ENERGIRON DRI PLANTS FLEXIBILITY FOR ANY STEELMAKING REQUIREMENT 17th Metal Bulletin Middle East Iron & Steel Dubai UAE, December 9-11, 2013
ENERGIRON is the the innovative HYL Direct Reduction Technology developed jointly by Tenova and Danieli.
The Smart Choice For the DRI market, our technology advances have made us the perfect choice for the new market conditions in terms of virgin iron supply: PROCESS: Simpler, same scheme for all energy sources available, smaller in size yet larger in capacity than any competing technology. PRODUCT QUALITY: Unique DRI quality: hot or cold discharge with 94-96% Metallization and Carbon ~4%. ENVIRONMENTAL IMPACT: Lowest NO x, and selective elimination of CO 2 as integral system to our technology, with lucrative byproduct options (currently commercialized in various DRP s), makes ENERGIRON the greenest option.
The Smart Choice The ENERGIRON process is the most competitive way to produce the best virgin iron source for optimizing liquid steel production cost. In-situ reforming allows optimization of the investment and production costs while maximising the hourly production without affecting the quality. The carbon content is optimised to fit the requirements of the EAF melting process The product is stable and safe to store and transport.
PROVIDING FLEXIBILITY FOR STEELMAKERS SOME EXAMPLES
Points to Consider Plant sizes Iron ore consumption Energy consumption Overall OPEX Hot DRI charging Benefits in the EAF
PLANT SIZES Smallest.LARGEST
ENERGIRON Standard Module Sizes 2.5 5 million tpa Blast Furnace
Sized to Compete with Integrated Mills Using both Natural Gas and Syngas/COG. Client Country Mtpy Welspun Maxsteel Ltd. 2 India 0.60 Emirates Steel I (revamp project) UAE 1.60 2.00 Gulf Sponge Iron UAE 0.20 Emirates Steel II (revamp project) UAE 1.60 2.00 Sidor Venezuela 0.80 Ezz Rolling Mills Egypt 1.90 Suez Steel Egypt 1.95 Taichin China 0.50 PT Krakatau expansion Indonesia 0.75 Nucor Steel USA 2.50 JSPL India 2.50
Iron Ore Consumption ENERGIRON Other Iron ore (screened) 1.39 t/t (>3.2mm) >1.4 t/t (>6.3mm) Iron ore (before screening)* 1.42 t/t (>3.2mm) 1.45 t/t (>6.3mm) Lower iron ore requirements for Energiron based on: Pressurized operation Less fines lost to dust carryover *Minimum iron ore savings for a 2 million tpy ENERGIRON plant = (1.45-1.42) t/t x $170/t = $5.10/t $10,200,000/y
Energy Consumption ENERGIRON Other Natural gas (Gcal/t) 2.25 2.38 2.35 2.50 Electricity (kwh/t) core plant 60 75 95 125 Lower energy for Energiron based on: Pressurized operation Heat recovery, CO 2 absorption Energy savings for a 2 million tpy ENERGIRON plant = (2.35 2.25) Gcal/t x $5 = $0.50/t $1,000,000/y (95 60) kwh/t x $0.05 = $1.75/t $3,500,000/y
Other OPEX ENERGIRON Other Consumibles & Maintenance < $3.50/t $5.00 Lower consumibles and maintenance based on: no reformer no catalyst to maintain Savings for a 2 million tpy ENERGIRON plant = (5.00 3.50) $/t = $1.50/t $3,000,000/y
Overall OPEX Savings $5.10 Iron ore $0.50 Natural gas $1.75 Electric power $1.50 Consumibles & Maintenance $8.85/t x 2.0 million tpy = $18 Million/year Minimum Savings, PLUS: Credit for CO 2 sale to offtakers for a 2 million tpy ENERGIRON plant, where possible = ($8 30 per ton of CO 2 ) 250 kg. CO 2 /t DRI x $8.00/t = $4,000,000/yr. MINIMUM Added Income
HOT DRI CHARGING - Benefits in the EAF using the World s Most Proven and Reliable Hot DRI Transport System The HYL HYTEMP System
HYL HYTEMP System - hot DRI transport Pneumatic transport; totally enclosed Flexible for feeding >1 EAF; no layout restrictions No effect on DRI quality; carrier inert gas Distance up to 400-500m Fully automated and integrated system No wearing parts and almost maintenance-free Minimum heat losses (~80 C) N 2 make-up: 5-8 Nm 3 /t Power consumption: 3-6 kwh/t Compliance with all safety regulations
Hot, High Carbon DRI in the EAF The combination of High-Carbon at high temperature DRI yields a power decrease of >160 kwh/tls and a productivity increase of up to 22% for a practice of 90% hot-10% cold DRI (as compared to cold, low-c DRI). Compared to scrap, melting DRI in EAF normally demands more power because of DRI gangue content. However, the difference almost become null when comparing melting 100% scrap vs 100% high-carbon, Hot DRI in the EAF. For both cases, the power consumption ranges from 360-400 kwh/tls.
