ThyssenKrupp Steel Europe AG, Duisburg, Germany:

Hirsch A., Dr. Eng., Project Engineer, Ironmaking Technology,

alexandra.hirsch@thyssenkrupp.com

Tata Steel Europe, Ijmuiden, The Netherlands:

van der Stel J., Knowledge Group Leader, Tata Steel Research Development & Technology

ArcelorMittal, Maizi`eres-l`es-Metz Cedex, France:

Sert D., Researcher, Global Research and Development

The ULCOS blast furnace process (ULCOS BF) aims at minimizing CO₂ emission of the blast furnace by at least 50 %. This process is based on the replacement of hot blast by cold oxygen, the recycling of decarbonated top gas into the lower shaft and normal tuyeres, the capture of CO₂ and its storage in a geological trap (full CCS process). Technological improvements in blast furnace process and development of reducing agent rate in Europe are analyzed. The ULCOS process routes are displayed and the ULCOS blast furnace concept has been demonstrated during three campaigns at the LKAB Experimental Blast Furnace in Luleå, Sweden. Following the success of these trials, the construction of a demonstration unit is currently under progress. These three campaigns proved that the new top gas recycling process can be operated safely and lead to efficient and stable process conditions. A  considerable reduction in a fossil carbon (coke and coal) consumption was achieved by the re-injection of decarbonated top gas, in accordance with the preliminary heat and mass balance calculations. The results show that by applying top gas recycling and CCS technology a reduction in CO₂ emission in industrial operation of around 50 to 60% per t of hot-rolled coil seems feasible. It is mentioned that the core members of ULCOS consortium have now reorganized in an ULCOS II consortium to continue the developments of the four selected process routes (ULCOS-BF, Hisarna, ULCORED and ULCOWIN/ULCOLYSIS). The first operation of ULCOS BF mode with CO₂ storage is expected in Florange for 2016 and in Eisenhüttenstadt without CO₂ storage for 2014.

1. Ameling, D.; Endemann, G.: stahl u. eisen 127 (2007) No. 8, p. 85/93.

2. Schmöle, P.; Lüngen, H. B.: stahl u. eisen 124 (2004) No. 5, p. 27/34.

3. www.ulcos.org

4. Birat, J. P.: CO₂-lean steelmaking: ULCOS, other international programs and emerging concepts, 1^st Intern. Conf. on Energy Efficiency and CO₂ Reduction in the Steel Industry (EECR), 27 June — 1 July 2011, Düsseldorf, Germany.

5. van der Stel, J. et al.: Developments and evaluation of the ULCOS blast furnace process at the LKAB Experimental BF in Luleå, Scrap Substitutes and Alternative Ironmaking V, 2 Nov 2008, Baltimore, USA.

6. Zuo, G..; Hirsch, A.: Rev. de Mét. CIT (2009) No. 9, p. 387/92.

7. van der Stel, J. et al.: Developments of the ULCOS low CO₂ blast furnace process at the LKAB Experimental BF in Luleå,  1^st Intern. Conf. on Energy Efficiency and CO₂ Reduction in the Steel Industry (EECR), 27 June — 1 July 2011, Düsseldorf, Germany.

8. Zuo, G.: Trials of ULCOS-NBF at LKAB’s Experimental Blast Furnace, 6^th Europ. Coke and Ironmaking Congr. (ECIC), 27 June — 1 July 2011, Düsseldorf, Germany.

9. Bertram, E.: Arch. Eisenhüttenw. 1 (1927) p. 19/32.

10. Korthas, B.; Peters, M.; Schmöle, P.: Back to the future — ideas for new blast furnace concepts, 5^th European Coke and Ironmaking Congress (ECIC), 12–15 June 2005, Stockholm, Sweden.

11. Tseitllin, M. A.; Lazutkin, S. E.; Styopin, G. M.: ISIJ Intern. 34 (1994) No. 7, p. 570/73.

12. Final report RFCS project: ULCOS New Blast Furnace Process, RFSRCT-2004-00005.

13. RFCS project: ULCOS Top Gas Recycling Blast Furnace, RFSRCT-2009-00002.