The Technology Whitespace for Deep Decarbonization of ...
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The Technology Whitespace for Deep Decarbonization of Steel Production
Christina M. Chang, Ph.D.ARPA-E Fellow
Tuesday, August 31, 2021Zero-Emissions Iron- and Steelmaking Workshop
These slides will be made available on the ARPA-E website after the Workshop.
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O2
Fe (s)Solid Iron
Fundamental steelmaking steps
Fe2O3Iron Ore
mineseparate
Useablesteel
productOre
deposit
New Constraints:• Process emissions: 0• Full lifecycle emissions: as low as possible
heat + melt(may be optional)
Fe (l)Molten Iron
C, other
Christina M. Chang – August 31, 2021
US iron & steel industry process map
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Emissions in 106 tonnes CO2e (Mt CO2e)Production vol in 106 tonnes metal (Mt)
moltenSteel
Coke
Iron ores Sinter; Pellets
Blast FurnaceReduction(27 Mt Fe)
Sintering/pelletizing
Coal Coking
liquid iron
Basic Oxygen FurnaceSteelmaking(35 Mt steel)
scrap(61 Mt steel)
40 Mt CO2e0.34 quads
3 Mt CO2e0.04 quads
12 Mt CO2e0.04 quads
~4 Mt CO2e0.02 quads
25%
75%
US annual steel demand ~ 138 Mt
Annual US steel demand (138 Mt steel) is 8% of global demand (1800 Mt = 1.8 Gt steel)
landfill
~85%recycled
15%
casting rollingsteps
fabricationsteps
millproducts
steelproducts
15 Mt CO2e0.3 quads
~120 Mt CO2e1 quad
0.02 quads
Domestic steel production
89 Mt steel
240 Mt CO2 (3.6% of US)2 quads (2% of US)
43 Mt steel
80 Mt CO2
0.8 quads
Imports (semifinished + in goods)
Breakdown shown in this process map
CO + H2from CH4
DirectReduction(2 Mt Fe)
direct reducediron (solid)
Electric Arc FurnaceSteelmaking(54 Mt steel)
44 Mt CO2e0.1 quads
1-10%
90-99%
~3 Mt CO2e(89 Mt)
22
26
Values if grid were 100% renewable
Reimagined steel industry process map
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US annual steel demand ~ 138 Mt
138 Mt steel
0 process CO2e< 3 quads (< 3% of US)
clean electricity
Christina M. Chang – August 31, 2021
Domestic steel production
Reduce Ore ElectrochemicallyOre electrolysis (disproportionation)
Reduce Ore with CarbonCCUS, carbon looping, biomass, plastics, and beyond
Reduce Ore with Hydrogen & Hydrogen PlasmaNon-C renewable reductants, e.g. H2 and H2 Plasma
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1
3
moltensteel
casting, rolling, etc. fabrication
mill productssteel
products
integrated steelmaking
BOFor EAF
Reducing ore with carbon
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FeOxIron Ore
CO2 FeIron
Synthetic renewable C reductants‣ E.g., CO from direct air capture or flue
stream; carbon looping‣ What new reactors will be required for
carbon molecules of the future renewable carbon economy?
C
Biomass‣ Land use & land use change?‣ Food & land competition?‣ Zero-emissions processing to convert
biomass into bioreductant form (dehydration)?
Carbon Capture, Utilization & Storage (CCUS) Retrofit‣ How prevalent will CCUS retrofit
become in the U.S. by 2050?‣ As industry and FECM take the lead, is
there a role for ARPA-E?
CC U
S
CCUS
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Tuesday Breakout Session
Reducing ore electrochemically
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FeOxIron Ore
O2
FeIron
Ferri+ e-
- e-
Ferro
Avoid redox shuttlingwhich wastes energy
High-T ore electrolysis• fast reactions and diffusion• molten Fe product
Low-T ore electrolysis• on-off flexibility to run only
while electricity is ultra cheap• potentially low capital cost• solid Fe product
Faster charge transferwith novel electrode designs:• 3D electrodes?• continuous flow reactors?
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Tuesday Breakout Session
Reducing ore thermochemically without carbon
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FeOxIron Ore
ROx FeIron
R
What options exist?
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Tuesday Breakout Session
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HH2 Gas-Based Ironmaking‣ What innovations / avenues
could reduce H2 ironmaking cost very quickly, to dramatically accelerate deployment timeline?
