Innovative DR Technology for

Innovative Steelmaking

Thomas Scarnati
MB North African Steel Conference
June 2-5, 2008
Cairo, Egypt
Overview

• The ENERGIRON Alliance

• Direct Reduction technologies and services
• Innovative solutions for energy and efficiency
• The importance of a strong technology partner
Technology Sustains Survival

• Becoming cost-efficient is key to sustaining market share.

9 Inefficient technologies are unsustainable
9 Environmental factors are critical
• Reducing raw materials costs, increasing product quality and providing
higher returns on investment imply of necessity the use of the best
technologies and practices
• For steel companies to improve and succeed, the importance of a
strong technology partner cannot be overstated.
• ENERGIRON brings the combined support of two premier companies –
Tenova and Danieli – to the world iron and steel industry.
• ENERGIRON is the innovative HYL direct reduction
technology jointly developed by Techint and Danieli, and
whose name derives from the unique DRI product which
distinguishes this technology from other available
processes.
ENERGIRON Alliance

• HYL Technologies, the pioneer of DRI Technology now known as

Tenova HYL, has joined with Danieli to serve the direct reduction plant
market.
• ENERGIRON is the innovative HYL direct reduction technology, jointly
developed by Techint/Tenova and Danieli.
• This strategic alliance allows the companies to join their own know-how
and technology for the design and construction of Gas Based Direct
Reduction Plants, offered worldwide, under the new ENERGIRON
trademark.
• With this collaboration, HYL and Danieli can offer any project approach
– from any size DR plant to a complete integrated minimill facility; from
technology packages to EPC turn-key projects.
ENERGIRON Alliance

• The combined resources and potentials of these partners in the field of

DRI include:
9 A heritage of 47 direct reduction modules built or contracted for,
including the first commercial plant worldwide, built in 1957.
9 A major steel maker, the Techint Group, with a production of over
7.5 Mtpy DRI and HBI, and over 15 Mtpy of annual steel production.
9 Patented DR technologies of HYL and Danieli as well as future
developments.
9 Impressive plant making capabilities and powerful international
networks of Danieli and Tenova.
ENERGIRON DR Technology
Iron Ore Size: Wide range of raw material
Selective removal 3.2 - 18 mm quality
of oxidants from (Sulphur in Iron Ore is not a
Flexibility for using the reduction Iron Ore limitation)
different sources of process (H2O and Minimum iron ore
Reducing gases with CO2): losses in top gas:
the SAME Basic Optimisation of <1%
Scheme energy Reactor pressure:
consumption ≥6 bar (low gas
velocity)
H2O Flow feeders (1-row)
Reducing gases sources CO2 adoption for large DR
¾ Natural Gas (+H2S) shafts/hot discharge:
¾ Reformed Gas control of burden flow
¾ Coal Gasification
¾ COG
¾ others

O2
fuel
NG
Flexibility to process
any Natural gas Low NOx emissions
quality -High-
High-Carbon DRI
Highest yield: DRI -Hot DRI with HYTEMP System
(Iron ore / DRI) <1.36 t oxide / t DRI -HBI
ENERGIRON ZR Process
Basic Principles
• The ZR process allows the reduction of iron ores without the use of a
reformer by taking advantage of the fact that metallic Iron is a very
good catalyst for natural gas reforming.
• The reduction zone of the DR shaft is used to perform simultaneously
the Reduction of the Iron Ore and the reforming of natural gas.
• When Natural gas reforming takes place under a limited amount of
steam, some carburization of the catalyst will occur.
• In the case of the ZR, since the catalyst is the DRI, carburization is
intentional and controlled.
• The rate of Carburization can be controlled by adjusting the content of
steam present in the gas stream.
• In the ZR process the carburization of the catalyst (DRI) takes place at
high temperature resulting in the formation of Iron Carbide Fe3C.
ENERGIRON ZR Process
Main Features
• High-Carbon (controlled) in DRI: 2% – 5%.
• Due to the process configuration, the ZR plant:
9 is simple, very easy to operate and very stable,
9 has lower maintenance cost since no catalyst is ever replaced; the only
high temperature equipment is a standard gas heater.
9 the compressors in the ENERGIRON ZR plant are standard centrifugal
type.
9 Operates with any source of Natural gas quality without any treatment, such
as hydrogenation, desulphurization, heavy hydrocarbons removal, etc.
9 can easily process high percentages of lump ores even with high sulfur
content.
9 is the most environmentally friendly specially regarding NOx emissions
since there is no preheating of the combustion air.
ENERGIRON ZR Process
Energy Optimization
The overall energy efficiency of the ZR process is optimized by the integration of high
reduction temperature (above 1050°C), “in-situ” reforming inside the shaft furnace, as well as
by a lower utilization of thermal equipment in the plant. Therefore, the product takes most of
the energy supplied to the process, with minimum energy losses to the environment.
Flue gases
Evaporation 0.05
0.30 DRI
Sensible Heat
0.12

