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1 FEATURE : New Energy Technologies .. Development of Energy Consumption and Productivity of a Gas-based Direct Reduction Iron-making Processes Robert M. Klawonn Glenn E. Hoffman . Akira Kawamura Ryuhei Misumi Ryuhei Misumi Hiroshi Uemura Kobe Steel started producing direct reduced iron in 1978 in Qatar with the MIDREX Process. Since then many plants based on continuous improvements of this technology have been built all over the world. This paper presents an overview of the history of the technical developments in these processes, as well as the latest development in this field. MIDREX 1 . 1 . 1978 . MIDREX . 2 .. CO H2 . 3 . HBI . CO H2 . 30 25 .. 1970 780 1980 . 850 . HBI 13 1990 .. 2005 900 . MIDREX 11 MIDREX . MIDREX . 1 .. 2 . 1983 . 100 .. 64 MIDREX . 12 20 Nm3/t-DRI .. 1990 . HBI Hot Briquetted Iron . 1,000 900 . 12 . 2005 OXY.

2 OXY .. Midrex Technologies Inc.. 32 KOBE STEEL ENGINEERING REPORTS/Vol. 56 No. 2 Aug. 2006 . FASTMET Plants (Green). 1. Nippon Steel Hirohata (1). 2. Kobe Steel Kakogawa (1). COREX/MIDREX Plants (Red) 7. CORUS Mobile (2) 17. LISCO (3). 1. Saldanha Steel (1) 8. Delta Steel (2) 18. Mobarakeh Steel Company (5). 9. Essar Steel (3) 19. OEMK (4). MIDREX Plants (Blue) 10. Georgetown Steel (1) 20. OPCO (1). 1. Acindar (1) 11. Hadeed (3) 21. QASCO (1). 2. American Iron Reduction (1) 12. IMEXSA (1) 22. SIDERCA (1). 3. Amsteel Mills (1) 13. Ispat HSW (1) 23. SIDOR (4). 4. ANSDK (3) 14. Ispat Industries (1) 24. VENPRECAR (1). 5. Caribbean Ispat Ltd. (3) 15. Ispat Sidbec (1 + 1) 25. Lion Group (1). 6. COMSIGUA (1) 16. Khouzestan Steel (4) 26. LGOK (1). Numbers in parentheses indicate the installed plant number. 1 MIDREX .. MIDREX plant in the world Iron Flue oxide gas Natural Process gas system gas Process gas Top gas compressors scrubber Shaft furnace Reformer Main air Reducing gas blower Cooling gas scrubber Natural gas Flue O2.

3 Gas Cooling gas Ejector compressor Feed gas Natural stack Combustion air Natural gas gas Heat recovery MIDREX. direct reduced iron 2 MIDREX .. Standard process flow of MIDREX process 2CH4 O2 2CO 4H2. CH4 C. s . 2H2. CO H2O CO2 H2. OXY CO 2 MIDREX . H2 . 3 . OXY 4 1.. 1970 1990 .. CH4 H2O CO 3H2 Burden temperature . CH4 CO2 2CO 2H2 . /Vol. 56 No. 2 Aug. 2006 33. 300 250 Natural gas, Electricity Natural gas Shaft 1,000 200 Productivity OXY center injection furnace Burden temp. 150 500 100 Hot 50 reducing 0 0 gas Case1 Case2 Case3 Case4 Case5 Case6. Productivity ( ), Electricity (kWh/t). Natural gas (Nm3/t), Burden Temp. ( ). Productivities in case 2 through case 6 are ratios to case 1. Reformer Oxygen Natural gas Explanations about the cases are shown in Table 1. 3 MIDREX 4 .. Updated process flow of MIDREX process .. Comparison of productivities 1 MIDREX.

4 History of productivity increase DRI. DRI Enrichment Reducing Burden O2 Natural production Electricity Case production natural gas temp. temp. addition gas ratio to (kWh/t). (t/h) gas ( ) ( ) ( ) (Nm3/t) (Nm3/t). case 1. 1 780 789 135. 2 850 814 120. 3 918 834 109. 4 1,050 860 99. 5 961 857 93. 6 1,050 898 90. Case 1 Original practice 1970 s Case 2 Practice using lump ore 1980 s Case 3 Practice using coating of oxide feed materials 1990 . s Case 4 Oxygen injection practice late 1990 s Case 5 OXY practice 2000. Case 6 Combined practice with oxygen injection & OXY Future . B DRI . 1990 . OXY . OXY .. 3 HOTLINK . 3 . MIDREX HOTLINK 700 .. 4 . 3 . 5 .. 5 HOTLINK .. 5 . 5 HOTLINK . 5 . A HBI 5 HOTLINK .. 5 Essar .. 34 KOBE STEEL ENGINEERING REPORTS/Vol. 56 No. 2 Aug. 2006 . Hot discharge HOTLINK/Hot transport/Hot briquetting Flue Iron gas oxide Natural Process gas system gas Process gas Top gas compressors scrubber Shaft furnace Reformer Main air Reducing gas blower Fuel gas Natural gas O2.

5 Flue gas Natural Ejector Feed gas gas Hot DRI. stack Combustion air Heat recovery Optional DRI cooler Sealed Briquette hot transport machine Hot transport conveyer Electric arc furnace . A.. HOTLINK . B DRI storage HBI.. Fuel: Natural gas Feed: Pellet/Lump 5 .. Hot discharge HOTLINK. 4 HOTLINK . Furnace charge hopper HOTLINK Oxide Cold day bin DRI for Proportioning hopper reheating . Reduction furnace .. DRI From DRI. HDRI feeder cooler storage . HDRI. Cold Vibrating surge bin DRI. feeder surge bin HDRI feeder .. DRI storage . Electric arc furnace cold DRI 5 . 5 . 6 HOTLINK .. Process flow of HOTLINK. HBI 6 . 5 . 2 HOTLINK .. Productivities comparison of HOTLINK.. Case1 Case2 Case3 Case4. HOTLINK 6 . Starting product from MIDREX plant Hot DRI Cold DRI Cold DRI HBI. 2 Fe yield: DRI/HBI to liquid steel Energy usage: Natural gas used (mmBtu*/t-liq.)

6 Stl.) Power used (kWh/t-liq. stl.) 565 695 701 742. Oxygen used (Nm3/t-liq. stl.) 15-20 15-20 15-20 15-20. Case 1 Adjacent 100 hot DRI use via HOTLINK. Case 2 Adjacent 100 cold DRI use in an EAF. Case 3 Remote use of 100 cold DRI in an EAF. Case 4 Remote use of 100 HBI in an EAF. /Vol. 56 No. 2 Aug. 2006 35. DRI 3 .. Products specifications EAF Electric Arc Furnace . DRI Hot DRI HBI. 120 140kWh/t-liquid steel Fe total ( ) 90-94 . EAF Fe metallic 83-89 . Metallization ( ) 92-95 . steel Carbon ( ) . EAF EAF P* ( ) . S* ( ) .. Gang* ( ) . Mn, Cu, Ni, Mo, Sn, Pb, and Zn ( ) trace . Bulk density (t/m3) .. Apparent density (t/m3) HBI Discharge temperature ( ) 40 700 80. HBI DRI *Depend on iron ore source. MIDREX . DRI .. 3 .. MIDREX . MIDREX . MIDREX 64 . 2004 . 2005 .. Lion Gr. MIDREX . QASCO . Lebedinsky GOK ITmk3 . Al-Ghaith . HADEED.

7 NUCOR . Al-Tuwairqi Gr. 36 KOBE STEEL ENGINEERING REPORTS/Vol. 56 No. 2 Aug. 2006.