Techno-Economic Evaluation of DeployingEconomic Evaluation ... · Techno-Economic Evaluation of...

Techno-Economic Evaluation of DeployingTechno-Economic Evaluation of Deploying CO2 Capture in an Integrated Steel Mill

Stanley Santos1*, Lawrence Hooey2, Jeremy Johns3, A d T bi 4Andrew Tobiesens4

Clean Coal Technology ConferenceClean Coal Technology ConferenceThessaloniki, Greece

May 2013May 20131IEA Greenhouse Gas R&D Programme

2Swerea MEFOS3Tata Steel Consulting

4Sintef Chemistry and Materials

Members of

St i C ittSteering Committee• Nils Edberg SSAB Chairperson• Nils Edberg, SSAB – Chairperson• Camilla Axelsson, Swedish Energy Agency

Helen Axelsson Jernkontoret• Helen Axelsson, Jernkontoret• Kim Kaersrud, SSAB

A it L S di h E A• Anita Larsson, Swedish Energy Agency• Stanley Santos, IEAGHG

P t Sik t LKAB• Peter Sikstrom, LKAB• Jan Olov Wikstrom, Swerea MEFOS

G Qi Z LKAB• Guang Qing Zuo, LKAB

Total value of the Project: 4 4 million SKrTotal value of the Project: 4.4 million SKrIEA GHG Contribution: 1.2 million SKr

Co-Authors of this Studyy• Swerea MEFOS Team

• Lawrence Hooey (Project Manager)• Mikael Larsson• Axel Boden

T t St l C lti• Tata Steel Consulting• Jeremy Johns• Vic Abraham• Vic Abraham• Mike Knight

• SINTEF Chemistry and MaterialsSINTEF Chemistry and Materials• Andrew Tobiesen• Karl Anders Hoff• Geir Haugen

• IEA Greenhouse Gas R&D Programme• Stanley Santos• Steve Goldthorpe

Objectives of the StudyObjectives of the Study• To specify a “REFERENCE” steel mill typical to Western• To specify a REFERENCE steel mill typical to Western

European configuration and evaluate the techno-economic performance of the integrated steel mill with and without CO2p gcapture.

• To determine the techno-economic performance, CO2 emissions and avoidance cost of the following cases:• An integrated steel mill typical to Western Europe as the base case.• An end of pipe CO2 capture using conventional MEA at two different levels

of CO2 capture rateof CO2 capture rate• An Oxygen Blast Furnace (OBF) and using MDEA for CO2 capture.

Terminologies / AbbreviationsTerminologies / Abbreviations

• OBF Oxy-Blast Furnace• OBF Oxy-Blast Furnace• OBF-PG Oxy-Blast Furnace Process Gas• OBF-TG Oxy-Blast Furnace Top Gas• TGR Top Gas Recycle• TGR Top Gas Recycle• BFG Blast Furnace Gas• BOFG Basic Oxygen Furnace Gas• COG Coke Oven Gas• COG Coke Oven Gas• SGP Steam Generation Plant

Integrated Steelmaking ProcessProcess• Raw Materials Preparation Plants

• Coke Production• Coke Production• Ore Agglomerating Plant (Sinter

Production)Li P d ti• Lime Production

• Ironmaking• Blast Furnace• Hot Metal Desulphurisation

• SteelmakingB i O St l ki (P i )• Basic Oxygen Steelmaking (Primary)

• Secondary Steelmaking (Ladle Metallurgy)

• Casting• Continuous Casting

• Finishing Mills• Finishing Mills• Hot Rolling Mills (Reheating & Rolling)

Extra-Ordinary Assumptions(For European Scenarios)(For European Scenarios)

• Only one type of steel product (standard grade HRC) produced and soldproduced and sold.

• Plant Ownership Structure not typical to European St l Mill S iSteel Mill Scenario• Captive Ownership: Power Plant, ASU and Lime Plant

• Captive Power Plant with Balanced Electricity Supply to the Steel Mill.

• Captive Coke Plant with Balanced Supply of Coke to the Steel Mill.

• Direct emissions related to the Pellets and Merchant Scrap not included in overall CO2 emissionScrap not included in overall CO2 emission accounting.

Direct CO2 Emissions from h REFERENCE S l Millthe REFERENCE Steel Mill

• Nearly 95% of the total CO2

Emissions from the Coke Plant9.31%

Power Plant46.99%

Integrated Mill that produces 4 million tonnes of Sinter Plant

13.85%

Hot Rolled Coil:• Power Plant (47.0%) Lime Plant

3.43%( )• Ironmaking (21.2%)• Sinter Production (14.0%)

Iron Making21.18%

Steelmaking

Slab Casting0.04%

Reheating & HRM2.76%

( )• Coke Production (9.3%)• Lime Production (3.4%)

REFERENCE Integrated Steel Mill(2090 kg per tonne of Hot Rolled Coil)

2.44%

( )

Key Messages from this StudyKey Messages from this Study

An Integrated Steel Mill is a complex industrialAn Integrated Steel Mill is a complex industrial process which consists of Multiple Point Sources of

CO2 EmissionsEmissions

Annual Emission

(kg/t HRC) (t/y)

100 Coke oven flue gas 191.37 765,495

UNIT Source of CO2 Emissions

CO2 Emissions

g ,

100 Coke oven gas flare 3.30 13,196

200 Sinter plant f lue gas (CO2 + CO) 289.46 1,157,825

300 Hot Stove f lue gas 415.19 1,660,769

400/1300 PCI Coal drying torpedo car and ladle heating (HM Desulphurisation) dif fue emissions 7 76 31 042

Coke Plant9.31%

Power Plant46.99%

400/1300 PCI Coal drying, torpedo car and ladle heating (HM Desulphurisation) dif fue emissions 7.76 31,042

300 Blast Furnace Gas flare 19.73 78,931

500/600 Basic Oxygen Furnace gas f lared and system losses, SM diffuse Emissions 51.02 204,089

700 Continuous Casting - dif fuse emissions (from slab cutting) 0.80 3,188

800 Reheating Furnace flue gas 57 71 230 833

Sinter Plant13.85%

800 Reheating Furnace f lue gas 57.71 230,833

900 Hot Rolling Mills - dif fuse emissions (from cutting and scarfing) 0.04 179

1000 Lime Plant f lue gas 71.62 286,493

1200 Pow er Plant f lue gas 982.13 3,928,513

Iron Making21.18%

Slab Casting


Lime Plant3.43%

1300 Ancillaries transport fuel emissions (trucks and rails) 4.00 16,000

2094.14 8,376,554Total Emissions Steelmaking2.44%

0.04%


An Integrated Steel Mill is a complex industrialAn Integrated Steel Mill is a complex industrial process which consists of Multiple Point Sources of