Total NG NG to Process DRI Energy

2.30 1.70
DR Process
1.83

DRI characteristics at ZR Overall

Fuel NG
shaft furnace discharge: Efficiency
Fuel NG to others
to Gas Heater 0.12 Metallization: 94% Hot DRI: 87%
0.48 Carbon: 3.5% Cold DRI: 83%
Temperature: 700°C
Others: < 70%
It is important to note the efficient use of energy
while producing a high-energy content DRI with
3.5% C and 700°C.
ENERGIRON DR Technology
N. Gas Reformer
Iron
water fuel Ore

Nat. gas H2O

CO2

DR Shaft

fuel

DRI

Reformer Reduction Section

ENERGIRON DR Technology
N. Gas Reformer
• Main Features:
9 Flexibility for carbon control in DRI: 1% – 3%.
9 Minimum power consumption: ≤ 35 kWh/t.
9 The scheme has the flexibility to process any natural gas
quality.
9 No restrictions related to sulfur content in the iron ores,
which is foreseen an important issue in the next future.
9 Possibility for power co-generation -to even attain “zero”
power consumption- taking advantage of the steam
produced in the reformer convective section.
Environmental Aspects –
CO2 Emissions
CO2 Emissions / tonne of Liquid Steel
Scenario DR-EAF: ZR High Carbon DRI vs. other DRI
Location: Power generation: 0,74 kg CO2/kWh
other Cold DRI ZR Cold High-C DRI other Hot DRI ZR Hot High-C DRI
Scheme
94% Mtz.; 2% C 94% Mtz.; 3.7% C 94% Mtz.; 1.5% C 94% Mtz.; 3.7% C
Item/unit kg CO2/t LS kg CO2/t LS kg CO2/t LS kg CO2/t LS
Iron ore (production) 132 129 132 129
CO2 in flue gases + removal system 447 455 455 461
Electricity & O2 to DR plant 90 80 98 86
Subtotal DR Plant 669 664 684 676
Power & O2 requirements 443 415 339 305
Carbon addition 35 3 59 3
Subtotal EAF 478 419 399 308
Total DR-EAF route 1147 1082 1082 984
As % -6% -10%

• As compared to other DR schemes, the ENERGIRON ZR-based configuration

reduces overall CO2 emissions by 6% to 10% for cold and hot DRI, respectively, for
liquid steel production.
• Additionally, about 55% of total CO2 emissions from the ENERGIRON ZR plant is
selectively removed and can be specially disposed, sequestrated or used for other
applications.
 HYL HYTEMP
Pneumatic Transport System
Iron Ore
• Deliver hot DRI to:
9 EAF charging bins
system. Reducing gases - CO2 H2O
Reactor
Possible sources
9 External cooler ¾ Natural Gas
¾Reformed Gas
O2
• External cooler for cold ¾Syngas (coal)
¾ others
DRI production, fuel
HYTEMP® System
whenever the EAF HYTEMP® System External
Cooler
cannot receive hot DRI.
Transp.
• Capacity for 100% cold Gas
N
Hot DRI Make up
DRI or 100% hot DRI from 0 – 100%
G

production or any
combination.
EAF
Cold DRI
from 0 – 100%
HYTEMP System –
Designed for Optimized Steelmaking
• Delivers energy to the EAF via
highly carburized DRI
• Totally enclosed system
9 Increases yield, as there are
no fines or dust losses – all
go to the furnace.
9 No environmental
repercussions.
9 Virtually maintenance free
operation. No mechanical
parts.
• In 10 years of operation, there
has been no downtime from the
HYTEMP System.
A History of Innovation

