UTIS moves forward with innovative initiative for decarbonization in the steel industry

A solution developed by Portuguese company UTIS, capable of reducing fossil fuel consumption through the use of renewable hydrogen, was officially incorporated this month into the regenerators of blast furnace 2 at CSN’s Usina Presidente Vargas (UPV), in Volta Redonda, (RJ). Known as UC3 – Ultimate Cell Continuous Combustion, the technology, with results in other sectors around the world, such as cement, biomass, and solid waste combustion, is patented by UTIS and initially underwent a period of intense testing at UPV and consolidation of results, with CSN being the first steel mill in the world to adopt the resource.

The initiative is a partnership between the Portuguese company, CSN’s steel division, and CSN Inova, the CSN Group’s innovation platform, which focused on studying the production processes of some areas of the plant with the potential to receive the technology at this early stage. The application of the UC3 system in the regenerators of blast furnace 2 aims to optimize combustion, bring more stability to the process, and ensure higher blowing temperatures, since regenerators play a crucial role in recovering and reusing the energy from the gases generated in pig iron production, increasing thermal efficiency and reducing fossil fuel consumption in the blast furnace.

The reduction of these fuels, such as coke in the blast furnace and coke oven gas or natural gas in the regenerators, for the enrichment of combustion gas through the use of renewable hydrogen in the regenerators, enabled by the UTIS solution, is in line with the goal of reducing greenhouse gases from the steelmaking process. CSN, which is working to achieve by 2030 the goal that the rest of the sector has set for 2050, is a case study of how the use of the UC3 solution can accelerate the decarbonization process in a critical sector such as steelmaking.

“CSN relies on the support of partners and strategic solutions, such as UC3, to solve complex and urgent challenges, such as decarbonization. Through UTIS technology, we are managing to significantly reduce fossil fuel consumption, delivering significant environmental gains, in addition to reducing costs,” says Fabiam Franklin, Director of Metallurgy at CSN.

The UTIS system stands out for its easy installation, in the form of containers, where the water electrolysis process takes place, resulting in renewable hydrogen. According to Fabiam, the results so far have exceeded expectations. “It was possible to achieve a 7% increase in the blowing temperature of the regenerators, which has enabled several improvements, such as reducing the use of coke per ton of pig iron produced, increasing productivity, and positively impacting the reduction of CO2 emissions from the blast furnace.”

In the race for decarbonization, UC3 technology stands out as one of the major initiatives to reduce carbon dioxide emissions in production processes. Although this is the first application in a steel mill in the world, the Portuguese company is already a partner of the CSN Group in cement, presenting important results at the Arcos (MG) plant since 2020, with the optimization of combustion through the injection of controlled amounts of hydrogen for cement manufacturing.

With the application of UC3 technology at CSN Cimentos in Arcos, CSN reduced CO2 emissions per ton of clinker produced by approximately 5%. The initiative also brings other gains, such as increased kiln productivity, reduced use of fossil fuels (petroleum coke), and reduced electricity consumption, resulting in cost savings, as well as environmental and strategic benefits. Another important aspect is the safety of using the technology, since the gases produced are never stored. In other words, there is on-demand production and consumption of H2 and O2, which are injected at specific points of combustion, ensuring maximum reliability throughout the process.

“We are very excited about the progress of our partnership with CSN, now also in steelmaking processes. The goal is to optimize steel production while substantially reducing carbon emissions, contributing to a more sustainable future for the industry,” concludes Paulo Gonçalo, CEO of UTIS.

The basics of UC3 technology

The patented UC3 – Ultimate Cell Continuous Combustion technology enables increased combustion efficiency through the injection of controlled amounts of hydrogen and oxygen. The basic principle of the technology is to accelerate the reactions of the continuous combustion process, making it more efficient as more energy is released with the same amount of fuel. This gain in energy efficiency is reflected in environmental terms (reduction in CO2 emissions), in lower fossil fuel consumption and energy costs, as well as in improved final product quality, where applicable.

The system is supplied in the form of containers that are easy to install in industrial settings, requiring only electrical connections, communication, mains water, and sewage. The concept behind the “plug and play” product is that customers need to make minimal changes to their production process in order to obtain the advantages associated with the product.

About UTIS

A Portuguese company founded in 2018, resulting from a joint venture between SECIL and ULTIMATE CELL, and since December 2021, with the SEMAPA Group, in a joint effort to create a strategic solution aimed at energy efficiency.

UTIS has developed an innovative technology – UC3, Ultimate Cell Continuous Combustion, which contributes in a sustainable and economical way to improving the efficiency of continuous combustion processes in industry.

The goal of this revolutionary and scalable technology is to reduce the use of fossil fuels, pollutant emission levels, and energy consumption, helping to make operations greener and more sustainable.

About CSN

Founded in 1941, CSN was the first integrated flat steel producer in Brazil, a milestone in the country’s industrialization process. In 1993, after more than five decades as a state-owned company, the Company entered a new era when it was privatized and assumed a new market position. Today, CSN is not only a national steel company, but also a world-renowned company in the mining, cement, energy and logistics sectors, thanks to the dedication of its more than 40,000 employees.

Currently, the CSN Group is present in 17 brazilian states and also operates in several other countries, such as Germany, Portugal, the United States and Switzerland, with its shares listed on the São Paulo Stock Exchange (BM&FBovespa) and the New York Stock Exchange (NYSE). The company’s social leadership is concentrated in the Fundação CSN, with projects that contribute to the social transformation of the community in the areas of education, community development, culture, and sports.