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Innovative Steelmaking
Thomas Scarnati
MB North African Steel Conference
June 2-5, 2008
Cairo, Egypt
Overview
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
CO2
DR Shaft
fuel
DRI
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%
• 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
• Design, manufacturing,
assembly, project
management and R&D
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