CO2 Emissions

I ki P i ibl f l 80% f

CO2 Emissions

Ironmaking Process is responsible for nearly 80% of the Carbon Input that causes the majority of the Direct CO E i i (i 1640 t f 2090 k CO / t HRC) fCO2 Emissions (i.e. 1640 out of 2090 kg CO2 / t HRC) of

the Integrated Steel Mill

Nitrogen2 Nm3

R M t i l

BFG to Flare/Lost23 Nm3

Top Gas Cleaning

BFG Gas Holder

Raw MaterialsCoke 355 kgSinter 1120 kg (70%)Pellets 352 kg (22%)Lump 125 kg (8%)

BFG to Power Plant935 Nm3

BFG to Coke Plant185 Nm3

BF Dust15 kg

Limestone 13 kgQuartzite 11 kg

BF Screen Undersize BF Sludge

kFlue GasCOG

BFG to Hot Stoves479 Nm3

185 Nm3

23 kg 4 kg 780 Nm3COG7 Nm3Air358 Nm3DRR: 31%

FT: 2056oC

Recuperator

TGT: 140oCHM Si: 0.5%HM C:4.7%

Hot Blast

M i Ai

Cold Blast

Hot Stoves

PCI Coal152 kg

Nitrogen3 Nm3

48 Nm3Oxygen

Main Air Compressor

Air995 Nm3

BF Slag280 kg

Hot Metal1000 kg1470oC Steam

8 kgStea

All Values are reported as kg or Nm3 per tonne of hot metal (thm)

Carbon Balance of Ironmaking ProcessDirect CO2 Emissions of an Integrated Steel Mill (REFERENCE) Producing 4 MTPY Hot Rolled Coil2090 kg CO2/t HRC (2107 kg CO2/thm )

Carbon Input Carbon OutputCarbon Balance of Ironmaking Process

Carbon Input(kg C/thm)

Carbon Output(kg C/thm)

Coke 312.4 Hot Metal 47.0

Limestone 1.5 BF Screen Undersize 6.3

PCI Coal 132.2 Dust & Sludge 8.0

COG 1.3 BFG Export 266.4

BFG Flared 5.4

Hot Stove’s Flue For this case study, it was demonstrated that the ironmaking process is responsible for 78% of theHot Stove s Flue Gas 114.1

Total 447.5 Total 447.2

For this case study, it was demonstrated that the ironmaking process is responsible for 78% of thetotal carbon input of the steel mill. BUT only 21% of the carbon emitted as CO2 emissions isattributed to this process. The rest of the carbon emitted as CO2 are accounted to other processes(mostly end users of the by-product fuel gases) within the steel mill.

Carbon Balance of Ironmaking ProcessDirect CO2 Emissions of an Integrated Steel Mill (REFERENCE) Producing 4 MTPY Hot Rolled Coil2090 kg CO2/t HRC (2107 kg CO2/thm )2090 kg CO2/t HRC (2107 kg CO2/thm )

Carbon from Coke & Limestone

314 kg Cg

Carbon from screen reject

Carbon Balance of Ironmaking Process

jto Sinter Plant

(Mostly as Reclaimed Coke)

6 kg C






COG 1.3 BFG Export 266.4

BFG Flared 5.4

For this case study, it was demonstrated that the ironmaking process is responsible for 78% of the total

Carbon from PCI Coal

132 kg C

Carbon in Hot Metal to BOS Plant

47 kg C

Hot Stove’s Flue Gas 114.1


o t s case study, t as de o st ated t at t e o a g p ocess s espo s b e o 8% o t e totacarbon input of the steel mill. BUT only 21% of the carbon emitted as CO2 emissions is attributed to thisprocess. The rest of the carbon emitted as CO2 are accounted to other processes (mostly end users ofthe by‐product fuel gases) within the steel mill.

STEEL MILL Battery Limit(REFERENCE Integrated Steel Mill)

UNIT 100: UNIT 200: UNIT 300:

COKE PRODUCTION SINTER PRODUCTIONHOT METAL PRODUCTION


HOT METAL DESULPHURISATION

BASIC OXYGEN STEELMAKING

SECONDARY STEELMAKING


CONTINUOUS SLAB CASTING

SLAB REHEATING HOT ROLLING MILL

UNIT 1000: UNIT 1100: UNIT 1200:

LIME PRODUCTION AIR SEPARATION UNIT (OXYGEN PRODUCTION)

POWER PLANT(OXYGEN PRODUCTION)

UNIT 1300:

ANCILLARY UNITSANCILLARY UNITS

STEEL MILL Battery Limit(Steel Mill with OBF & MDEA CO2 Capture)

UNIT 200 UNIT 300UNIT 100 UNIT 200:

SINTER PRODUCTION

UNIT 300:

HOT METAL PRODUCTION

UNIT 400:

UNIT 100:

COKE PRODUCTION

UNIT 500: UNIT 600:UNIT 400: UNIT 500:

BASIC OXYGEN STEELMAKING

UNIT 600:

SECONDARY STEELMAKING

HOT METAL DESULPHURISATION


UNIT 1000:

HOT ROLLING MILL

UNIT 1100: UNIT 1200:

CONTINUOUS SLAB CASTING

SLAB REHEATING

UNIT 2000:

LIME PRODUCTION AIR SEPARATION UNIT (HIGH PURITY O2 PROD.)

POWER PLANT

UNIT 3000: UNIT 4000:

STEAM GENERATION PLANT

AIR SEPARATION UNIT (LOW PURITY O2 PROD.)

CO2 CAPTURE & COMPRESSION PLANT

UNIT 1300:

ANCILLARY UNITS

Integrated Steel Mill with OBFIntegrated Steel Mill with OBF and MDEA CO2 Captureand MDEA CO2 Capture Technology

Changes to the Steel Mill as compared to theChanges to the Steel Mill as compared to the REFERENCE Steel Mill (Base Case)

Materials Input & OutputM j R M t i l I t Prod cts and B Prod cts• Major Raw Materials Input:

• Iron Burden (Fines, Lumps, Pellets)• Energy and Reductant

C ki C l

• Products and By-Products:• Hot Rolled Coil (Standard Grade)• Coking Plant By-Products

C d T BTX d S l ho Coking Coal o PCI Coalo Natural Gas

• Fluxes (Limestone Quartzite Olivine

o Crude Tar, BTX and Sulphur• Steel Mill Slag

o Granulated BF Slag (Sale)o De S Slag (Landfill)• Fluxes (Limestone, Quartzite, Olivine,

CaC2, Burnt Dolomite) Merchant Scrap (External)

• Ferroalloys (FeMnC, FeSi-75,

o De-S Slag (Landfill)o BOF Slag (Sale & Landfill)o SM Slag (Landfill)

