Numerical analysis of carbon saving potential in a top gas recycling oxygen blast furnace

Aiming at the current characteristics of blast furnace (BF) process, carbon saving potential of blast furnace was investigated from the perspective of the relationship between degree of direct reduction and carbon consumption. A new relationship chart between carbon consumption and degree of direct reduction, which can reflect more real situation of blast furnace operation, was established. Furthermore, the carbon saving potential of hydrogen-rich oxygen blast furnace (OBF) process was analyzed. Then, the policy implications based on this relationship chart established were suggested. On this basis, the method of improving the carbon saving potential of blast furnace was recycling the top gas with removal of CO₂ and H₂O or increasing hydrogen in BF gas and full oxygen blast. The results show that the carbon saving potential in traditional blast furnace (TBF) is only 38–56 kg · t⁻¹ while that in OBF is 138 kg · t⁻¹. Theoretically, the lowest carbon consumption of OBF is 261 kg · t⁻¹ and the corresponding degree of direct reduction is 0.04. In addition, the theoretical lowest carbon consumption of hydrogen-rich OBF is 257 kg · t⁻¹. The modeling analysis can be used to estimate the carbon savings potential in new ironmaking process and its related CO₂ emissions.