• Beginning with the first successful industrial scale DR plant in 1957, virtually all major
advances in the field of direct reduction are traceable to HYL technology developments
and patents. Some of which are:
9 1958 – Batch charging of DRI to the EAF at 600°C.
9 1965 – Use of more than 30% DRI in an EAF charge, eventually increasing in stages
up to 100% by 1972.
9 1968 – Continuous feeding of DRI to the EAF.
9 1972 – Production of extra-deep drawing steels in EAF using DRI.
9 1984 – First pilot operation of a DR plant without external gas reformer.
9 1993 – HYTEMP pneumatic transportation system and hot DRI feeding to the EAF.
9 1993 – First Zero kWh direct reduction plant begins operation at Vikram Ispat plant,
India.
9 1994 – HYL begins producing high carbon DRI with 3.0 to 5% carbon content.
9 2000 – First plant to successfully use 100% lump ore charge on a routine basis
(Usiba HYL plant, Brazil). Vikram Ispat becomes second in 2006.
9 2003 – Successful design of HYL ZR plants based on coal gasification and COG.
 Solid Plant Operation Results
Plant Location Capacity Prod. 2006 Cap. Util. Prod. 2007 Cap. Util.
LebGOK Russia 0.90 1,027,500 114% 1,029,440 114%
Usiba Brazil 0.31 376,100 121% 364,529 118%
Vikram Ispat India 0.75/0.50 466,596 62% 595,190 99%
PTKS Indonesia 1.35 1,289,986 96% 1,417,282 105%
Perwaja Steel Malaysia 1.20 953,929 79% 1,070,083 89%

Ternium 3M5 Mexico 0.50 676,262 135% 688,538 138%

ArcelorMittal LC Mexico 2.00 2,231,318 112% 2,364,839 118%

Ternium 2P5 Mexico 0.61 737,061 121% 832,424 136%

Ternium 4M Mexico 0.68 857,047 127% 775,763 115%
Hadeed D Saudi Arabia 1.10 974,201 89% 968,181 88%
Ironmaking & Steelmaking Services

• Tenova HYL has its roots in steelmaking

9 Ironmaking technology is designed to optimize steelmaking
• We provide training, technical assistance and maintenance/operation
services for all aspects of the industry – from mines to DR to meltshop
and finished products.
Solid Technology Partners – Tenova

• Tenova is a network of
technologies and companies.
• Each company preserves its
specific competences and
distinctive skills.
• Each company preserves its
name under a single global
brand.
• Materials handling, plant
equipment manufacture,
steelmaking equipment and
optimization technologies.
Solid Technology Partners – Danieli

• EPC Contractor for iron and

steel projects worldwide

• Design, manufacturing,
assembly, project
management and R&D

• Partner with Tenova HYL in

direct reduction process,
equipment and plant
development
ENERGIRON – HYL III/ZR modules
Capacity Product
(Million Quality Start
Plant Country Modules Technology Product
ton/yr) % Met. Up
Design (Carbon)

Al Nasser UAE 1 HYL-ZR DRI 0.20 93.0 (3.5) 2008

Sidor Venezuela 1 HYL III DRI 0.80 94.0 (2.8) 2008

Vikram Ispat 2006 /

India 1 HYL III/ZR DRI 0.50 94.0 (3.0)
(d) 2008
ENERGIRON HYTEMP
GHC-1 Abu Dhabi 1 1.60 94.0 (3.0) 2009
III /DRI
ENERGIRON HYTEMP
Jindal (e) India 1 1.70 94.0 (2.0) 2009
ZR /DRI
ENERGIRON HYTEMP
GHC-2 Abu Dhabi 1 1.60 94.0 (3.0) 2010
III /DRI
ENERGIRON HYTEMP
DETAL Azerbaijan 1 1.20 94.0 (3.5) 2010
ZR /DRI
HYTEMP
2 Plants Egypt 2 ENERGIRON 3.55 94.0 (3.5) 2010
/DRI

Notes:
d) 100% lump ore feed New Projects since end of 2005 (under execution)
e) Syngas based plant New Projects signed in 2008 (under execution)
Final Remarks

• The most cost-efficient producers will be those that adopt the best
technologies and practices
• The ENERGIRON alliance brings together two strong companies as
technology partners for iron and steel makers worldwide.
• Based on the ENERGIRON process and the HYL HYTEMP System,
this technology leads the way in innovation, productivity, cost-
effectiveness and environmental compliance.
• Hot, high carbon DRI fed directly to an EAF is today’s most efficient and
cost-effective way to quality steel.
• Training support and technical services in iron and steelmaking assure
that client companies maintain their operations at the forefront of
industry competitiveness.
 ‫ﺷﻜﺮًا‬
Thank You