• BF Sludge and Dust (Landfill)y ( , ,De-Ox Aluminium)

• Major Intermediate Products• Coke (Lump & Breeze)

BF Sludge and Dust (Landfill)• MDEA Sludge (Landfill)• Liquid Argon

• Gas Network within Site( p )• Sinter• Hot Metal• Liquid Steel

• Gas Network within Site• Industrial Gases

o HP & LP Oxygen, Nitrogen and Argon• Off-GasesLiquid Steel

• Slab• Lime• HP & LP Oxygen

Off-Gaseso OBF Top Gaso OBF Process Gas (PG)o Coke Oven Gas (COG)HP & LP Oxygen

• Electricity• Steam

( )o Basic Oxygen Furnace Gas (BOFG)

• Steam (9 Bar, saturated)• Carbon Dioxide

Sinter Fines (Sweden) [ 61.6 ] [ 47.3 ]

BF/BOS Dust & Sludge [ 14.9 ]

Q t it [ 32.4 ]

Sinter Fines (Australia) [ 88.0 ] [ 5.1 ] Reclaimed Coke [ 5.1 ]

(ex BF Screen)

Sinter Fines (Brazil) [ 730.7 ] [ 15.2 ] BF Screen Undersize

(excl. coke)[ 15.2 ]

[ 239.8 ]Hard Coking Coal

Limestone [ 97.6 ]

[ 24.0 ]M ill Scales

[ 159.8 ]Soft Coking Coal

[ 8.7 ]

[ 7.8 ]

Olivine [ 22.6 ]

[ 34.1 ]BOS Slag

[ 34.1 ]

Quartzite[ 7.8 ]

HM Spillage / De-S Slag

Benzole (BTX)UNIT 1000 UNIT 200 UNIT 100 [ 3.8 ]

Sulphur

[ 146.0 ] LimePlant [ 10.9 ] Sinter Plant [ 54.4 ] Coke Plant

Crude Tar

Lime C o ke B reeze [ 12.8 ]

am

[ 5.8 ] Iron Making BF SludgeUNIT 300 & 400 [ 4.0 ]

Iron Ore Pellets [ 349.8 ] [ 150.8 ]

PCI CoalBF Granulated Slag

[ 3.3 ] [ 256.6 ] . [ 233.2 ]

LimeIron Ore Lumps

[ 124.3 ] S inter (58% F e) Lump C o ke [ 0.9 ]

[ 1,087.3 ]

Dia

gra

e)

[ 13.3 ]

M DEA Sludge[ 0.2 ]

CO2 Capture PlantUNIT 4000

Burnt Dolomite [ 11.8 ]

Calcium Carbide Purchased Scrap [ 126.4 ] H o t M eta l (95% F e)

[ 973.5 ]

FerroAlloy & A l [ 16.8 ]

UNIT 300 & 400 [ 4.0 ]

[ 3.2 ] de-S Slag

Flow

DO

2C

aptu

re

[ 31.7 ]

SM Slag

Liquid Steel (99% F e)

[ 8.6 ]

BOS Slag (Sale)

[ 1,086.3 ]

Burnt Dolomite

[ 56.0 ]

[ 75.5 ] Steel Making

BOS Slag

[ 5.2 ] UNIT 500 & 600

oces

s F/

MD

EA C

O

S lab [ 1,052.6 ]

[ 9.2 ]

Slab CasterUNIT 700 [ 27.2 ]

rial P

roll

with

OB

F

Legend M ill Scales

[ 1,000.0 ]

Reheating & HRM [ 42.1 ] Scrap

[xxx.x] - kg/t HRC (Dry Basis) UNIT 800 & 900 Hot Rolled Coil

[ 14.8 ]

Mat

er(S

teel

Mil

Material Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture)

Sinter Fines (Sweden) [ 61.6 ] [ 47.3 ]

BF/BOS Dust & Sludge [ 14.9 ]

Quartzite [ 32.4 ]

Sinter Fines (Australia) [ 88.0 ] [ 5.1 ] Reclaimed Coke [ 5.1 ]

(ex BF Screen)

Sinter Fines (Brazil) [ 730.7 ] [ 15.2 ] BF Screen Undersize

(excl. coke)[ 15.2 ]• Installation of Oxy-Blast Furnace

• Reduced coke consumptionR d d fl ti

[ 239.8 ]Hard Coking Coal

Limestone [ 97.6 ]

[ 24.0 ]M ill Scales

[ 159.8 ]Soft Coking Coal

[ 8.7 ]

[ 7.8 ]

Olivine [ 22.6 ]

[ 34.1 ]BOS Slag

[ 34.1 ]

[ 7.8 ]HM Spillage / De-S Slag• Reduced flux consumption

• Reduced GBF slag production• Reduce Coke Plant Capacity

[ 349.8 ] [ 150.8 ]

LimeIron Ore Lumps

[ 124.3 ] Sinter (58% F e) Lump C o ke [ 0.9 ]

[ 1,087.3 ]

Benzole (BTX)UNIT 1000 UNIT 200 UNIT 100 [ 3.8 ]

Sulphur

[ 146.0 ] LimePlant [ 10.9 ] Sinter Plant [ 54.4 ] Coke Plant

Crude Tar

Lime C o ke B reeze [ 12.8 ]• Reduced coking coal consumption• Reduced by-products production to sale

• Changes in Sinter Plant

[ 13.3 ]

M DEA Sl dCO2 Capture Plant

Calcium Carbide Purchased Scrap [ 126.4 ] H o t M etal (95% F e)

[ 973.5 ]

[ 5.8 ] Iron Making

[ 16 8 ]

BF SludgeUNIT 300 & 400 [ 4.0 ]

[ 3.2 ] de-S Slag

Iron Ore Pellets[ ] [ ]

PCI CoalBF Granulated Slag

[ 3.3 ] [ 256.6 ] . [ 233.2 ]• Reduced sinter ‘s CaO/SiO2 ratio from 1.80 to 1.65

• Reduced flux consumptionM DEA Sludge

[ 0.2 ]CO2 Capture Plant

UNIT 4000

[ 31.7 ]

SM Slag

Liquid Steel (99% F e)

BOS Slag (Sale)

[ 1,086.3 ]

Burnt Dolomite [ 11.8 ]

[ 56.0 ]

[ 75.5 ] Steel Making

BOS Slag

[ 5.2 ] UNIT 500 & 600

FerroAlloy & Al[ 16.8 ]

• Reduced in Flux Consumption• Limestone, Quartzite (OBF / Sinter)• Lime, Olivine (Sinter)

[ 8.6 ]

Slab [ 1,052.6 ]

[ 9.2 ]

