Several approaches were chosen to simulate the combustion of carbon particles recycled in the melter gasifier of the COREX plant via a dust burner. Reaction rates from different literature sources were analysed to develop a functional reaction set for the carbon combustion. These models were tested in a 180 0 sector of the burner domain and were compared among each other. The results were transferred into a full 3D model of the dome region in the melter gasifier.

The blast furnace is the most important process for the production of hot metal. An integral part of this process route is the coking of coal and sintering of fine ore. The FINEX®‐process is a new technology for hot metal production which uses untreated fine ores and coal instead of sinter and coke. This paper deals with the investigation of integration concepts of the blast furnace and FINEX®. Low reduced iron (LRI) and/or reducing gas are/is produced in FINEX® and are/is considered as substitute/s of burden and fuel in the blast furnace, respectively. In the article the overall fuel demand and CO2 emissions for the integration of the blast furnace and FINEX® are shown. For that reason two case studies for the integration are carried out and compared with the base case, that is, the two‐independent processes. The CO2 emissions are calculated considering the fuel and electric power consumption of the different cases.

Export gases from iron‐making processes are typically used as an energy source for heat and power generation within the iron and steel industry, although their calorific value is comparatively low. The fact that COREX® and FINEX® smelting‐reduction export gases typically consist of the major syngas‐components CO and H2 (approx. 50% of gas composition), makes them attractive for utilization in the direct reduction of iron ores and in the chemical synthesis industry. This paper will discuss the required process steps for converting smelting‐reduction export gases into synthesis gas (syngas) using the example of methanol production. The calculated CO2‐balance shows promising results for chemical utilization of COREX® export gas compared to energy utilization in conventional or combined power plants.

By using waste materials as alternative fuels in metallurgical plants it is possible to minimize the traditionally used reducing agents, such as coke, coal, oil or natural gas. Moreover, by using waste materials in the metallurgical industry it is feasible to recover these materials as far as possible. This also represents another step towards environmental protection because carbon dioxide emissions can be reduced, if the H(2) content of the waste material is greater in comparison with that of the substituted fuel and the effects of global warming can therefore be reduced. In the present article various solid recovered fuels and their applications in the metallurgical industry are detailed.

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