ULCORED

Direct Reduction Concept

for ULCOS
a brief intoduction

Peter Sikström
LKAB

11th November 2013

OUTLINE
• Introduction
• Todays dominating processes
• Potential for new DR-process
• Proposal for new processes
– Natural gas based
– Coal based
• Summary
INTRODUCTION
Requirements for a new DR-Process proposed 2006:
1. Different from existing processes like Midrex or HYL.

2. The Plant should only have one source where CO2 leave the process.

3. The Energy consumption has to be less than 8,4 GJ / t DRI.

4. Equipment and operation has to be simple.

5. Potential for use of fuels other than natural gas.

6. Investment costs has to be comparable to existing plants / plant concepts.

7. There must be good reasons for tests – technically and economic.

 TODAYS DOMINATING PROCESSES
Midrex HYL
Midrex process configuration

5
HYL PROCESS CONFIGURATION

6
• Introduction
• Todays dominating processes
• Potential for new DR-process
• Proposal for new processes
– Natural gas based
– Coal based
• Summing-up
 Dominating CO2 emissions from DR – EAF route
arises from the DR-plant.

The main features for ULCORED :

• Use of oxygen instead of air in DR-plants results in
an off gas of 100 % CO2, which needs only to be
compressed.
• There should be possibilities to reduce the need of
natural gas in DR-processes by 15 – 20 %.
• Coal-, biomass-, bio waste gasification and
hydrogen can be an alternatives to natural gas.

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REACTIONS STARTING FROM METHANE
Endothermic
CO2 reforming CH4 + CO2 ↔ 2 CO + 2 H2 Ht = 247 kJ/mol Midrex

Steam Reforming CH4 + H2O ↔ CO + 3 H2 Ht = 206 kJ/mol HYL

Thermal cracking CH4 ↔ C + 2 H2 Ht = 75 kJ/mol

Partial oxidation CH4 + ½ O2 → CO + 2 H2 Ht = -36 kJ/mol Ulcored

Water gas shift CO + H2O ↔ CO2 + H2 Ht = -41 kJ/mol

Boudouards reaction 2 CO ↔ C + CO2 Ht = -173 kJ/mol

Complete combustion CH4 + 2 O2 → CO2 + 2 H2O Ht = -803 kJ/mol

Exothermic

Source:
9 TUDelft
 SYNGAS PRODUCTION TECHNIQUES
Feed
(CnHm, …)

Steam Methane Reforming (SMR) Auto-Thermal Reforming (ATR): Partial Oxidation (POx).
Endothermic: heating necessary Combined oxidation and steam Steam used for enhancing CH4
reforming  heat is balanced conversion and avoid soots

SMR ATR Pox

reactants CH4 + steam CH4 + O2 + steam CH4+O2 +steam
NG 450°C
inlet T° 500-600 °C 750 °C
O2 200°C
outlet T° 870 °C 900-1000 °C 1300-1400 °C
H/C in syngas 3-6 1,8 – 3,7 1,6 – 1,9
H2O content 5% 18 % 10-13 %
estimated cost without piping, 20 M€
10 M€ 20 M€ ?
10 for ~ 40 000 Nm3/h (POx without shift)
 MIDREX HYL ZR
Iron Ore
T= 420°C

T= 780°C
T= 1085°C

CO2 reforming Steam reforming DRI

CH4 + CO2 + Heat ↔ 2 CO + 2 H2 CH4 + H2O + Heat ↔ CO + 3 H2

CO2 + N2 in off gas CO2 + (N2) in off gas

POX
pilot
Partial oxidation

CH4 + ½ O2 ↔ CO + 2 H2 + Heat
CO2 in off gas
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POX PILOT AT LINDE
• Tested in two campaigns
• New designed burner for H2 rich feed gas
• Tube reactor with preheated gas
- 60% H2
- 40% CH4
ERPOX, Linde LE

TI

FIR TIR PIR

Data registration 902

O2 101 101 101

HH TI
TIRS
803a
Local measurement 901
QE 1, Feed HH N2, T ca. 25 °C, ca. 3
TIRS
TIR
FIR TIR PIR 802
803b
Nm³/h
LNG 201 201 201 B 02
DN 80

CH4,LNG,C3H8,H2 DN 800
SG
FI
608
607 V611
DN 1400
FI
602
R 01 V602
QE 2, Combustion Probe distance to burner:
N2 FI
chamber
HH_P HH_P
609
90/150/210/270 cm
H H
FIR SG
TIRS TIRS
901 608
701/1 701/2

TI HH_P
H
901 TIRS
702/1

PI HH_P
902 H
TIRS TI
703/1 504
H2- D
Cooling water, T=15 °C,
HH_P HH_P FI
Trailer TIRS
H H
TIRS
502
V512
ca. 3 m³/h
704/1 704/2