Slab CasterUNIT 700 [ 27.2 ]

( )• Addition of CO2 capture plant

• handling of Make Up MDEA/Pz solvent and disposal of MDEA sludge

Legend M ill Scales

[ 1,000.0 ]

Reheating & HRM [ 42.1 ] Scrap

[xxx.x] - kg/t HRC (Dry Basis) UNIT 800 & 900 Hot Rolled Coil

[ 14.8 ]

p g

(YEAR 06)

kg/t HRC

CO2 to Pipeline

859.8

UNIT 100

GJ/ t H R C

GJ/t HRC GJ/t HRC

Ancilliary Units Lime Plant Sinter Plant Coke Plant2.4247UNIT 1300 UNIT 1000 UNIT 200

GJ/t HRC GJ/t HRC GJ/t HRC GJ/t HRC

0.8289 0.0000

0.0000GJ/t HRC

0.0897 0.3022 0.0794 0.2280

Flare/Lost

COG

`

3.84

Nm3/t HRC5.02

kg/t HRC

728.50

7.79

ASU - LP O2 Prod.UNIT 3000

1 x 4200 TPD O2 Nm3/t HRC* 1580m3 working volume GJ/t HRC

UNIT 300

0.74472 x 8.5m diamet er heart h

46.64

251.04 1.6742kg/t HRC

N m 3 / t H R C Blast Furnace GJ/ t H R C

2 x PFR Kiln 1 x 410m2 st rand area m/ c 3 Bat t er ies / 120 Ovens

OBF PG

ptur

e)

kg/t HRC CO2 Capture PlantUNIT 4000

2x Absorbers & 1x St r ipper

2 x 220t Vessels GJ/ t H R C GJ/t HRC

55.73 UNIT 500

0.8817 0.2967Nm3/t HRC

Nm3/t HRC* UNIT 400

0.33 81.06Nm3/t HRC* BOS Plant kg/ t H R C

0.14Desulphurisation

Plant

Steam

BOFG

FD A C

O2

Cap

GJ/t HRCNm3/t HRC 2 x Laddle St at ions

0.11Nm3/t HRC Continuous Caster

0.0196UNIT 700

0.78Nm3/t HRC

Ladle Metallurgy0.2322

2.28UNIT 600

rk –

PFB

F/M

DEA

GJ/t HRC4 x Walking Beam Furnace

GJ/t HRCNm3/t HRC 2 x 2-St rands

Reheating1.4737UNIT 800

2.17Vent/Lost

WasteNitrogen

Net

wor

ill w

ith O

0.8453Nm3/t HRC1x 1250 TPDO2 8 x St eam Boilers(@50 t ph each) GJ/t HRC

Nm3/t HRC 2 x Reversing Mills

6 x Finishing Mills & 3 x Coilers

0.6597

6.28ASU - HP O2 Prod. Steam GenerationPower Plant

UNIT 1200

1x 215 MWe

GJ/t HRCUNIT 1100 UNIT 2000

2.63Hot Rolling Mill

UNIT 800

AO2

N2Gas

N(S

teel

M

kg/ t H R C702.06

GJ/t HRC

1 x 1250 TPD O2 8 x St eam Boilers (@ 50 t ph each) GJ/t C

Natural Gas

1 x 215 MWe

kg/t HRC

4.141.56 kg/t HRC

0.6535GJ/t HRC

3.6472Liquid Argon to Sale

Ar

(YEAR 06)

859.8

Gas Network - Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture)

kg/t HRC

CO2 to P ipeline


0.0000GJ/t HRC

0.0897 0.3022 0.0794 0.2280

Flare/Lost

• Installation of Oxy-Blast Furnace• Added the Recycling of Top Gas with CO2 removal.• Delivery of Top Gas to the CO2 Capture and

3.84kg/t HRC ASU - LP O2 Prod.

UNIT 3000 UNIT 300

46.64

251.04 1.6742kg/t HRC


UNIT 100

GJ/ t H R C2 x PFR Kiln 1 x 410m2 st rand area m/c 3 Bat t er ies / 120 Ovens

GJ/t HRC GJ/t HRC



0.8289 0.0000

COG

OBF PG

• Delivery of Top Gas to the CO2 Capture and Compression Plant

• Introduction of OBF Process Gas (OBF PG -Recycled Top Gas after CO2 removal) to shaft and t

`

Nm3/t HRC5.02

728.50kg/t HRC

7.79UNIT 3000

1 x 4200 TPD O2



Nm3/t HRC* UNIT 400

0 33 81 06

Nm3/t HRC* 1580m3 working volume GJ/t HRC


Plant

UNIT 300


Steam

tuyeres.• Reduced Off-Gas from BF as fuel for Plant Use.• Five folds increase to the consumption of Oxygen for

the blast furnace



0.78Nm3/t HRC


2.28UNIT 600

55.73 UNIT 500

0.8817 0.2967Nm3/t HRC

0.33 81.06Nm3/t HRC* BOS Plant kg/ t H R C

BOFG• Only requires 95% purity O2

• Oxygen is introduced to the OBF at the tuyeres level without pre-heating (cold).

• Replacement of Hot Stoves with Fired Heaters

GJ/t HRC




0.01962.17

UNIT 700

Vent/Lost

WasteNitrogen

ep ace e o o S o es ed ea e s• Purpose: to heat up the OBF-PG delivered to the shaft

level up to 900oC• Reduced COG consumption –

• NG is used as fuel for the Fired Heaters



0.6597ASU - HP O2 Prod. Steam GenerationPower Plant GJ/t HRC

4 x Walking Beam Furnace


UNIT 800

N2

NG is used as fuel for the Fired Heaters.• Increased COG consumption by the PCI Coal

Drying Units.• No BFG Flaring (significantly minimise to nearly

)

kg/ t H R C702.06

GJ/t HRC

0.8453Nm3/t HRC1 x 1250 TPD O2 8 x St eam Boilers (@ 50 t ph each) GJ/t HRC

6.28

Natural Gas

UNIT 1200

1 x 215 MWe

kg/t HRC

4.141.56 kg/t HRC

0.6535GJ/t HRC

3.6472

UNIT 1100 UNIT 2000

Liquid Argon to Sale

ArO2

2zero)

(YEAR 06)

kg/t HRC859.8

Gas Network - Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture) Delivery of CO2 to

kg/t HRC

CO2 to P ipeline


0.0000GJ/t HRC

0.0897 0.3022 0.0794 0.2280

Flare/Lost

• Installation of ASU with Low Purity O2

production to meet OBF demand.• Reduced the capacity of ASU – High Purity

yPipeline

3.84

5 02

kg/t HRC

7 79

ASU - LP O2 Prod.UNIT 3000 UNIT 300

0 74472 8 5 di t h t h

46.64

251.04 1.6742kg/t HRC


UNIT 100

GJ/ t H R C2 x PFR Kiln 1 x 410m2 st rand area m/ c 3 Bat t er ies / 120 Ovens

GJ/t HRC GJ/t HRC


0.8289 0.0000

COG

OBF PG

• Reduced the capacity of ASU – High Purity O2 Production by ~43%.

