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HBI
Fe total
9094
Fe metallic
8389
Metallization
9295
Carbon
1.03.5
P*
0.0050.09
S*
0.0010.03
2.86.0
trace
1.61.9
3.43.6
5.05.5
40
80
Gang*
Bulk densityt/m
3
Apparent densityt/m
Discharge temperature
50
DRI
HBI
Flue
gas
Natural
gas
Top gas
scrubber
Process gas
compressors
Reduction:
Fe2O33H22Fe3H2O
Fe2O33CO2Fe3CO2
80mm
0mm
80mm
Shaft
furnace
Reformer
Main air
blower
Carburization:
3FeCOH2Fe3CH2O
3FeCH4Fe3C2H2
0mm
Iron
oxide
Reforming:
CH4CO22CO2H2
CH4H2OCO3H2
Reducing gas
Flue
gas
Fuel
gas
Cooling gas
scrubber
Natural gas
O2
Cooling gas
compressor
Ejector
stock
Heat recovery
Feed gas
Combustion air
Natural gas
Natural gas
MIDREX
Direct reduced iron
2.0
1.8
1.6
Productivity
1.4
1.2
1.0
0.8
0.6
0.4
0.2
Oxygen
Natural
gas
0.0
700
750
800
850
900
950 1,000
Bustle gas temperature ()
Original
; 1970's
Improved solid/gas contact ; 1980's
Raw material coating
; 1990's
1,050
1,100
Oxygen blow
; 1990's
OXY
; 2000's
Oxygen blowOXY ; from 2010 and on
Reformer
Shaft furnace
5.5m
7.15m
5.0m
Natural gas
4.25m
Hot
reducing
gas
Shaft furnace
Reformer
MIDREX
MINIMOD
Module
500,000
1960s
MIDREX
Series 500
Module
500,000
to
750,000
MIDREX
Series 750
Module
750,000
to
1,000,000
1970s
1980s
MIDREX
MIDREX
MEGAMOD SUPER MEGAMOD
Module
Module
1,000,000
2,000,000
to
2,000,000
19902006
2007
Capacity (ton/y)
Oxygen Natural gas
52
management. Because of this, since 2004, a threedimensional CAD has been adopted for the entire
designing process. The three-dimensional CAD
allows the retrieval of structural calculation data, as
well as the direct output of isometric drawings of
piping and material spreadsheets. The threedimensional CAD is also utilized at construction sites
for planning construction schedules. Fig. 8 is a threedimensional CAD drawing showing an entire DR
Plant for Qatar Steel.
Plant
Location
Capacity
Start up
(million tont/y)
EZDK III
Egypt
0.8
2000
India
1.0
2004
Nu-Iron
Trinidad
1.6
2006
India
1.5
2007
HADEED Module-E
Saudi Arabia
1.76
2007
QASCO Module-II
Qatar
1.5
2007
LGOK Module-II
Russia
1.4
2007
Al-Tuwairqi Damman
Saudi Arabia
1.0
2007
LION
Malaysia
1.54
2008
India
1.8
2009
SHADEED
Oman
1.5
2010
ESISCO
Egypt
1.76
2010
Al-Tuwairqi Pakistan
Pakistan
1.28
2010
53
54
Iron oxide
Hot DRI
(or DRI
or HBI)
MIDREX DR plant
Ladle furnace
Fig.13 Overall flow sheet for integrated steel mill equipped with MIDREX plant
Hot transport
vessel
Hot transport
conveyor
HOTLINK
Briquetting
machine
DRI
cooler
HDRI
HDRI
HBI
DRI
180
Reduction
furnace
DRI
cooler
DRI
storage
DRI cooler
HDRI
surge
bin
HDRI
surge bin
160
140
HDRI
in charge
120
20
40
60
80
100
100
80
60
40
20
EAF
Transformer
Electric arc
furnace
DRI
storage
START-UP
TYPE SYSTEM
Essar steel
Module-I, II, III, IV
India
19992004
Hot transport
vessel
HADEED Module-E
Saudi Arabia
2007
Hot transport
conveyor
LION
Malaysia
2008
Hot transport
vessel
ESISCO
Egypt
2010
HOTLINK
SHADEED
Oman
2010
HOTLINK
0.7
PLANT
0.6
HDRI
in charge
0.5
20
40
60
80
100
0.4
0.3
0.2
0.1
0
0
56
Coal
Pet coke
Refinery bottoms
Iron ore
Recycle gas
Gasifier
Gas cleaning &
conditioning
CO2
removal
Scrubber
MIDREX
MIDREX
shaft
furnace
O2
Reducing
gas
Gas heater
Turboexpander
Air separation
plant
Gasification plant
MIDREX
direct reduction plant
DRI / HBI
Fig.18 Process flow of MIDREX process combined with coal gasification plant
Conclusions
The origin and development of the MIDREX
process have been introduced along with the new
technologies that have been developed or are
presently being developed by Kobe Steel.
Since the inauguration of the first commercial
plant in 1969, seventy-two MIDREX plants have
been built in twenty-one countries so far. The
MIDREX process occupies a market share of about
60% among DRI making plants. This is a result of
the improved reliability of the MIDREX process, as
well as improved process efficiency, which is
widely recognized and highly evaluated.
57