HH
DN 800 H
PI TIRS
401 401

flare
E 01
V510
DN 10

QE 3, Product gas
LI
501

TIR
502 TI
503
DN 10

V509

DN25
DN 25 H
AT (°C)
V503 AD (barü)
zum Siphon

Proj.- Nr.: 2471 2972

Piping and Instrument Diagram Tautz ERPOX
23.9.08
ERPOX _ H2 rich feed gas Datum Ausgabe PFP01
12
Y : / EFV / !Projekte/ 2471_XL-ATR / Umbau / Zeichnungen /Fließschema14.vsd
CONCLUSIONS BY LINDE
• The burner and reactor could be operated without problems.
• A stable flame without significant noise production could be
demonstrated.
• The soot production is expected lower than 300-460 mg/Nm³
wet gas volume.
• Due to the atm pressure, the CO2 and CH4 content will be
higher than the pre-calculations on the basis of assumed
equilibrium.
• A higher operation pressure up to 7 bar(a) will reduce this
contents
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• Introduction
• Todays dominating processes
• Potential new DR-process
• Proposal for new processes
– Natural gas based
– Coal based
• Summary
ULCORED
• No reformer
• No heater
• High pressure
 Less gas velocity in the shaft, gives less fluidisation, less
fines leaving the shaft
 CO2-removal and POx units are smaller than Midrex/HYL
shifter/reformer
 Less electric power need for recycle compressor
 PSA instead of VPSA can be used

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ULCORED

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In depth studies of ULCORED

Fundamental modeling
– Pellet scale models
• LSG2M and NTNU
– Reduction models – reduction kinetics

– Shaft models
• LSG2M, NTNU and SSSA

– Process models by flow sheet simulations

• MEFOS developed an HSC-model in SP 12
• IRMA developed in SP 2 by Corus
• ASPEN developed by LSG2M in SP 9

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 Achievements from modeling
Fundamental reduction modelling
– Fundamental understanding of the DR process including
dissemination of knowledge to the Universities
Flow sheet modelling
– Optimisation of the process layout to fit the ULCORED
process in steel plant environment
– Process understanding including dynamics
Different approaches - similar results
– Create credible basis for evaluation of the concept in
different scenarios

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Natural gas ULCORED

Useful fuel for complete plant

Concept details
Full CO2 capture in the process
 CO2 storage potential
O2 instead of air (low N2 in system)
Reforming by a POX reactor
High H2 content in reduction
shaft by water-gas shifter
(CO + H2O = H2 + CO2)

Bleed of H2 containing N2

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Natural gas ULCORED H2 rich gas
H2 rich Bleeding N2 and for
use in the steel plant
CO2 removal

CO2 storage Gas cleaning

Shifter
CO+H2O=CO2+H2

DRI reactor

Feed to the cooling

Oxygen
zone to re-heat the
gas to the POX
DRI cooler
POX Natural gas

GREEN FIELD DRI

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 Coal based ULCORED
Excess gas for Concept details
external users

CO2 removal Reducing gas from coal in a

CO2 storage Gas cleaning

Shifter
gasifier, e.g. Shell gasifier
CO2 storage
DRI reactor

O2 instead of air
Coal gasification
High H2 content in reduction
DRI cooler
Coal shaft by WGS water-gas shifter
Dust and sulphur removal GREEN FIELD DRI BROWN FIELD
Hot or cold H2 excess gas for external
Oxygen users

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Coal based ULCORED
Excess gas for
external users

CO2 removal
CO2 storage Gas cleaning

Shifter

DRI reactor

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Coal gasification

DRI cooler
Coal

Dust and sulphur GREEN FIELD DRI BROWN FIELD

removal Hot or cold

Oxygen
Integration into a steel plant
The purpose of an integration of ULCORED into the existing steelmaking system is to
utilise the possibility to have one CO2 emission point from the system, instead of having
one per heating gas consumer
CO2
Gas holder
H2 rich gas, in plant usage Natural gas / Coal
Power
station ULCORED Oxygen
DRI
92% Met.

Electric power

Electric Hot
Ladle
arc
furnace
Casting rolling HRC
furnace mill

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Material-Balance related to 1 t DRI (cold) (Metallization 92%, Carbon 2,76 %)

0 0

*Remark
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Mass-Balance for new DR-Concept (cold DRI)

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Energy-Balance for new DR-Concept (cold DRI)

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Energy consumption and CO2 emissions

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Capex & Opex

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SUMMARY

• Can be ”quick-fix” for a brown field improvement of CO2

emissions, especially where natural gas is relatively cheap.

• By integration in a steel plant, LRI can be a choice considering

the successful tests made in the LKAB Experimental BF.
– The LRI-tests with a DR-product reduced to only 65% metallization
degree respond very positive in the BF with stable operation and coke
consumption at 200 kg/tHM.

• Tests has to be done to prove the concept.

EXPERIMENTAL DR PLANT

• Production: 1 ton Fe/h

• Recirculation of top gas
• Working pressure (shaft) 0-8 bar (g)
• Gas flow: ~1700-3100 Nm3/h
• Temp to shaft: 900-1050 ºC

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EXPERIMENTAL DR PLANT

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 WE STRIVING FOR A SUSTAINABLE FUTURE

THANK YOU

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CHARGING A PRE-REDUCED BURDEN INTO EBF

Trials during 2 campaigns in the Experimental BF

DRI at 15, 30 and 60 % of the burden LRI at 50 and 100 % of the burden

Reductant rate decrease up to 26 % Reductant rate decrease up to 33 %

Emission of CO2 decreased up to 24% Emission of CO2 decreased up to 37%

DRI metallisation degree over 90 %. LRI metallization degree about 65%

Significant productivity increase with increasing amount

of pre-reduced iron ore