• Reduced Liquid Argon to Sale• Reduce Coke Plant Capacity

`

Nm3/t HRC5.02

728.50kg/t HRC

7.791 x 4200 TPD O2



Nm3/t HRC* UNIT 400

0.33 81.063 BOS Pl t k / H R C



Plant


Steam

• Reduce Coke Plant Capacity• Reduced COG supply to the steel mill• Modification to coke oven’s underfire

heating fuel demand & composition



0.78Nm3/t HRC


2.28UNIT 600

55.73 UNIT 500

0.8817 0.2967Nm3/t HRC

Nm3/t HRC* BOS Plant kg/ t H R CBOFG

heating fuel demand & composition.• Reduced Fuel demand• Reduced COG consumption• Replacement of BFG by OBF-PG





0.01962.17

UNIT 700

Vent/Lost

WasteNitrogen

• Flaring should be nearly zero to meet COG demand

• Addition of CO2 capture plant



0.6597


UNIT 1200GJ/t HRC

UNIT 1100 UNIT 2000


UNIT 800

N2

• Requires processing of OBF Top Gas prior to CO2 capture.

• Delivery of the OBF Process Gas to OBF

kg/ t H R C702.06

GJ/t HRC


Natural Gas

1 x 215 MWe

kg/t HRC

4.141.56 kg/t HRC

0.6535GJ/t HRC


ArO2and other Plant Users

• Requires low pressure steam for solvent regeneration

(YEAR 06)

kg/t HRC859.8

Gas Network - Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture)

kg/t HRC

CO2 to P ipeline


0.0000GJ/t HRC

0.0897 0.3022 0.0794 0.2280

Flare/Lost

• Steam supplied by the Waste Heat Boilers of the Basic Oxygen Furnace

3.84

5 02

kg/t HRC

7 79

ASU - LP O2 Prod.UNIT 3000 UNIT 300

0 74472 8 5 di t h t h

46.64

251.04 1.6742kg/t HRC


UNIT 100

GJ/ t H R C2 x PFR Kiln 1 x 410m2 st rand area m/c 3 Bat t er ies / 120 Ovens

GJ/t HRC GJ/t HRC


0.8289 0.0000

COG

OBF PG

• Supply steam to meet demand of:• Coke Plant• ASU – HP O2 Production

`

Nm3/t HRC5.02

728.50kg/t HRC

7.791 x 4200 TPD O2



Nm3/t HRC* UNIT 400

0.33 81.063 BOS Pl t k / H R C



Plant


Steam

• ASU – LP O2 Production• No steam demand by the OBF

• Maximise the steam production from the



0.78Nm3/t HRC


2.28UNIT 600

55.73 UNIT 500

0.8817 0.2967Nm3/t HRC

Nm3/t HRC* BOS Plant kg/ t H R CBOFGWaste Heat Boilers installed at the Basic

Oxygen Furnace and deliver excess steam to CO2 capture plant.





0.01962.17

UNIT 700

Vent/Lost

WasteNitrogen

• Installation of Low Pressure Steam Generation Plant to meet CO2 Capture Pl t d d



0.6597


UNIT 1200GJ/t HRC

UNIT 1100 UNIT 2000


UNIT 800

N2

Plant demand.• Used OBF-PG and BOFG as the main fuel

and with NG as supplementary fuel to meet demand of the boilers

kg/ t H R C702.06

GJ/t HRC


Natural Gas

1 x 215 MWe

kg/t HRC

4.141.56 kg/t HRC

0.6535GJ/t HRC


ArO2meet demand of the boilers.

Electricity Network of the Integrated Steel Mill(Steel Mill with OBF/MDEA CO2 Capture)

kWh/ t H R C kWh/ t H R C kWh/ t H R C

Lime Plant Sinter Plant Coke PlantUNIT 1000 UNIT 200 UNIT 100

2.6 34.8 10.9Captive Power Plant

REF. Steel Mill OBF Steel Mill w/ CO2

Capture

38.0ASU - HP O2 Prod.

UNIT 1100

kWh/ t H R C1 x 1200 TPD O2

Blast FurnaceUNIT 300

2 x 8.5m diamet er heart h

1580m3 working volume

2 x PFR Kiln 1 x 410m2 st rand area m/ c 3 Bat t er ies / 120 Ovens

215 MWe (Net) 292 MWe (Net)

32.1% 56.9%

BFG BOFG NG NG

UNIT 3000

kWh/ t H R C120.3

ASU - LP O2 Prod.

1 x 4100 TPD O2

DesulphurisationPlantUNIT 400

29.8kWh/ t H R C

BFG, BOFG, NG NG

400 kWh/t HRC 573 kWh/t HRC

85% Load Factor 89% Load Factor


Steam Generation

143.2CO2 Capture Plant

kWh/ t H R CUNIT 4000

2 x 220t Vessels

48.8kWh/ t H R C

Ladle Metallurgy

UNIT 500BOS PlantGas Fired Boiler NGCC Single Shaft

4.8Ancilliary Units

UNIT 1300

8 x St eam Boilers (@ 50 t ph each)

11.0Steam Generation


Continuous Caster10.9UNIT 700

Ladle MetallurgyUNIT 600

2 x Laddle St at ions• Scope for Improvements:

• Deployment of CHP or COGEN Plant instead of Steam Boilers to generate steam for CO2capture plant

kWh/ t H R C

4 x Walking Beam Furnace

ReheatingUNIT 800

kWh/ t H R C2 x 2-St rands

capture plant• To evaluate other possible waste heat

recovery within the steel mill for steam generation.

• BUT – this may not be possible for

573.4 UNIT 1200

1 x GT-HRSG-ST (Single Shaf t )

2 x Reversing Mills

105.3kWh/ t H R C


Hot Rolling MillPower Plant


a g ea u ace

several European Steel Mills as they provide district heating.

