Mirror Group, Brussels, 9 November 2010 1
ULCOS program: status & progress
Jean-Pierre Birat, European
Coordinator of the ULCOS program
Ultra Low CO2 Steelmaking
Mirror Group, Brussels, 9 November 2010 2
Outline
• what is ULCOS?
– a vision, a methodology for choosing breakthrough
processes, a set of dedicated partners and talented
people, more than 20 CO2-lean processes and 4
ULCOS breakthrough processes (CO2 cuts>50%)
• the ULCOS processes
• socio-economic analysis of the ULCOS solutions
• foresight and long-term vision
• conclusion
Mirror Group, Brussels, 9 November 2010 3
Outline
• what is ULCOS?
– a vision, a methodology for choosing breakthrough
processes, a set of dedicated partners and talented
people, more than 20 CO2-lean processes and 4
ULCOS breakthrough processes (CO2 cuts>50%)
• the ULCOS processes
• socio-economic analysis of the ULCOS solutions
• foresight and long-term vision
• conclusion
Mirror Group, Brussels, 9 November 2010 4
The 48 partners…
Mirror Group, Brussels, 9 November 2010 5
Partners active
in phase II of ULCOS I
Mirror Group, Brussels, 9 November 2010 6
ULCOS II consortium
Mirror Group, Brussels, 9 November 2010 7
Outline
• what is ULCOS?
– a vision, a methodology for choosing breakthrough
processes, a set of dedicated partners and talented
people, more than 20 CO2-lean processes and 4
ULCOS breakthrough processes (CO2 cuts>50%)
• the ULCOS processes
• socio-economic analysis of the ULCOS solutions
• foresight and long-term vision
• conclusion
Mirror Group, Brussels, 9 November 2010 8
ULCOS processes…
Coal & sustainable biomass Natural gas Electricity
Revamped BF Greenfield Revamped DR Greenfield
ULCOS-BF HIsarna ULCORED ULCOWIN
ULCOLYSIS
Pilot tests (1.5 t/h)
Demonstration
under way
Pilot plant (8 t/h)
start-up 2010
Pilot plant (1 t/h)
to be erected in
2011 ?
Laboratory
Mirror Group, Brussels, 9 November 2010 9
Technology Program 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2025 2030 2031 +
ULCOS-BF FP6 ULCOS
RFCS ULCOS
RFCS IDEOGAS
RFCS TGR-BF
Florange demonstrator
Green BF
1st commercial implementation
Hisarna FP6 ULCOS
Hisarna RFCS
Hisarna demonstrator
Hisarna 1st commercial
ULCORED FP6 ULCOS
ULCORED RFCS
ULCORED demonstrator
ULCORED 1st commercial
Electrolysis
(ULCOWIN &
ULCOLYSIS)
FP6 ULCOS
RFCS IERO
ANR ASCOPE
Autothermal cell
Electrolysis demonstrator
1st commercial
H2 prereduction FP6 ULCOS
further work…
Use of biomass FP6 ULCOS
further work…
program either on-going or under cosntruction
on-going program's uncertainty on time scope
new programs to be organized
concept - no programs under cosntruction
ULCOS I
ULCOS II
1st commercial implementation
On-going & future projects
Mirror Group, Brussels, 9 November 2010 10
ULCOS-BF
Mirror Group, Brussels, 9 November 2010 11
ULCOS-BF
CO2
COO2
Underground
storage of CO2
0.8 t/tsteel
-100 kg coke/tsteel
CO2 emissions of the steel plant: - 60%
Mirror Group, Brussels, 9 November 2010 12
iron
Iron ore
Coal
Oxygen
Oxygen
CCF cyclone
(CORUS)
Smelter
(HIsmelt)
HIsarnaCCS
Mirror Group, Brussels, 9 November 2010 13
ULCORED
• EDRP* planned by LKAB in
Luleå
• ULCORED features
implemented within an RFCS
project to be proposed in 2011
* Experimental Direct Reduction Pilot
Mirror Group, Brussels, 9 November 2010 14
ULCOWIN
• alkaline electrolyte with
dispersed hematite particles
• 3.5 kg samples of pure iron
• 3 MWh/t, 90% Faradic yield
targets
• 0.1 A/m2, 1.8 V (target: 1.6)
• electrode materials identified
• inert anode
electrowinning cell
Mirror Group, Brussels, 9 November 2010 15
Outline
• what is ULCOS?
