On August 31, the world's first non-fossil-free sponge iron pilot plant was launched in Luleå, Sweden. HYBRIT is Sweden’s "Breakthrough Hydrogen Ironmaking Technology" technical research project, which was jointly established by three industry giants (SSAB, Europe’s largest iron ore producer LKAB, and one of Europe’s largest power producers) Sweden’s Great Falls Power Company HYBRIT Development Co., Ltd. is responsible for the promotion. SSAB, LKAB and Vattenfall plan to build the world's first "fossil-free steel manufacturing" value chain.
SSAB’s goal is to be the first in the world to achieve fossil-free smelting technology through HYBRIT technology by 2026; by 2045, SSAB will completely manufacture steel based on a fossil-free process route.
The pilot project includes 3 units:
(1) Direct reduction iron and hydrogen production unit in Luleå
The unit is in SSAB's Svartön factory. Produce hydrogen in a pilot plant and use hydrogen to directly reduce iron ore (DRI). The main energy source is fossil-free electricity from Vattenfall. Using electrolysis of water to produce hydrogen on a large scale and electric arc furnace technology to replace coal with electricity and hydrogen requires 15 TWh per year, equivalent to 1/10 of Sweden’s annual electricity generation.
(2) Fossil-free pellet units located in Malmberge and Luleå
An experimental burner in Luleå and a factory in Malmberge are experimenting with alternative fuels and new heating technologies, which will transform heating from fossil fuels to heating with renewable biofuels. The experimental bio-oil system is part of the experimental phase, with the goal of converting a pellet plant at LKAB from fossil fuels to 100% renewable fuels. Carbon dioxide emissions from Malmberge’s fossils will be reduced by 40%, equivalent to about 60,000 tons per year.
(3) Hydrogen storage unit in Luleå (planned to be constructed in 2021)
Plans to build a hydrogen storage research facility for energy storage. The pilot plant is located in SSAB's industrial area in Luleå. The possibility of building a temporary small-scale experimental storage area in the old iron ore storage area of Svartöberget near the SSAB industrial area is under investigation. It can balance the power grid through peak staggering. This will be an important part of supporting and stabilizing the energy system in the future.
The process flow comparison between HYBRIT and traditional blast furnace is shown in the figure below: (The process route of traditional blast furnace is on the left, and the process route of HYBRIT is on the right).
The total cost of the pilot phase is estimated to be around SEK 2 billion. The Swedish Energy Agency has pledged to invest 599 million Swedish kronor, and the three owners of SSAB, LKAB and Vattenfall will contribute equal shares.
The next step of the HYBRIT project
(1) The industrial-grade demonstration line is constructed simultaneously with the HYBRIT pilot line.
The start of the industrial-grade demonstration line was 3 years earlier than the original plan. It is planned to start construction in 2023 and put into production a demonstration plant in 2025. The demonstration plant has an annual capacity of 1 million metric tons, which is 20% of LKAB's total capacity in Malmberget, and nearly half of SSAB's blast furnace in Luleå.
At the same time, SSAB's Oxelösund blast furnace will be transformed, and it is planned to realize a commercial iron ore-based, fossil-free smelting process route in 2026. SSAB will reduce CO₂ emissions by 25% as early as 2025.
(2) After the demonstration plant is successful, carry out a thorough transformation of the traditional process route.
It is planned to switch all its traditional blast furnaces to electric arc furnaces between 2030 and 2040. At the same time, SSAB has begun to phase out the fossil fuel process of the entire company's rolling mills and heat treatment plants, and will completely realize fossil-free steel manufacturing in 2045.