Hydrogen1.008
1H2 Plasma-Based Ironmaking‣ What R&D could put us on a
path to have this tech ready and by the time H2 price has declined?
FeOxIron Ore
H2O FeIron
H2
Reducing ore with hydrogen and hydrogen plasma3
Tuesday Breakout Session
Reimagined steel industry process map
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US annual steel demand ~ 138 Mt
138 Mt steel
0 process CO2e< 3 quads (< 3% of US)
clean electricity
intensified steelmaking (“direct” to powder or part)
Value Chain Innovation:Alternative ProductsPowders & NNS, purer Fe, alloys, etc.
moltensteel
casting, rolling, etc. fabrication
mill productssteel
products
integrated steelmaking
BOFor EAF
Christina M. Chang – August 31, 2021
Value Chain Innovation:Alternative Fe Sourcese.g., fines, taconite, mixed ores…
Domestic steel production
Reduce Ore ElectrochemicallyOre electrolysis (disproportionation)2
Reduce Ore with CarbonCCUS, carbon looping, biomass, plastics, and beyond
1
Reduce Ore with Hydrogen & Hydrogen PlasmaNon-C renewable reductants, e.g. H2 and H2 Plasma
3
4
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Value Chain Innovation: Alternative Fe sources
Steel Industry “Wastes”‣ Tailings, BF dust, etc.‣ What annual tonnage of Fe
could be produced? How does that value compare with our potential scalability metric?
‣ What R&D is truly disruptive?
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Mine tailings
Fines Iron Ore Fines‣ What new, green ironmaking
processes can be designed to utilize fines?
‣ Can fines give rise to newproducts, like Fe powders?
Taconite
Low-grade Ores‣ Taconite, chert-magnetite,
etc.‣ Can solvent extraction or
leaching isolate Fe from SiO2or other byproducts?
REEs interspersed in Fe ores
Mixed-metal ores‣ What separations
technologies will unlock these ores cost-effectively?
‣ Can the co-sale of other metals create viable value propositions?
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Tuesday Breakout Session
‣ How will the breakdown of steel product demand change over time? ‣ Can cleanly-powered technologies make steel products that will be in increasing demand?‣ Flexibility for new green ironmaking processes process to not only make specialty products, but also translate to wider commodity
steel compositions is desirable, to mitigate the CO2e from commodity steels as well.
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New alloys
Pure Fe intermediate
Powders from fines?
Near net shape
Value Chain Innovation: Alternative Products4
Electrical steel and other ultralow-C steels
Tuesday Breakout Session
Process Intensification:Decarbonized heating, reaction monitoring/modelling, AI/ML
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Reimagined steel industry process map
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US annual steel demand ~ 138 Mt
138 Mt steel
0 process CO2e< 3 quads (< 3% of US)
clean electricity
intensified steelmaking (“direct” to powder or part)
Value Chain Innovation:Alternative ProductsPowders & NNS, purer Fe, alloys, etc.
moltensteel
casting, rolling, etc. fabrication
mill productssteel
products
integrated steelmaking
BOFor EAF
Christina M. Chang – August 31, 2021
Value Chain Innovation:Alternative Fe Sourcese.g., fines, taconite, mixed ores…
Domestic steel production
Reduce Ore ElectrochemicallyOre electrolysis (disproportionation)2
Reduce Ore with CarbonCCUS, carbon looping, biomass, plastics, and beyond
1
Reduce Ore with Hydrogen & Hydrogen PlasmaNon-C renewable reductants, e.g. H2 and H2 Plasma
3
4
4
Process Intensification
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Cross-cutting principles and tools for developing the next generation of ironmaking technologies
1. System levelHow will regional and (inter)national factorsa shape the future distribution
of ironmaking tech?
a) transportation costs, policy, availability of resources (land, renewable electricity, scrap, human capital), etc.
2. Facility levelAre modular design & deployment and flexible operation a good strategy for
(some) future ironmaking technologies?
3. Microscopic levelWhat process-intensifying techniquesb
will enable in green iron- and steelmaking?
b) hybrid separations, integrating reaction with separation, with heat exchange, or with phase transition, techniques using light, ultrasound, or intensive mixing, new process-control methods, etc.
