Boosting Reduction of Energy Intensity in cleaN STeelwork platfORM

Lead Research Organisation: University of Manchester
Department Name: Chem Eng and Analytical Science

Abstract

Iron and steel is the largest UK manufacturing industry in terms of energy demand and greenhouse gas (GHG) emissions. Currently, more than 6 Mt of steel per year are produced in six blast furnaces at two steelworks with specific energy consumptions of 19 GJ/t of steel and overall direct CO2 emissions of 13 Mt, contributing 25% to GHG emissions from UK manufacturing. Combustion of blast furnace gas (BFG) in the power station causes ~ 50% of CO2 emissions.

In BREIN-STORM we propose to convert the BFG from steel mills into valuable products, such as hydrogen and pure carbon dioxide. This will be achieved by combining calcium and chemical looping gas-solid reactions (CaL-CLC). This four-year project comprises four interlinked work packages (WPs):
1. WP1 will develop and scale up different multi-functional materials based on calcium oxide as sorbent and copper-oxide oxygen carriers. We will focus on increasing the stability over cycling operation and the sorption capacity of the materials. The produced material will be tested and characterised to examine longevity. The kinetics models will be derived to enable the scale up.
2. WP2 will focus on the development and testing of the reactor. We will carry out the experimental demonstration and long-term testing under different reactive conditions in packed and fluidised bed configurations. The experimental results will be used to validate the reactor model. The knowledge gained both from the experimental and numerical activities will be used as guidance for future pilot-scale demonstration of the technology.
3. In WP3, the CaL-CLC process will be integrated into the steelworks through a conceptual design. The techno-economic performance of the process will be compared with standard state-of-the-art technologies in the steel sector. The integration of renewables sources will be studied with the aim of designing a first 'green' steelworks plant.
4. In WP4, the developed process will be evaluated on environmental impacts as well as social and policy implications.

Planned Impact

The BREIN-STORM project will develop a new, promising technology to reduce energy consumption and GHG emissions in the steel sector. The results are expected to generate significant impacts as follows:

- Industry: the BREIN-STORM project will help the sector to reduce its energy use by 20% and its GHG emissions by up to 90%.
- Policy: A white paper will be produced to guide policy makers on policy instruments needed to stimulate the transition of the steel industry towards a low-energy future within a circular economy context.
- Knowledge: The project will develop cutting-edge materials, technology and sustainability analyses that will have an impact of researchers internationally, particularly those working in the fields of manufacturing, energy, process design and sustainability assessment.
- People: By working in a multidisciplinary team, the early-career researchers will gain knowledge outside their own discipline and learn how to communicate to those outside their field. By working closely with industry, they will be able to appreciate the balance between fundamental research and the needs of the commercial sector.
- Economy and society: By reducing GHG emissions and improving other environmental and social sustainability aspects associated with energy provision, the project will contribute to a better quality of life in the UK. Reducing energy use will also reduce costs of steel production. This will in turn help to improve the productivity in UK manufacturing, benefiting the economy as a whole.

Publications

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Jeswani H (2022) Environmental sustainability of negative emissions technologies: A review in Sustainable Production and Consumption

 
Description The BREINSTORM project has shown high potential to reduce carbon emissions from steel industry in view of the use of the blast furnace gas which represents approximately 50% of the CO2 generated in the integrated steelmill. In case of CCS, the cost of CO2 avoidance will depend on the type of utilities used to supply the additional energy for the separation, in particular for the electricity which is needed to allow for the gas separation.
in case of carbon capture and utilisation, the combination of blast furnace gas and green hydrogen could lead to a large production of low-carbon fuels and substantially reuse the the carbon by reducing the impact on fossil fuel depletion. The project have identified few relevant applications and already engaged with policy makers and industrial stakeholders to consider further development and improvment.
Exploitation Route Continuous interactions between academics and industrial partners
Improvement of the developed tools to understand the technology more accurately and provide solid theoretical and industrial background to partners
Finalise the techno-economic and environmental performance to provide the necessary indicators which would quantify the real impact on society.
Sectors Chemicals

Energy

 
Description The results of this project has generated interest among industrial company within UK and Europe. As an example, TotalEnergies, Johnson Matthey and Arcelor Mittal have engaged with us to develop further study for the decarbonisation of chemical and energy processes and steel industry. the research grants which are following this project includes the scale up of the technology to decarbonise also steel industry.
First Year Of Impact 2023
Sector Chemicals,Energy
Impact Types Economic

 
Description (C4U) - Advanced Carbon Capture for steel industries integrated in CCUS Clusters
Amount € 13,845,497 (EUR)
Funding ID 884418 
Organisation European Commission 
Sector Public
Country European Union (EU)
Start 03/2020 
End 03/2024
 
Description Low Carbon Hydrogen Supply 2 Stream 1 Phase 1 Competition: RECYCLE
Amount £288,668 (GBP)
Funding ID HYS2137 
Organisation Department for Business, Energy & Industrial Strategy 
Sector Public
Country United Kingdom
Start 01/2022 
End 10/2022
 
Description RECYCLE BEIS - Phase II
Amount £5,110,205 (GBP)
Organisation Department for Business, Energy & Industrial Strategy 
Sector Public
Country United Kingdom
Start 03/2023 
End 01/2025
 
Title High pressure laboratories for gas-solid reactions 
Description We have an advanced chemical engineering laboratory that has been upgraded in the past year in which we can operate fluidised and packed beds for gas-solid and catalytic reactions that could operate up to 10 bar and 900 °C using different reactive gases such as methane, air, carbon monoxide and carbon dioxide, water/steam, hydrogen, helium, nitrogen. 
Type Of Material Improvements to research infrastructure 
Year Produced 2022 
Provided To Others? Yes  
Impact Scientific and technical impacts. The laboratory has attracted interest of companies which can now test their materials at relevant conditions. 
 
Title 1D and 2D model for gas-solid reactions 
Description in the framework of this project, we have develop and 1D and 2D model to simulate the performance of gas-solid reaction that operates at very high temperatures in presence of a high heat of reactions. The model has been successfully validated with experimental results. the model is developed in C++ 
Type Of Material Computer model/algorithm 
Year Produced 2021 
Provided To Others? No  
Impact Scientific and Economic Impact the model proposed is unique and industries (Johnson Matthey and TotalEnergies) are interested to use it for the design and scale up of chemical and energy processes 
 
Description UKCCSRC - collaboration with UCL 
Organisation University College London
Country United Kingdom 
Sector Academic/University 
PI Contribution This is a collaboration with UCL, Prof. Haroun Mahgerefteh to perform a feasibility study on how to covert waste blast furnace gas into valuable chemical product.
Collaborator Contribution the UCL is carrying out the thermodynamic performance analysis of one of the technology to be developed in BREISTORM integrated with a system for the synthesis of liquid fuels
Impact the collaboration is currently ongoing
Start Year 2019
 
Description collaboration with Clariant Produkte (Deutschland) GmbH 
Organisation Coriant
Country Germany 
Sector Private 
PI Contribution Clariant is interested to explore and exploit the integration of chemical looping and reverse water gas shift using their materials. The University of Manchester has tested their material over a series of relevant conditions. The results obtained are leading to the preparation of a separate research proposal to follow up this work
Collaborator Contribution CLARIANT has supplied up to 2 kg of synthesis catalysts which was prepared for the testing in this project
Impact - material synthesized by CLARIANT - testing of the innovative process developed in this Project using industrial samples
Start Year 2023