– a vision, a methodology for choosing breakthrough
processes, a set of dedicated partners and talented
people, more than 20 CO2-lean processes and 4
ULCOS breakthrough processes (CO2 cuts>50%)
• the ULCOS processes
• socio-economic analysis of the ULCOS solutions
• foresight and long-term vision
• conclusion
Mirror Group, Brussels, 9 November 2010 16
Energy consumption
0,0
5,0
10,0
15,0
20,0
25,0
BBF
BBF+C
CS(P
P)
TGR-B
F V4
HIS
ARNA
HIS
ARNA+C
CS
HIS
ARNA+E
AF
HIS
ARNA+C
CS+E
AF
MID
REX
MID
REX+C
CS
ULC
ORED
ULC
OW
IN
ULC
OLY
SIS
GJ/t
HR
C
Coals, oil and other C-rich sources Natural gas and biomass gas Electricity and energy vectors (steam, H2)
Mirror Group, Brussels, 9 November 2010 17
CO2 emissions – 370 g/kWh
-2,0
-1,5
-1,0
-0,5
0,0
0,5
1,0
1,5
2,0
BBF
BBF+C
CS(P
P)
TGR-B
F V4
HIS
ARNA
HIS
ARNA+C
CS
HIS
ARNA+E
AF
HIS
ARNA+C
CS+E
AF
MID
REX
MID
REX+C
CS
ULC
ORED
ULC
OW
IN
ULC
OLY
SIS
t C
O2/t
HR
C
Scope 1 Scope 2 CO2 captured
Mirror Group, Brussels, 9 November 2010 18
CO2 emissions – 5 g/kWh
-2,0
-1,5
-1,0
-0,5
0,0
0,5
1,0
1,5
2,0
BBF
BBF+C
CS(P
P)
TGR-B
F V4
HIS
ARNA
HIS
ARNA+C
CS
HIS
ARNA+E
AF
HIS
ARNA+C
CS+E
AF
MID
REX
MID
REX+C
CS
ULC
ORED
ULC
OW
IN
ULC
OLY
SIS
t C
O2/t
HR
C
Scope 1 Scope 2 CO2 captured
Mirror Group, Brussels, 9 November 2010 19
CO2 emissions – 160 g/kWh
-2,0
-1,5
-1,0
-0,5
0,0
0,5
1,0
1,5
2,0
BBF
BBF+C
CS(P
P)
TGR-B
F V4
HIS
ARNA
HIS
ARNA+C
CS
HIS
ARNA+E
AF
HIS
ARNA+C
CS+E
AF
MID
REX
MID
REX+C
CS
ULC
ORED
ULC
OW
IN
ULC
OLY
SIS
t C
O2
/t H
RC
Scope 1 Scope 2 CO2 captured
Mirror Group, Brussels, 9 November 2010 20
OPEX index - 2010
0
20
40
60
80
100
120
140
BB
F
BB
F+
CC
S(P
P)
TG
RB
F V
4
HIS
AR
NA
HIS
AR
NA
+E
AF
HIS
AR
NA
+C
CS
HIS
AR
NA
+C
CS
+E
AF
ULC
OR
ED
MID
RE
X
MID
RE
X +
CC
S
ULC
OW
IN
ULC
OLY
SIS
CO2 release
Raw material and energy
Fix
Mirror Group, Brussels, 9 November 2010 21
OPEX index - 2050
0
50
100
150
200
250
300
350
BB
F
BB
F+
CC
S(P
P)
TG
RB
F V
4
HIS
AR
NA
HIS
AR
NA
+E
AF
HIS
AR
NA
+C
CS
HIS
AR
NA
+C
CS
+E
AF
UL
CO
RE
D
MID
RE
X
MID
RE
X +
CC
S
UL
CO
WIN
UL
CO
LY
SIS
CO2 release
Raw material and energy
Fix
F2 World DCV scenario
POLES model
Mirror Group, Brussels, 9 November 2010 22
ULCOS-BF with >>50% CCS
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
1,00
1,10
ULCOS-
BF
sinter
plant
reheating
furnace
steel
plant
hot
stoves
lime kiln coke
ovens
compared to ULCOS-BF Mill
emissions
compared to emissions of the
benchmark Mill
Rate of CO2 capture (each bar means
adding one more plant to the Steel Mill)
Mirror Group, Brussels, 9 November 2010 23
Outline
• what is ULCOS?
– a vision, a methodology for choosing breakthrough
processes, a set of dedicated partners and talented
people, more than 20 CO2-lean processes and 4
ULCOS breakthrough processes (CO2 cuts>50%)
• the ULCOS processes
• socio-economic analysis of the ULCOS solutions
• foresight and long-term vision
• conclusion
Mirror Group, Brussels, 9 November 2010 24
Virgin & recycling routes…
0
500
1000
1500
2000
2500
3000
2010 2050 trend 2050 LC
Steel production (Mt/yr)
CO2 generation (Mt/yr)
Mirror Group, Brussels, 9 November 2010 25
Timeline - 1
13
Ligne de temps…
2010
2015
2020
2030-
TGR-BF with CCS
ULCORED
HIsarna
ULCOWIN,
ULCOLYSIS
500 M€
1,500 M€
Mirror Group, Brussels, 9 November 2010 26
Timeline -2
13
Ligne de temps…
2010
2015
2020
2030-
2020
2030
2040
TGR-BF with CCS
ULCORED
HIsarna
ULCOWIN,
ULCOLYSIS
2020
Mirror Group, Brussels, 9 November 2010 27
Outline
• what is ULCOS?
– a vision, a methodology for choosing breakthrough
processes, a set of dedicated partners and talented
people, more than 20 CO2-lean processes and 4
ULCOS breakthrough processes (CO2 cuts>50%)
• the ULCOS processes
• socio-economic analysis of the ULCOS solutions
• foresight and long-term vision
• conclusion
Mirror Group, Brussels, 9 November 2010 28
Conclusion: innovation & risks
• if the demonstrators are successful…
• …and if the economic conditions for
implementing the ULCOS routes are
right…
• … then deployment should follow up for
most of the Steel Mills in Europe, and,
eventually in the world, for the Steel
Industry to meet its post-Kyoto targets
Mirror Group, Brussels, 9 November 2010 29
Thank you!
Mirror Group, Brussels, 9 November 2010 30
Program, projects
FP6: ULCOS, 2004-2010
RFCS: ULCOS, 2004-2009
RFCS: IDEOGAS, 2006-2011
RFCS: TGR-BF, 2009-2011
RFCS: IERO, 2010-2012
ADEME: ULCOS II
ANR: ASCOPE
RFCS: HIsarna
RFCS: ULCORED, etc.