Nitrogen2 Nm3

BFG to Flare/Lost23 Nm3

Top Gas Cleaning

BFG Gas Holder

Raw MaterialsCoke 355 kgSinter 1120 kg (70%)Pellets 352 kg (22%)

BFG to Power Plant935 Nm3

BFG to Coke PlantCleaning Gas Holder

BF Dust15 kg

Lump 125 kg (8%)Limestone 13 kgQuartzite 11 kg

BF Screen U d i BF Sl d

BFG to Hot Stoves479 Nm3

BFG to Coke Plant185 Nm3

Undersize23 kg

BF Sludge4 kg

Flue Gas780 Nm3

COG7 Nm3Air358 Nm3DRR: 31%

FT 2056 C

Recuperator

FT: 2056oCTGT: 140oCHM Si: 0.5%HM C:4.7%

Hot Blast Cold Blast

Hot Stoves

PCI Coal152 kg

Nitrogen3 Nm3

48 Nm3Oxygen

Main Air Compressor

Air995 Nm3

BF Slag280 kg

Hot Metal1000 kg152 kg1470oC

8 kgSteam

Oxy-Blast Furnace Operation(Picture of OBF courtesy of Tata Steel)

Raw Materials OBF Top Carbon Dioxide867 kg

Coke 253 kg

Nitrogen5 Nm3

CO2 Capture & Compression Plant

pGas

Top Gas Cleaning1385 Nm3

Coke 253 kgSinter 1096 kg (70%)Pellets 353 kg (22%)Lump 125 kg (8%)Limestone 6 kgQ i 3 k

OBF Process GasBF Dust

BF Sludge15 kg 938 Nm3

Quartzite 3 kg

Steam2.0 GJ

OBF Screen Undersize21 kg

Natural Gas Flue Gas352 Nm3

BF Sludge

Air

4 kg

332 Nm3 18 Nm3DRR: 11%FT: 2140oCTGT: 170oCHM Si 0 5%

563 Nm3900oC

OBF Process Gas Fired Heaters

HM Si: 0.5%HM C:4.7%

BF Slag

OBF‐PG to Steel Works

Oxygen

235 k

253 Nm3

205 Nm341oC

171 Nm3Nitrogen

Hot MetalPCI Coal1000 kg1470oC

152 kg

235 kg 171 Nm3Nitrogen5 Nm3

Carbon Balance of Ironmaking Process(Equipped with OBF and MDEA/Pz CO2 Capture)

Direct CO2 Emissions of an Integrated Steel Mill (with OBF & MDEA CO2Capture) Producing 4 MTPY Hot Rolled Coil1115 kg CO2/t HRC (1124 kg CO2/thm ) Nitrogen

(Equipped with OBF and MDEA/Pz CO2 Capture)

1115 kg CO2/t HRC (1124 kg CO2/thm )

Lime Plant

Power Plant18.94%

Steam Generation Plant

25.13%

Raw Materials

CO2 Capture & Compression Plant

OBF Top Gas

Carbon Dioxide

Top Gas Cleaning1385 Nm3

867 kgCoke 253 kgSinter 1096 kg (70%)Pellets 353 kg (22%)Lump 125 kg (8%)Limestone 6 kg

g5 Nm3

Coke Plant11.22%

Sinter Plant23.83%Iron Making

4.65%

Steelmaking4.58%

Slab Casting0.07%


Lime Plant6.41%

Compression Plant

OBF Process GasBF Dust

BF Sludge15 kg

4 kg

938 Nm3

Limestone 6 kgQuartzite 3 kg

Steam2.0 GJ

OBF Screen Undersize21 kg

C b I t C b O t t

Carbon Balance of Ironmaking Process563 Nm3

OBF Process Gas Fi d H t

Natural Gas Flue Gas352 Nm3

Air332 Nm3 18 Nm3

DRR: 11%FT: 2140oCTGT: 170oCHM Si: 0.5%HM C:4.7%





900oC

BF Slag

Fired Heaters

OBF‐PG to Steel Works

Oxygen

235 kg

253 Nm3

205 Nm341oC

171 Nm3Nitrogen


Natural Gas 12.0 OBF PG Export 64.5

PG Heater Flue Gas 12.0 For this case study, the Oxy-Blast Furnace has the potential to reduce carbon input to theiron making process by 17% as compared to the REFERENCE case (@447 5 kg C/thm)

Hot MetalPCI Coal1000 kg1470oC

152 kg

235 kgg5 Nm3

CO2 Captured 236.3


iron making process by 17% as compared to the REFERENCE case (@447.5 kg C/thm).This is due to the reduced consumption of the coke. ULCOS has reported a higher carboninput reduction potential of up to ~28%. Further reduction of CO2 emissions could only beachieved by CCS.

Note:Note:• Current study only illustrates one of• Current study only illustrates one of

the many options available for oxy-y p yblast furnaces

This do not represents the choice• This do not represents the choice made by the ULCOS Programme.made by the ULCOS Programme.• Florange Project

Ei hütt t dt P j t• Eisenhüttenstadt Project

The Ulcos Blast Furnace Concepts

Coke Top gas Coke Top gas

Gas cleaning

Coke p g(CO, CO2, H2, N2)

Gas net(N2 purge)

Gas cleaning

Coke p g(CO, CO2, H2, N2)

Gas net(N2 purge)

CO2 400 Nm3/tCO2

scrubber CO2 400 Nm3/tCO2

scrubber

Gas heater

CO, H2, N2V4900 °C

V3X

V1900 °C

Gas heater

CO, H2, N2V4900 °CV4900 °C

V3X

V3X

V1900 °CV1900 °C

Oxygen

PCI Re-injection

1250 °C 1250 °C 25 °COxygen

PCI Re-injection

1250 °C1250 °C 1250 °C1250 °C 25 °C25 °C

Re injection Expected C-savings

25 % 24 % 21 %

Re injection Expected C-savings

25 % 24 % 21 %

Expected C-savings

25 % 24 % 21 %

29

CO2 Capture & Compression Plant PFD(Steel Mill – OBF and MDEA CO2 Capture)(Steel Mill – OBF and MDEA CO2 Capture)

CO2 Capture & Compression Plant PFD(Steel Mill – OBF and MDEA CO2 Capture)(Steel Mill OBF and MDEA CO2 Capture)

• Equipment Configuration:• 2x Process Gas Compressors (2 to 4 Bara)2x Process Gas Compressors (2 to 4 Bara)• 2x Absorbers (1 per OBF)• 1x Stripper Column• 2x CO2 Compression Train with Glycol (TEG) Dehydration Unit

• Solvent• MDEA 40%• Piperazine 10%

E D d• Energy Demand• Steam 2.02 GJ/t HRC• Electricity 143 2 kWh/t HRC• Electricity 143.2 kWh/t HRC

• Capture Performance• ~860 kg/t HRC (867 kg/thm)860 kg/t HRC (867 kg/thm)• ~47% CO2 Avoided• 94% capture rate

Separation and Capture of CO2 from OBF also has several other optionsalso has several other options(Data from ULCOS Programme)

