Climate Change, the Steel Industry and the Race to the
MoonMoon
Lawrence Kavanagh
January 8, 2008
Goal is relatively clear…but not how to get there
•Reduce CO2 emissions by 50% by 20502050
•Believed to result in temperature increase of < 2 degrees
Energy use
R & D into new processes
R & D into new processes opens up large energy savings and CO 2
mitigation opportunities
1990 2006
Lowest energy/CO 2possible today’s processes
2020
Lowest energy/CO 2possible tomorrow’s processes
Energy consumption per ton shipped in U.S. steel industry
60
M B
TU
/Ton
29% reduction29% reduction29% reduction29% reduction
Energy consumption per ton shipped inU.S. steel industry [MBTU]
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M B
TU
/Ton
29% reduction29% reduction29% reduction29% reduction
Energy use
R & D into new processes
R & D into new processes opens up large energy savings and CO 2
mitigation opportunities
1990 2006
Lowest energy/CO 2possible today’s processes
2020
Lowest energy/CO 2possible tomorrow’s processes
CO2 Breakthrough Program
• Two projects ready for Phase 2:– Molten Oxide Electrolysis—MIT
– Hydrogen Flash Smelting—Univ. of Utah
• Two still under study– Sequestration using Steelmaking Slags—UMR
– Steel Works as Sequestration Works—Columbia University
Hydrogen Flash Smelting
• Develop an ironmaking process based on:
– Hydrogen
– Without coke– Without coke
– Without pelletization/sintering
• Main goal:
Significant reduction in energy consumption
and CO2 generation in the steel industry
CO2 Emissions
BF[kg/tonHM]
Prop'd (Using
H2)[kg/ton
Prop'd (Using CH4)
[kg/ton
Prop'd (Using Coal)
[kg/ton
Calculated CO2 Emissions
HM] [kg/tonHM]
[kg/tonHM]
[kg/tonHM]
CO2Emission 1671* 71 650 1145
Bench-Scale Flash Furnace
Hydrogen Flash SmeltingPhase Two
• Comprehensive tests of various gaseous reducing agents & fuels
• Pilot Scale Research
� Complete material and energy balances; economics; scale-up factors
• Design & cost estimation of the industrial test facility
Molten Oxide Electrolysis-Objectives
� Assess the technical viability of the
production of iron by molten oxide
electrolysiselectrolysis
� Identify inert anode and its ability to sustain oxygen evolution
� Develop a fully functional laboratory-scale electrolysis cell that produces metallic iron along with by-product oxygen
Environmental Impact & Energy Savings
� COCOCOCO2222 emissions reduced from 1750 emissions reduced from 1750 emissions reduced from 1750 emissions reduced from 1750
kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast
furnace technology to 345 kg/tonne liquid furnace technology to 345 kg/tonne liquid furnace technology to 345 kg/tonne liquid furnace technology to 345 kg/tonne liquid
steel: a fivesteel: a fivesteel: a fivesteel: a five----fold reductionfold reductionfold reductionfold reduction
Electrolytic production of molten iron
iron
Steelmaking by Molten Oxide ElectrolysisBuild Pilot Cell
10,000 Amp
2.3 Volts
~ 180 kg/day Fe
~ 77 kg/day O2
Anode Area 2 m2
(FeOx) Fe+2(llll) + ½ O2
Current density 5A/cm2
1800oK
Variables to Measure:
Efficiency
Vary Temperature
Vary Voltages
Process Operating Costs
Process Parameters
Fe+2+2e Feo
100
120
140
160
180
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The Race to the Moon
Call to action: May 25, 1961
Apollo 11 launch: July 16, 1969
Eight Years to Success•Eight years
•$23 billion
•National Goal
•Coordinated approach
Man lands on Moon: July 20, 1969
•Coordinated approach
The Solution to Global Climate Change….
• is based on technology, e.g., new process development [energy supply, cars, ind.]• should be a national program based on a • should be a national program based on a national goal [50% by 2050?]• linked to a global program
Follow the Space Program model…