Digital Tools‣ Modelling, monitoring,
visualization, digital twins, gamification, AI/ML
Decarbonized Heating‣ Electrotechnologies: microwave, EAF,
plasma heating, induction, resistive, etc.‣ Renewable Fuels: biomass, synthetic
electrofuels (hydrogen, ammonia, methanol)
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Wednesday Breakout Session
Reimagined steel industry process map
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US annual steel demand ~ 138 Mt
Process Intensification:Decarbonized heating, reaction monitoring/modelling, AI/ML
138 Mt steel
0 process CO2e< 3 quads (< 3% of US)
clean electricity
intensified steelmaking (“direct” to powder or part)
Value Chain Innovation:Alternative ProductsPowders & NNS, purer Fe, alloys, etc.
moltensteel
casting, rolling, etc. fabrication
mill productssteel
products
integrated steelmaking
BOFor EAF
Christina M. Chang – August 31, 2021
Value Chain Innovation:Alternative Fe Sourcese.g., fines, taconite, mixed ores…
Domestic steel production
Reduce Ore ElectrochemicallyOre electrolysis (disproportionation)2
Reduce Ore with CarbonCCUS, carbon looping, biomass, plastics, and beyond
1
Reduce Ore with Hydrogen & Hydrogen PlasmaNon-C renewable reductants, e.g. H2 and H2 Plasma
3
4
4
scrap
100%recycled
Circular EconomyDemand reduction, improving scrap, systemic material efficiency
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Circular Economy
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Wednesday Breakout Session
Technologies to Improve Scrap, Material Recycling, and Systemic Sustainability
Hot shortness cracking due to residual Cu
Garza and Van Tyne, Journal of Materials Processing Technology, 159, 2, 2005 pp. 169-180. doi:10.1016/j.jmatprotec.2004.05.004
The future of steel: time to wake up (2016), Allwood.
Systemic Sustainability‣ Could the energy and CO2e savings of technology to reduce primary demand reduction
surpass those of new green steelmaking technologies?
‣ Use less metal by design, e.g.lightweighting
‣ Re-use metal components
‣ Longer lifetime and more intense use
‣ Societal demand reduction (e.g., ride-sharing)
Technologies to Improve Scrap Recycling
A little help with this entropy, Maxwell?
Fe
Cu
‣ How could we recover prime scrap (high purity Fe) cheaper than virgin ironmaking?
~50 lbs of Cu in a car
The Workshop’s 8 Breakout Sessions
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US annual steel demand ~ 138 MtDomestic
steel production
Process IntensificationDecarbonized heating, reaction monitoring/modelling, AI/ML
138 Mt steel
0 process CO2e< 3 quads (< 3% of US)
Tracking Impact: CO2e Emissions and BeyondLCA, GHG emissions tracking, waste, water, etc.
intensified steelmaking (“direct” to powder or part)
Value Chain Innovation:Better & Emerging ProductsPowders & NNS, purer Fe, alloys, etc.
moltensteel
casting, rolling, etc. fabrication
integrated steelmaking
BOFor EAF
Prof. Zak Fang & Dr. Joe King Dr. Martin Pei
Dr. Peter de Bock Prof. Chenn Zhou Prof. Tyamo Okosun
Dr. Jack Lewnard Dr. Vincent Chevrier
Prof. Brajendra MishraDr. Doug Wicks
Dr. Joe King &Dr. Dave Tew Dr. Katie Daehn
Dr. Joe Marriott, Dr. Jack Lewnard
Tech to MarketMarkets, metrics, partnering, investment, deployment, etc.
Patrick Finch Traci Forrester Pedro Prendes-AriasBen Kowing
Circular EconomyDemand reduction, improving scrap, systemic material efficiency
Prof. Antoine AllanoreDr. Halle Cheeseman
Prof. Mark Johnson
Cross-cutting: Dr. Doug Wicks & Dr. Peter de Bock
Cross-cutting: Dr. Vincent Chevrier & Dr. Katie Daehn
Dr. Kevin Zeik
Legend:• Tuesday Breakouts• Wednesday Breakouts• ARPA-E Breakout Facilitators• External speakers
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Value Chain Innovation:Alternative Fe Sourcese.g., fines, taconite, mixed ores…
Reduce Ore ElectrochemicallyOre electrolysis (disproportionation)2
Reduce Ore with CarbonCCUS, carbon looping, biomass, plastics, and beyond
1
Reduce Ore with Hydrogen & Hydrogen PlasmaNon-C renewable reductants, e.g. H2 and H2 Plasma
3
4
6
Dr. Dave Miracle
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https://arpa-e.energy.gov
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