STEPWISE: cost effective capturing of CO in the Iron ... · in the Iron & Steel industry ... •Platform Technology for Syngas Treatment –Upgrade Blast Furnace Gas: remove CO 2,

TCCS9 Trondheim 2017

www.ecn.nl

STEPWISE: cost effective capturing

of CO2 in the Iron & Steel industry

Sorption-Enhanced Water-Gas Shift (SEWGS)

TCCS9, Trondheim

13/06/2017


Sorption-Enhanced Water Gas Shift

Sorption-Enhanced Water-Gas Shift - SEWGS

• Platform Technology for Syngas Treatment – Upgrade Blast Furnace Gas: remove CO2, convert CO to H2

– Valorization of H2 in CO2/CO containing syngas streams

• Technology - High carbon capture ratio with unique low steam use (H2O/CO2 < 1.0)

- Able to operate under sour conditions and to remove H2S as well as CO2

- SEWGS technology builds further on the vast industrial experience with PSA systems.

- Combination of several process steps into one (process intensification)

- Highest efficiencies for short-to-medium term developments

• Cost effective CCS solution for BFG – For BFG, cost per ton CO2 avoided estimated 25% lower than state of the art


ECN’s current involvement in

decarbonisation of the Iron & Steel industry

Decarbonisation of blast furnace gas (BFG) for the iron & steel industry power plant

Utilization of the energy content of the residual steel gases for production of methanol from CO2

Use timely power price opportunities, in order to provide affordable H2 for current uses in the steel making processes

Wednesday 13:20-40 D5-CCUS

STEPWISE Project Introduction


SEWGS

• Sorption-Enhanced Water-Gas Shift (SEWGS) – Initial targeted application Carbon Capture and Sequestration (CCS)

– Power production with CO2 capture

CO + H2O CO2 + H2 DH = -41 kJ/mol

• Practical Reaction Conditions – Two stage conversion of CO

– 12% 3% 0.5%

– 350-400°C 180-250°C

– 20-30 bar

In situ removal of carbon dioxide


Stepwise pilot approach

CC BFG

WGS SEP

CO2

- Hot separation - Pre-shift ↓

>10 GJ/tonne CO2

Heat exchange


The Intensification Step

• Combines the Water-Gas-Shift reaction with sorbent material to simultaneously produce H2 at high temperature whilst also capturing CO2

H2

H2O

H2O

CO

H2

CO2

H2O H2O

CO2

Water-Gas Shift: CO + H2O CO2 + H2

Carbonate Formation

Decarbonisation


Process Intensification Intensified

PSA SEWGS

Dry Syngas

>50% H2

99.9%+ H2 purity 99%+ H2 recovery

H2/CO/CO2

(30% H2)

CO2

(99%+ CO2)

Syngas

<65% CO+CO2

H2O

Ads1

Ads2

Ads3

Ads4

Ads1

CO2 capture H2S capture COS conversion CO conversion

H2


SEWGS: moving into the future


Ambition Level


Partners: supply chain


Development Timeline

• 2004 – First experimental tests

– proving feasibility of high temperature CO2 capture

• 2005 – First systems analysis – indicating high efficiency compared to base-case systems

• 2006 – High Pressure Single-Column Unit – 2m column taking industrial relevant materials

• 2007 – SEWGS for gasification

– proving feasibility in sour gas applications

• 2008 – Multi-Column Unit – 6x6m column system demonstrations of full cycle

• 2010 – Process Improvements – significant reduction in steam use for regeneration

• 2011 – New sorbent class

– boosting performance by 100%

• 2012 – Techno-economic evaluation – 35% lower that base-case state-of-the-art system IGCC

• 2014 – Further reduction in steam demand

– New cycles for Blast Furnace Gas

• 2015 – Industrial Scale Production of Sorbent

• 2016 – Start construction pilot plant 800m3/hr

Major Innovations

Sorbent Stability

H2S recovery Shift Activity

H2S/CO2

separation “Stress Test” Low steam

demand WGS


Stepwise Pilot Demonstration:

Progress

CC

BFG WGS SEWGS

CO2

Utilities

Blast Furnace


WGS: Impact of BFG conditions

14

1) BFG composition significantly different from conventional WGS operation

Fe2O3 ↔ Fe3O4 ↔ FeO → Fe

At S/CO=2.8 mol/mol

Dry gas (%) CO CO2 H2 N2 R

SRG 12.9 7.5 56.5 22.5 1.6

BFG 20.3 24.5 3.3 51.4 0.3

2) BFG contains 10-30 ppm H2S+COS

fresh active phase over-reduction

side-reactions1)

CO+3H2 → CH4+H2O 2CO → C+CO2

OHCO

HCOR

22

2

<1.62)

1) Twigg, Catalyst Handbook, second edition, 1989 2) Smith et al., Int.J.Chem.Reaction.Eng., 8, 2010, review R4


WGS catalyst lab testing

• Promising performance of FeCr-based catalyst in presence of 15 ppm H2S

15

= lowered steam operation

clean BFG 15ppm H2S BFG

temperature CH4

temperature

CH4

25 bar, pellets, simulated BFG

15


SEWGS sorbent

• Chemical composition tuned and validated – Al–Mg content

• Industrial production of 14 tonnes base material – Utilization of industrial standards and procedures

• Optimization of processing and shaping – On-going activities

16


Main Message in One Sheet

Sorption-Enhanced Water-Gas Shift - SEWGS

• Technology - High carbon capture ratio with unique low steam use

- Able to operate under sour conditions and to remove H2S as well as CO2

- SEWGS technology builds further on the vast industrial experience with PSA systems.

- Combination of several process steps into one (process intensification)

- Highest efficiencies

- For BFG, costs per ton CO2 avoided estimated to be 25% lower than state of the art

- Better understanding of H2O/CO2 interaction leads to new cycle design

• Platform technology for syngas treatment, near future – STEPWISE will extend the SEWGS technology to TRL6 for BFG


7th High Temperature Solid

Looping Cycles Network Meeting

• 4-5th September 2017

• Luleå, Northern Sweden

Pilot Grand Opening

http://www.ieaghg.org/networks/high-temperature






Acknowledgement

This presentation is part of the STEPWISE project that has received funding from the European

Union’s Horizon 2020 research and innovation programme under grant agreement No. 640769

www.stepwise.eu

[email protected]


Thank you for your attention

ECN

Westerduinweg 3 P.O. Box 1

1755 LE Petten 1755 ZG Petten

The Netherlands The Netherlands

T +31 88 515 49 49 [email protected]

F +31 88 515 44 80 www.ecn.nl

Iron & Steel related projects STEPWISE – decarbonised power FReSMe – methanol H2Future – H2-fueled production CURE – Urea from residual steel gases Other opportunities SEWGS for decarbonisation of H2 streams

Documents

STEPWISE: cost effective capturing of CO in the Iron ... · in the Iron & Steel industry ... •Platform Technology for Syngas Treatment –Upgrade Blast Furnace Gas: remove CO 2,