PSA VPSA• PSA, VPSA• VPSA +VPSA

Cryogenics Separation ofSeparation of non-CO2

tcomponents• Chemical

Absorption

Techno-Economic Model(REFRENCE Steel Mill)( C Stee )

MAIN INTERMEDIATE PRODUCTS

WASTE PRODUCTSRAW MATERIALS MAJOR PROCESSES EXPORTED PRODUCTS

N atural Gas

ENERGY BY-PRODUCTS & OTHER IND. GASES

PLANT BY-PRODUCTS

Power PlantUNIT 1200

Electricity

Air Separation UnitUNIT 1100

P C I C o al

UNIT 1200

Oxygen Waste N itro genLiquid A rgo n

H ard C o king C o al

Semi-So ft C o king C o alN itro gen

A rgo n

Olivine

Coke PlantQuartzite

C o ke Oven Gas C rude T ar, B enzo le, Sulphur

Lime

C o ke B reeze

Lump C o ke

Lime PlantUNIT 1000

Limesto ne

UNIT 100

Iron Making

Sinter

B F R eturns & R eclaimed

UNIT 200Sinter F ines R eturnsSinter Plant

Iro n Ore - Lumps

Iro n Ore - F ines

Iro n Ore - P e llets

B OS Slag, D ust & SludgeSteel Making

ScrapUNIT 500 & 600

UNIT 300 & 400

B OS Gas

Steam

M erchant Scrap

B F Gas Iron Making Granulated B F Slag de-S Slag & B F SludgeC o ke, B F D ust , de-S Slag/ H M Spillage

H o t M etal

B OS Slag & SM SlagB OS SlagLiquid Steel

F erro A llo ys / D eo x A l

UNIT 700

UNIT 800 & 900

M ill ScaleReheating & Rolling

ScrapSlab

Hot Rolled CoilC o nsummables and Other Wo rks & Operat io n Scrap

Continuous Caster

C aC 2 P o wder

B urnt D o lo mite M ill Scale

Plant By-Products Sold to Users at Fixed Price & Credit to Producers

Energy & Fuel Gases So ld at Fixed Price to Users & Credit to Producers

Exported By-Products Sold at Fixed Price

Expenses

Waste Products Charged at Cost to Producers

Waste Nitrogen Vented at Zero Value

Raw M aterials & Consummables Bought at Fixed Price and Sold Directly to the Users

INTERNAL CUSTOM ERS (USERS) Products Sold to Users at Producer's Direct Cost

Hot Rolled Co il So ld at Variable / M arket PriceBy-Product Gases Sold to Users at Zero Value

Techno-Economic Model(Steel Mill with OBF & MDEA CO2 Capture)(Stee t O & CO Captu e)


EXPORTED PRODUCTS WASTE PRODUCTS

N atural Gas Power Plant Electric ityUNIT 1200

RAW MATERIALS ENERGY BY-PRODUCTS & OTHER IND. GASES MAJOR PROCESSES MAIN INTERMEDIATE

PRODUCTS PLANT BY-PRODUCTS Captured CO2 Emission


Semi-So f t C o king C o al

Steam Boiler SteamUNIT 2000

Limesto neLime Plant Lime

UNIT 1000

P C I C o al

Olivine

C rude T ar, B enzo le , Sulphur

QuartziteUNIT 100

Lump C o ke

C o ke B reezeC o ke Oven Gas Coke Plant

Iro n Ore - F ines

Sinter F ines R eturnsSinter Plant SinterUNIT 200

Iro n Ore - Lumps

B F R eturns & R eclaimed C o ke, B F D ust, de-S

Slag/ H M SpillageC O2 C aptured fro m OB FIro n Ore - P ellets B F Gas Iron Making H o t M etal Granulated B F Slag de-S Slag & B F Sludge

UNIT 300 & 400

M erchant Scrap

B OS Gas B OS Slag, D ust & SludgeSteel Making Liquid Stee l B OS Slag B OS Slag & SM Slag

SteamUNIT 500 & 600

ScrapF erro A llo ys / D eo x A l

B urnt D o lo mite M ill ScaleContinuous Caster Slab

UNIT 700Scrap

C alcium C arbide

M ill ScaleC o nsummables and

Other Wo rks & Operat io n Expenses

Reheating & Rolling Hot Rolled CoilUNIT 800 & 900Scrap

N itro genAir Separation Unit H igh P urity Oxygen Liquid A rgo n Waste N itro gen

A rgo nUNIT 1100

Air Separation Unit Lo w P urity Oxygen Waste N itro gen/ A rgo nUNIT 3000

M D EA / P z CO2 Capture Plant C O2 (110 bar & 99%) M D EA SludgeUNIT 4000

C t M d l A t i d B i f C l l t i

Exported By-Products So ld at Fixed Price Waste Products Charged at Cost to Producers

By-Product Gases Sold to Users at Zero Value Sinter Fines Return Sold at Zero ValueHot Ro lled Coil Sold at Variable / M arket Price Waste Nitrogen Vented at Zero Value

Raw M aterials & Consummables Bought at Fixed Price and So ld Directly to the Users INTERNAL CUSTOM ERS (USERS)

Products So ld to Users at Producer's Direct Cost

Energy & Fuel Gases Sold at Fixed Price to Users & Credit to Producers

Plant By-Products Sold to Users at Fixed Price & Credit to Producers

Total Investment Cost(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)

Total Investment Cost - Cont’d(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)

Annual O&M Cost(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)

Revenues from By-Products(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)

Cost of Steel Production – BreakdownB k P i f $ 23Breakeven Price of $575.23

$575.23

$135Capital Cost

Break Even Price

55% of the Cost is related to

$120

$118

Iron Ore (Fines, Lumps & Pellets)

Fuel & Reductantto

Raw Materials, Energy and Reductant

$11

$53

Fluxes

Purchased Scrap & FerroAlloys

$70

$12

M i &O h O&M

Labour

Other Raw Mat'l & Consummables

$55

$0.0 $100.0 $200.0 $300.0 $400.0 $500.0 $600.0

Maintenance & Other O&M

B k P i f HRC &B kd ($/ )Breakeven Price of HRC & Breakdown ($/t)

Cost of Steel Production – BreakdownB k P i f $630 22Breakeven Price of $630.22

Increase in CAPEX and Fuel Cost due to the addition of the CO2 capture facilities represents a $47of the CO2 capture facilities represents a $47

increase in the breakeven price of HRC

Impact of the OBF/MDEA CO2 Capture Plant to the Breakeven Cost of HRC Production(Very Specific to this Study)

• Capital Cost increased by 18.8%• Fuel and Reductant Cost increased by 17.3%

• Coking Coal Cost – decreased by ~24%N t l G C t i d b 495%• Natural Gas Cost – increased by ~495%

