Staal zonder schoorsteenpluim: hoe koud en heet CO₂ uit hoogovengas halen
Stel je een staalfabriek voor. Dag en nacht walmt er een hoogoven, de grootste CO₂-bron van de hele site. Toch is die rook een vervelend raadsel voor wie CO₂ wil afvangen: het gas bevat maar een klein deel CO₂, de rest is vooral stikstof. Het is alsof je een paar druppels inkt uit een emmer water wilt filteren. Dat kost veel energie en dus veel geld.
In mijn masterthesis zocht ik een manier om dat probleem om te draaien. Wat als je de inkt eerst concentreert, en pas daarna filtert?
Een omweg via ijzer
Het idee komt van H2Loop, een proces van Rouge H2 Engineering, het bedrijf waar ik mijn onderzoek uitvoerde, samen met de TU Bergakademie Freiberg. Het hoogovengas wordt over ijzeroxide geleid. Dat haalt zuurstof uit de brandbare bestanddelen van het gas, koolmonoxide en waterstof, en wordt zo gereduceerd. Daarna blaast men stoom over het ijzer, dat zijn zuurstof terugneemt en daarbij waterstof vrijgeeft.
Het resultaat is dubbel. Je krijgt schone waterstof als bijproduct. En je houdt een gasstroom over met ongeveer 40 procent CO₂, een stuk meer dan in het oorspronkelijke gas. Daarmee verandert de vraag: welke techniek haalt die CO₂ er het best en het goedkoopst uit?
Zes kandidaten, twee finalisten
Ik begon met een uitgebreid literatuuronderzoek. Aminewassing, de techniek die vandaag het vaakst gebruikt wordt, werkt goed bij verdunde rookgassen en kost volgens de literatuur ongeveer 100 tot 115 euro per ton vermeden CO₂. Membranen zijn modulair en veelbelovend. Ook fysische absorptie en adsorptie kwamen aan bod. Voor een gasstroom die al rijk aan CO₂ is, bleven er twee kandidaten over.
De eerste is cryogene scheiding. Daarbij wordt het gas samengeperst en tot ongeveer min 95 graden afgekoeld, tot de CO₂ vloeibaar wordt en kan worden afgescheiden. De tweede is calciumlooping. Daarbij bindt kalk, bij ongeveer 650 graden, de CO₂ chemisch. In een tweede reactor, op 900 graden, laat de kalk de CO₂ weer los, zodat je een zuivere stroom krijgt.
Twee fabrieken in de computer
Geen van beide technieken bestond al in combinatie met H2Loop. Ik bouwde daarom voor allebei een volledig model in het simulatieprogramma Aspen Plus, voor een installatie die 1.000 kubieke meter hoogovengas per uur verwerkt. Beide modellen vertrekken van exact dezelfde voorbehandeling, zodat de vergelijking eerlijk is: verschillen in kost of prestatie komen dan echt van de scheidingstechniek en niet van het gas dat erin gaat. Met warmte-integratie liet ik de installaties zoveel mogelijk hun eigen restwarmte hergebruiken.
Vervolgens rekende ik uit wat elke installatie zou kosten om te bouwen en te laten draaien. Ik hield rekening met investeringen, onderhoud, personeel, elektriciteit en de Europese CO₂-prijs, en berekende zo de kost per ton opgevangen CO₂.
Beide werken, maar één is goedkoper
Technisch halen beide routes ruim de doelstellingen van meer dan 95 procent zuiverheid en 90 procent afvang. De cryogene installatie levert vloeibare CO₂ met een zuiverheid van 99,9 procent en vangt 95 procent van de CO₂ op die ze krijgt. Calciumlooping scoort 97,6 procent afvang en een bijna zuiver eindproduct. Telt men ook het koolstof mee dat als onverbrande koolmonoxide de installatie verlaat, dan komt de afvang van de hele installatie uit op ongeveer 85 procent voor cryogeen en 93 procent voor calciumlooping.
Het verschil zit in de rekening. Cryogene scheiding kost ongeveer 351 euro per ton CO₂, calciumlooping ongeveer 393 euro. De reden is de energie. Cryogeen vraagt vooral stroom voor compressoren en koeling, ongeveer 1,24 megawattuur per ton CO₂. Bij calciumlooping moet de kalk op 900 graden worden verhit om de CO₂ vrij te maken, en als dat elektrisch gebeurt, verbruikt de calciner alleen al ongeveer 71 procent van alle stroom in de installatie. In totaal gaat het om 1,88 megawattuur per ton CO₂.
Pas rendabel op grote schaal
Op deze proefschaal is geen van beide routes winstgevend. Maar wie opschaalt naar een industriële installatie van ongeveer 68.500 kubieke meter per uur, ziet de cryogene kost dalen naar tussen 213 en 220 euro per ton. Dat ligt onder de verkoopprijs van 260 euro per ton die ik veronderstelde, bijvoorbeeld voor toepassingen in de tuinbouw. Bij calciumlooping blijft de kost rond 280 euro per ton hangen, omdat de elektrische oven nauwelijks goedkoper wordt naarmate de installatie groter wordt.
Daar komt de waterstof bij: de ongeveer 70 ton per jaar die H2Loop oplevert, is goed voor circa 0,28 miljoen euro extra inkomsten per jaar. Aminewassing blijft met 100 tot 115 euro per ton wel goedkoper, omdat het goedkope stoom gebruikt in plaats van dure stroom.
De stroomprijs en de schaal bepalen dus het meest of een route haalbaar is, veel meer dan de investeringskost of de financiering. Voor dit soort geconcentreerd gas is cryogene scheiding daarom de aanbevolen keuze. Calciumlooping blijft op lange termijn interessant, maar enkel met een andere verwarming van de oven en een nuttige toepassing voor de vrijkomende hitte, bijvoorbeeld in samenwerking met een cementfabriek.
Wat ik niet kon bewijzen
Een simulatie is geen fabriek, en dat wil ik eerlijk zeggen. De modellen gaan uit van evenwicht, terwijl een echte installatie in cycli werkt. Voor ijzeroxide bestaat bovendien geen model dat het gedrag volledig juist beschrijft. Daarom geef ik mijn resultaten als een bandbreedte, met een optimistische bovengrens en een voorzichtigere ondergrens. In beide gevallen blijft de rangorde van de twee routes dezelfde.
Er is nog een aandachtspunt. Bij de lage temperaturen in de cryogene kolom kan CO₂ bevriezen. Een systeem dat dat voorkomt, zit nog niet in mijn kostenraming en moet nog worden ontworpen. Ook zijn proefinstallaties nodig om de resultaten te bevestigen.
Staal is onmisbaar en moeilijk te vervangen, dus elke euro die we besparen op afvang telt. Wat ik wel meeneem, is een les: er bestaat geen beste afvangtechniek. De juiste keuze hangt af van het gas dat je krijgt en van de stroom die je kunt betalen. Wie staal wil verduurzamen, doet er goed aan eerst het gas te concentreren, voor het gefilterd wordt. Dat is de kern van mijn onderzoek.
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