HIsarna, a Revolution in Steelmaking 06 21 HIsarna... · HIsarna, a Revolution in Steelmaking ......
Transcript of HIsarna, a Revolution in Steelmaking 06 21 HIsarna... · HIsarna, a Revolution in Steelmaking ......
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Paper & Steel : Common Ground?
• CO2 intensive (1.1% vs 4% of man made CO2)
• Energy intensive
• High recycling rate (70% vs 95%)
• Capital intensive
• Major facilities > 20 years life span • Large sites, large installations • Threshold for implementation of breakthrough technologies
• Trend of past 20 years
• Process efficiency, labour productivity increase • From Fragmented to Consolidated industry • Changing competitive landscape in major markets • Sustainability and Climate Change challenge
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The Challenge in Steelmaking
Growth Sustainability World steel consumption Ambition to cut CO2 emissions will double in 2050 by 50 % in 2050
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The International Approach
• Climate Change is Global
• Climate Change is Long Term
• Support at board level, governmental level, EU level
• Build industrial partnerships, bring people together
• Use a broad range of expertise
• Build a common language
The Brand:
Ultra Low CO2 Steelmaking
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The ULCOS project
Objective: 50% reduction in CO2 emissions per ton of
steel from iron ore based steel production by 2050
• Globally the largest steel industry project on Climate Change mitigation
• Core partners: ArcelorMittal, Tata Steel, ThyssenKrupp, Ilva, Voestalpine, LKAB, DillingerHütte/Saarstahl, SSAB, Rautaruukki
• Co-partners: 48 Institutes, Universities, Engineering companies, etc
• Budget: 75 M€ • Duration ULCOS I: 2004 – 2010 ULCOS II: 2011 – 201…
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Idea Experiment Pilot Demo Industry
CO2 and sustainability modelling
Selection Industrial Demo
ULCOS - I Project 2010 201.. 2004
Selection Criteria • CO2
• Economical • Technical maturity • Social acceptance • Other environmental aspects • Fit with existing configurations
Pilot plant
progress
ULCOS - II Project
Inventory of 200 process options
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Common approach, definitions, boundaries
Everything is assessed for one ton of Hot Rolled Coiled (HRC)
Classical Integrated Steel Mill
Gate to Gate approach for the
Focus area: Ironmaking is responsible for 85-90% of CO2 per HRC
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Selection Process: Funnelling the Options
CO2 and sustainability modelling
Selection
ULCOS - I Project 2010 201.. 2004 ULCOS - II Project
Top Gas Recycling Blast Furnace
Gas based reduction
Electrolysis of iron ore
HIsarna
4 processes selected
Inventory of 200 process options
Better use of Carbon in retro-fitted plants
Better use of Carbon in a new process
Replacing Carbon with Natural Gas or Hydrogen
Green power, mimic Aluminium production
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Top Three Hurdles to Manage
• Technical
• High intensity, high efficiency process development • Focus on generic long-term solutions
• Financial
• High risk, high reward • Partnering: sharing benefit + cost + effort + risk • Industry contribution
+ local / national / European funding • Organisational
• Consortium • People: availability, expertise, critical mass • Communication • Public relations • Intellectual property
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Iron ore
coal
Steel Production Process Route Where does HIsarna fit?
Ironmaking Steelmaking
Casting Rolling & Coating Steel
products
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Iron ore
coal
coke
sinter
Liquid iron
Blast furnace
HIsarna technology Comparison with the Blast Furnace route
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Iron ore
coal
coke
sinter
Liquid iron
Blast furnace
Direct use of coal and ore
No coking and agglomeration
HIsarna technology Comparison with the Blast Furnace route
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HIsarna pilot plant
2004
2009 2010
2011 2012
2007
Campaign A
Campaign C in progress
Engineering
Concept development
Negotiations with ULCOS
Construction
Campaign B
2015
Preparations Industrial Demo
2013
7 Years of preparation before the first hot metal was produced
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Key Success Factors
• Commitment from all levels
• Financial support
• Logistical, Engineering and R&D know-how on site
• Cooperation
• Perseverance
• Fast cycle of learning and improving
Construction
September 2010
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Campaigns A, B, C
• Campaign A (April – June 2011)
• The first metal was tapped on May 20, 2011 • Process works as expected but the number of operating hours was below
expectation • Many points for plant improvements were identified • Improvements were implemented before the start of Campaign B
• Campaign B (Oct – Dec 2012)
• Confirmed process efficiency and product quality • Name plate capacity of 8 t/h achieved • Promising results with respect to energy efficiency
• Campaign C (May – June 2013)
• In progress
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• With the ULCOS and HIsarna project the European steel industry is proactively approaching the Climate Change issue
• In the HIsarna project knowledge and experience of steelmakers and equipment suppliers from all over Europe is brought together
• HIsarna is a high risk/high reward innovation with the potential to have a strong environmental and economical impact on the steel industry
• Environmental impact:
• Without capture and storage: 20% CO2 reduction • With capture and storage: 80% CO2 reduction • Strong reduction of other emissions
• Economical impact:
• Wider range of raw materials • Lower CapEx, OpEx
HIsarna Summary
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Challenges for HIsarna Future
• Demonstrate robustness of technology
• Further pilot plant campaigns: people, time, funding
• Up-scaling to industrial size – “Valley of Death”
• Transition from “generic” to “specific” (location, size, configuration) • Investment 250 M€ (± 50 M€) • Demonstration scale should have a competitive business case • Governments can support this; mitigating the business risk • Many potential innovations in ironmaking have not survived this step
• Sustainable industry future, supported by National and European policies
• Review the 2050 Roadmap (environmental, economical, social landscape) • Develop business case for pushing out Blast Furnace technology
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What have we learned along the way?
• Think big: Focus on breakthrough, not incremental
• Partnerships, collaboration, trust
• Set scope, targets, common definitions
• Clear funnelling & selection process (ULCOS):
• Generic, Long Term solutions • Handle good ideas outside the scope
• Don’t bet on one horse
• When stakes get higher, stay connected with the business strategy
• Innovation comes from people with expertise