plant
21 Development of the chemical absorption process
Test Equipment ：Bench Plant（1ｔ/D）
Adjacent to No.4 BF at NIPPON STEEL Kimitsu Works CO2 Off Gas
Stripper Absorber
Reboiler
22 Development of the chemical absorption process
Test Equipment ：Process Evaluation Plant （30ｔ/D）
Absorber Stripper Pre-treatment System
Pre-treatment System Stripper
Absorber
BFG
BFG Rendering of chemical absorption process Evaluation plant November 11. 2009 23 Oｆｆ Gas Development of the chemical absorption process CO2 Lean Characteristics and Performance of Amine Solvent Ａ Absorber Stripper Feed Steam CO2 Recovery Rate, Heat Unit Consumption Gas Rich 100 5.0 Amine ） 80 4.5 Stripper Bottom （％） CO2
- Temperature
60 4.0 (GJ/t CO2 Recovery Rate Heat Unit Consumption 40 3.5 Recovery Rate Recovery
CO2 20 3.0
0 2.5 Heat Unit Consumption 100 105 110 115 120 125 130 Stripper Bottom Temperature （℃）
24 Oｆｆ Gas Development of the chemical absorption process CO2 Lean Characteristics and Performance of Amine Solvent Ａ Absorber Stripper Feed Steam CO2 Recovery Rate, Heat Unit Consumption Gas Rich 100 5.0 Amine
90 ） ： L：Amine Flow
CO2 G Feed Gas
80 4.5 - Flow Rate Rate （％） 70 GJ/t （ 60 4.0 CO2 Recovery Rate 50 Heat Unit Consumption 40 3.5 Recovery Rate Recovery 30
CO2 20 3.0
Heat Unit Consumption - Lean Amine Loading 0 2.5 - Stripper Bottom Temperature 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 Ｌ／Ｇ （L/Nm3）
25 Oｆｆ Gas Development of the chemical absorption process CO2 Lean Amine Characteristic and Performance of Absorber Stripper Solvent Ａ Feed Steam CO2 Recovery Rate, Heat Unit Consumption Gas Rich 100 5.0 Amine ）
CO2 Lean Amine
80 4.5 - Loading （％） GJ/t （ 60 4.0 CO2 Recovery Rate Heat Unit Consumption 40 3.5 Recovery Rate Recovery
CO2 20 3.0
Heat Unit Consumption - Stripper Bottom Temperature 0 2.5 0.00 0.05 0.10 0.15 0.20 0.25 0.30
Lean Amine Loading （mol/mol）
Optimum Point of Heat Unit Consumption = 2.8～2.9GJ/t-CO2
26 27 Physical Adsorption Technology
Aim : Capture CO2 and N2 separately from BFG by using physical adsorption technology.
CO2 Noncombustible gases BFG N2
Ｈ2 3％ ＣＯ 23％ ＣＯ2 ＣＯ Adsorbent Adsorbent ＣＯ2 22％
Ｎ2 52％
CO, N Blast Furnace 2 CO Combustible gases H2
Gas Separation Process (PSA)
P 27 28 PSA Laboratory Test Apparatus
Adsorption Tower
Flow meter Pressure gauge
Automatic changeover valve
Gas meter
P 28 Study on recovery amount of unused sensible heat & waste heat
【 ２nd stage】 ・Heat accumulation with PCM (Phase Change Material) Recovery of waste gas ・Heat pump after steam generation by 133℃ ・Power generation with low b.p. Exhaust gas from processes new technologies medium 375℃ Ａ Ｃ PCM heat accumulation Ｂ Thermal catalyst for chemical absorption Organic Rankine Cycle Transport 105℃
Direct use of T G sensible heat 140℃ steam 140℃ steam for chemical Fuel reforming for chemical 133℃ absorption absorption Power for physical adsorption Heat pump for 100℃ high temperature Kalina Cycle Heat pump Ｄ 【 1st stage】 T G Rankine cycle for Generation of saturated medium steam at 140℃ to the temperature lower temperature limit 75℃ P 29 Technological issues
Common issues Specific issues
Boiler Improvement of heat Heat pump exchanger Enhancement of chemical heat pump ・ Scaling up ・ Increased heat transfer rate reaction ・ ・ Increase in Compactification ・ Development of catalysts ・ rate of heat Prevention of corrosion & ・ Improvement of reactors absorption PCM clogging Development of PCM & release Thermal insulation ・ Extension of temperature range technology ・ Improvement of heat accumulation density Reduction in equipment ・ Control of expansion cost ・ Improvement of corrosivity Power generation Optimization of recovery Improvement of system efficiency with low boiling technologies for various Technology to prevent thermal point medium waste heat (including decomposition of working medium combination with heat Technology to prevent leakage Direct use of heat accumulation) Fuel reforming Development of catalysts Optimal reaction conditions (steam ratio, etc)
P 30 Technology development for sensible heat recovery from steelmaking slag
Regeneration of chemical absorbent in CO2 capture process requires energy.
Sensible heat recovery from steelmaking slag is targeted. Project Scope
Roll forming process Slag pot Sensible heat recovery process Molten slag Shape controlling roll ℃ Heat recovery equipment 1600 Solidified slag 3～5mm Air Regeneration of 200℃ 1200℃ CO2 absorbent Approx.1ｔ/min ≧ Trough 1000℃ [Target] Cooling roll 600℃ ① Recovered gas （Direct aging） temperature >140℃ ② Heat recovery CaO+H2O⇒ Ca(OH)2 efficiency > 30％ 200℃ Air Sand substitute Cement additive raw material
P 31 ※ 表示温度は例 Melting steelmaking slag
・Laboratory-scale roll forming apparatus under construction ・Bench-scale roll forming equipment under designing
P 32