carbon Capture and Use at a STeel plant with an Advanced solution to Reach Decarbonisation

Introduction

CUSTARD aims to reduce the carbon dioxide (CO2) emissions of a steel plant (managed by Acciaierie Bertoli Safau Spa). Thanks to innovative Carbon Capture and Usage (CCU) technology, about 13,000 tons of CO2 will be captured annually from the flue gases of a reheating furnace and used in a chemical reaction with caustic soda to produce a high value-added chemical compound (sodium bicarbonate) to be sold on the market.

Greenhouse Gas Reduction

In terms of relative greenhouse gas reduction, around 40% CO2 equivalent (CO2e) with respect to the most adopted method for bicarbonate production (the Solvay process for reference) will be saved during the first 10 years of operation.

Production Process

The sodium bicarbonate production route proposed by CUSTARD will be based on:

1. Caustic soda production from green electrolysis.
2. The available use of waste heat, thus reducing the final product’s carbon footprint.

After passing through a carbon capture and concentration unit and a caustic soda scrubbing unit, the reagents enter a 3-phase reactor where sodium bicarbonate is generated, followed by its crystallisation and purification to reach food grade quality. Furthermore, no by-products are generated.

Comparison with Other Industries

Similar CCU applications are already present in other industrial sectors, such as in energy; however, no CCU technologies of this kind (characterised by flue gases with variable flow rates and CO2 concentration) have been tested in the steel sector.

Impact on the Steel Industry

The CCU technology will impact the steel industry as a climate mitigation measure and energy-intensive industries in general. The reduction of CO2 could contribute to the decarbonisation goals set in the European Green Deal in all sectors. Once it has been industrially applied in the steel sector, the technology could be replicated in other steel plants in Europe as well as in other hard-to-abate (i.e., cement, glass, ceramic) industries, including the chemical sector.

Community Benefits

The local community will benefit from CUSTARD thanks to the creation of new jobs both in the direct workforce of the new plant and in the possible related services. The region will increase its gross domestic product since both sodium bicarbonate and caustic soda will be produced in the same local area.

Development of Regional Competence

Moreover, CUSTARD will promote the development of a regional centre of competence for circular carbon chemistry, including a private research centre (Serichim s.r.l.) with local universities that already collaborate with the project partners.