• Iron Burden Cost increased by 1.0%• Iron Ore (Fines Lumps and Pellets) Purchased Scrap & Ferroalloys• Iron Ore (Fines, Lumps and Pellets), Purchased Scrap & Ferroalloys

• Fluxes Cost decreased by 9.4%• Significant reduction of limestone and quartzite consumptiong q p

• Other Consumable Cost increased by 15.7%• Increased in cost of raw water consumption• Additional cost due to Chemicals & Consumables used by SGP.• Additional cost due to MDEA/Pz Solvent Make Up

• Labour Cost increased by 1 4%• Labour Cost increased by 1.4%• Maintenance and Other OPEX increased by 10.4%


To incorporate OBF and CO2 Capture in an IntegratedTo incorporate OBF and CO2 Capture in an Integrated Steel Mill prodcuing 4 million tonnes of HRC per year would require an additional $ 753 million in CAPEXwould require an additional $ 753 million in CAPEX

based on New Build Steel Mill Analysis

In terms of OPEX – the steel mill with OBF and MDEA CO2 Capture would require an additional p q

US$ 120 Million per year

This estimates is based on pre feasibility level havingThis estimates is based on pre-feasibility level – having a defined +/-30% accuracy -

and are based on conservative assumptionsand are based on conservative assumptions

Evolution of Coking Coal Price(Data provided by P. Baruya – IEA CCC)

Summary of Results$80.00

y(Sensitivity to Coke Price)

$60 00

$70.00

) OBF/MDEA Case+ $92/t Coke

$50.00

$60.00

ost (US$/t) /

EOP‐L1 Case

$

$30.00

$40.00

voidance Co

OBF Base CaseCO2 Avoidance Cost = ~$56.4/t

$20.00

$

CO2Av

$

It should be noted that Steel Mill used a significant variety of coking coal depending on market price (low to high quality coking coal)

$‐

$10.00 p g p ( g q y g )

COKE is a tradable commodity

0.5P 1P 1.5P 2P 2.5P

Price of Coking Coal

Important Notep• The OBF and MDEA CO2 Capture CAN NOT be p

classified as Post- or Oxy- or Pre- Combustion CO2

Capture TechnologiesCapture Technologies.• Blast furnace is a reduction process (not combustion!)• Separation of the CO2 from the top gas is more

analogous to the removal of CO2 during the processing of natural gas.

• Raw Top Gas from OBF is mainly CO (46%) and CO2

(34%)

Composition of OBF T G P G BOFG d COGOBF Top Gas, Process Gas, BOFG and COG.

OBF Process GasWet Basis (%vol.)

Coke Oven GasCOG

Wet Basis (%vol.)

Basic Oxygen Furnace Gas

(BOFG)

OBF Top Gas(OBF‐TG)

to CO2 Capture Plant

OBF Process Gas (OBF‐PG)

from CO2 Capture Plant Recycled to BF

CH4 23.04H2 59.53CO 3.84

H2 2.64 8.56 12.64

CO 56.92 45.69 67.46

CO2 0.96N2 5.76O 0 19

CO2 14.44 33.89 3.00

N2 13.83 10.07 14.86

12 16 1 79 2 04 O2 0.19H2O 3.98Other HC 2.69

H2O 12.16 1.79 2.04

LHV (MJ/Nm3) ‐wet 17.33

LHV (MJ/Nm3) ‐ wet

7.47 6.69 9.87

Concluding Remarksg• Steel Mill with OBF/MDEA CO2 Capture producing 4

MTPY standard Hot Rolled Coil was defined in detailMTPY standard Hot Rolled Coil was defined in detail in the study.

M B l• Mass Balance• Gas Network• Electricity Network• CO2 emissions of each unit

• Study was able to established a baseline cost for an yIntegrated Steel Mill equipped with OBF, Top Gas Recycle and MDEA/Pz CO2 capture technology.y p gy

Concluding RemarksCo c ud g e a s• Techno-Economics of Iron and Steel Production is very site

ifispecific. • Strategy for CCS Implementation to an integrated steel mill is also very site

specific.p

• IMPORTANT to have a like for like assessment between steel mills without and with CO2 capture.

• Re-emphasized that this study is not meant to develop and evaluate the best available technology for the steel mill and CO2

capture.• One of the main objectives of this study is to establish a Techno-

E i E l ti M th d l (T t) th t ld bEconomic Evaluation Methodology (Transparent) that could be used to estimate cost of CO2 capture in an integrated steel mill on a like for like basisa like for like basis.

Concluding Remarksg• This study only touches the surface...

REFERENCE Steel Mill is based on T pical• REFERENCE Steel Mill is based on Typical Average European Configuration.• It should be expected that there will be inefficiency

in some aspects of the steel mill.p• To maintain a like for like analysis – the CO2

capture configuration can’t include all the Bestcapture configuration can t include all the Best Available Technology as expected for Greenfield Steel Works. (For Example – Steam GenerationSteel Works. (For Example Steam Generation Plant)

Key Message from this Studyy g y• Key to the deployment of CO2 capture technologies using top

l t bl t f h ld l i i thgas recycle to a blast furnace should also maximise the reduction in the coke consumption to make it cost competitive.

• Post-Combustion CO2 Capture – i.e. capture of CO2 from the flue gas of different stacks within the integrated steel mill isflue gas of different stacks within the integrated steel mill - is not a cost competitive option!• This is not the options considered by the global steel community.p y g y

• REPORTING CO2 Avoidance Cost for a complex industrial REPORTING CO2 Avoidance Cost for a complex industrial processes is meaningless – without establishing the assumptions used for the REFERENCE Plant without CO2 Capture.• This is not a good indicator for these cases yet we are trapped in it...

Thank YouStanley SantosIEA Greenhouse Gas R&D ProgrammeIEA Greenhouse Gas R&D [email protected] @ g g g

Back Up Slidep

Key Price Inputsy p• Price inputs for externally and internally

d t i l b d t lsourced raw materials are based on actual operating price data adjusted to long term trends.

• Major intermediate products are priced basedMajor intermediate products are priced based on the gate of the specific operating unit (“Factory”)( Factory ).

• Revenues from sale of by-products is credited to the source of this materials.

• Details of these inputs are presented in the• Details of these inputs are presented in the excert of the Volume 1 Report

Notes on Investment CostNotes on Investment Cost• The integrated steel mill is assumed to have an g

economic life of 25 years as the basis for appraisalappraisal.

• The cost evaluation was developed in US$ (2010) Wh th i(2010). Where necessary, the conversion was based on the following exchange rates:• € 1.00 = US$ 1.34• £ 1 00 = US$ 1 55£ 1.00 = US$ 1.55

• The estimate accuracy is within the range +/-30%30%.

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