244
L. Ren et al.
emissions per ton of iron can be reduced by a maximum of 1270 kg, or 76% of total
CO 2 emission from this procedure.
ULCORED (Sweden), HYBRIT (Germany), SALCOS (Austria) H2FUTURE:
DRI by ULCORED technique uses reducing gases such as hydrogen generated from
natural gas to reduce lump ores or pellets directly to sponge iron as raw materials
for EAF steelmaking. The technical flow is as follows: loading sintered ores and
pellets into DRI vessel from the top; reducing gas generated from natural gas is
directly injected into DRI vessel for reduction reaction with iron ores to produce
sponge iron. For ULCORED project, conventional reducing agent coke is replaced
by reducing gas generated from natural gas, whose consumption is further reduced
by vessel top gas recycling and pre-heating. This technology, in conjunction with
CCS, can maximize CO 2 emission reduction while minimizing energy consumption,
cutting CO 2 emissions of BF routine by around 70%. HYBRIT was jointly kicked
off by Vattenfall, an energy supplier, SSAB and LKAB in April 2016, aiming at
developing breakthrough ironmaking technology using hydrogen to replace coal and
coke. According to project timeline, a feasibility study will be rolled out from 2018
to 2024, with a pilot plant built for experiments and a demo plant established between
2025 and 2035. This technology uses hydrogen as main reducing agent, which reacts
with pellets and produces directly reduced iron (DRI) and water, where DRI is used
as feed for EAF steelmaking. This technology curbs CO 2 emissions as the reducing
agent—hydrogen mainly comes from electrolysis of water using clean power such
as hydropower or wind power. Initiated by Salzgitter AG, SALCOS Project aims at
gradual renovation of the legacy BF-BOF steelmaking technical process, replacing
the carbon-intensive steelmaking technique based on BF with DRI-EAF technology,
together with multi-purpose use of surplus hydrogen. To achieve this goal, Salzgitter
AG plans to produce hydrogen by high temperature electrolysis using wind power
or power generated by waste heat from steel plants.
HIsarna: the process flowsheet of HIsarna is illustrated in Fig. 7.11. Iron ore is
loaded from the top of reactor, smelted in high-temperature cyclone smelting furnace
and drips down to the bottom of reactor. Pulverized coal injected into reactor reacts
with smelted ore, generating hot metal and CO 2 . The process flow consists of three
procedures: pre-heating and pyrolysis of coal, smelting and pre-reduction of iron ore
and molten iron finally reduced in furnace bottom bath. Compared to conventional
BF workflow, Hisarna uses much less coal as it gets rid of sintering and coking, both
featuring high energy consumption and pollution. Combined with CCS technology,
80% of CO 2 emissions can be reduced. In September 2010, TATA Steel Ijmuiden
launched Hisarna pilot plant, where 4 experiments have been carried out up to now.
If industrial application becomes successful, this technology will contribute to less
energy consumptions and CO 2 emissions, lower production costs and significantly
enhance resources efficiency.
ULCOWIN/ULCOLYSIS: this technique uses electricity to decompose iron ores
into iron and oxygen. Electrolysis in ironmaking generates zero emission. By
far, the most promising technical options of iron ore electrolysis are electrolysis
metallurgy (ULCOWIN) and direct reduction by current (ULCOLYSIS), both of
which are still in experimental phase. In small-scale pilot tests, the purity of iron
L. Ren et al.
emissions per ton of iron can be reduced by a maximum of 1270 kg, or 76% of total
CO 2 emission from this procedure.
ULCORED (Sweden), HYBRIT (Germany), SALCOS (Austria) H2FUTURE:
DRI by ULCORED technique uses reducing gases such as hydrogen generated from
natural gas to reduce lump ores or pellets directly to sponge iron as raw materials
for EAF steelmaking. The technical flow is as follows: loading sintered ores and
pellets into DRI vessel from the top; reducing gas generated from natural gas is
directly injected into DRI vessel for reduction reaction with iron ores to produce
sponge iron. For ULCORED project, conventional reducing agent coke is replaced
by reducing gas generated from natural gas, whose consumption is further reduced
by vessel top gas recycling and pre-heating. This technology, in conjunction with
CCS, can maximize CO 2 emission reduction while minimizing energy consumption,
cutting CO 2 emissions of BF routine by around 70%. HYBRIT was jointly kicked
off by Vattenfall, an energy supplier, SSAB and LKAB in April 2016, aiming at
developing breakthrough ironmaking technology using hydrogen to replace coal and
coke. According to project timeline, a feasibility study will be rolled out from 2018
to 2024, with a pilot plant built for experiments and a demo plant established between
2025 and 2035. This technology uses hydrogen as main reducing agent, which reacts
with pellets and produces directly reduced iron (DRI) and water, where DRI is used
as feed for EAF steelmaking. This technology curbs CO 2 emissions as the reducing
agent—hydrogen mainly comes from electrolysis of water using clean power such
as hydropower or wind power. Initiated by Salzgitter AG, SALCOS Project aims at
gradual renovation of the legacy BF-BOF steelmaking technical process, replacing
the carbon-intensive steelmaking technique based on BF with DRI-EAF technology,
together with multi-purpose use of surplus hydrogen. To achieve this goal, Salzgitter
AG plans to produce hydrogen by high temperature electrolysis using wind power
or power generated by waste heat from steel plants.
HIsarna: the process flowsheet of HIsarna is illustrated in Fig. 7.11. Iron ore is
loaded from the top of reactor, smelted in high-temperature cyclone smelting furnace
and drips down to the bottom of reactor. Pulverized coal injected into reactor reacts
with smelted ore, generating hot metal and CO 2 . The process flow consists of three
procedures: pre-heating and pyrolysis of coal, smelting and pre-reduction of iron ore
and molten iron finally reduced in furnace bottom bath. Compared to conventional
BF workflow, Hisarna uses much less coal as it gets rid of sintering and coking, both
featuring high energy consumption and pollution. Combined with CCS technology,
80% of CO 2 emissions can be reduced. In September 2010, TATA Steel Ijmuiden
launched Hisarna pilot plant, where 4 experiments have been carried out up to now.
If industrial application becomes successful, this technology will contribute to less
energy consumptions and CO 2 emissions, lower production costs and significantly
enhance resources efficiency.
ULCOWIN/ULCOLYSIS: this technique uses electricity to decompose iron ores
into iron and oxygen. Electrolysis in ironmaking generates zero emission. By
far, the most promising technical options of iron ore electrolysis are electrolysis
metallurgy (ULCOWIN) and direct reduction by current (ULCOLYSIS), both of
which are still in experimental phase. In small-scale pilot tests, the purity of iron