DR and Steelmaking Integration ESI-I Case Cold DRI (1) Hot DRI (2) Temperature ( C) 30 600 Production (tph) 148 196 Elect. Energy (kwh/tls) 550 < 400 Oxygen (Nm 3 /tls) 38 38 Electrodes (kg/tls) 1.6 1.4 Tap to tap time (min.) 61 < 46 (1) 95% cold DRI, 5% scrap (2) 90% hot DRI, 10% cold DRI + 32% PRODUCTIVITY AT THE EAF WITH HOT DRI (as compared to cold DRI)
ENERGIRON ZR DRI vs. SCRAP EAF ENERGY BALANCE: ENERGIRON ZR DRI vs. SCRAP Typical of ENERGIRON ZR COMPOSITIONS DRI SCRAP Total iron 91.2% 93.8% Si, Mn,... ---- 1% O 1.6% (as FeO) 0.4% C 3% 0.25% Gangue 4.2% 2.8% Yield 87% 91% Good quality IRON ORE ENERGY BALANCE COMPARISON Cold DRI SCRAP (2 buck.) ADDED CARBON 8 kg/tls 21 kg/tls SLAGBUILDERS 55 kg/tls 40 kg/tls OXYGEN 37 Nm3/tls 37 Nm3/tls FUEL ---- 5 Nm3/tls Steel 385 kwh/tls 385 kwh/tls Slag 82 kwh/tls 67 kwh/tls FeO reduction 28 kwh/tls ---- Fe oxidation ---- - 18 kwh/tls Fe 3 C decomp. - 17 kwh/tls ---- C oxidation potential - 377 kwh/tls - 193 kwh/tls Si, Mn, HC,... Oxidation ---- - 55 kwh/tls Fuel ---- -50 kwh/tls Off-gases 258 kwh/tls 135 kwh/tls Cooling water losses 121 kwh/tls 76 kwh/tls Electrical losses + other losses 40 kwh/tls 33 kwh/tls ELECTRIC ENERGY 520 kwh/tls 380 kwh/tls HOT DRI CHARGE energy consumption down to scrap process values DRI enthalpy Heat + electrical losses ELECTRIC ENERGY HOT DRI 600 ºC -119 kwh/tls -21 kwh/tls 380 kwh/tls
MW MW MW 125 100 75 50 25 0 125 100 75 50 25 0 125 100 75 50 25 0 EAF PRODUCTIVITY: ENERGIRON ZR DRI vs. SCRAP ACTIVE POWER PROFILE (520 kwh/t) preparation ACTIVE POWER PROFILE (380 kwh/t ) preparation melting 0 10 20 30 40 50 60 Time (minutes) ACTIVE POWER PROFILE (380 kwh/t) preparation bucket charge melting 0 10 20 30 40 50 60 Time (minutes) melting 1 melting 2 0 10 20 30 40 50 60 Time (minutes) refining refining tapping tapping ENERGIRON ZR DRI vs. SCRAP 100% COLD DRI refining tapping 100% HOT DRI 100% SCRAP Reference: 150 ton EAF, 7m 106 MW max power SCRAP HOT DRI SCRAP HOT DRI SCRAP HOT DRI POWER-OFF 11 min 8 min AVG. POWER 96 MW 98 MW PRODUCTIVITY 193 t/h 209 t/h
DRI properties & EAF performances EFFECT OF DRI CARBON CONTENT ELECTRIC ENERGY (kwh/t) 420 400 380 60 55 50 TAP TO TAP (min) OXYGEN (Nm3/t) Increased carbon content in DRI (ENERGIRON ZR process) 360 45 340 320 ENERGIRON 35 ZR PROCESS 300 30 1% 2% 3% 4% %C in DRI Graphic for 150 t 7m EAF Max. Power 106 MW Varc 460V Power-off 8 min 100% hot DRI, 94% MTZ, 4.2% gangue EAF inlet T = 550 C FeO in slag 25%, tapping T 1630 C 40 Energy benefit due to exothermic reaction : Fe 3 C 3Fe + C Energy benefit due to carbon oxidation Minimization of EAF carbon consumption ( down to 8 kg/t) High generation of CO bubbles optimal foaming, highest power input is possible
DRI properties & EAF performances EFFECT OF DRI METALLIZATION Higher DRI Metallization lower amount of oxidized iron in DRI (FeO) - 1% Metallization additional energy requirement due to endothermic reaction FeO + C Fe + CO additional carbon addition for FeO reduction additional slagbuilders addition to mantain slag chemistry, that would otherwise change due to carbon ashes - 0.3% yield + 14 kwh/t electric energy Low metallization can also affect slag foaming, due to local generation of low viscosity slag (with high FeO content)
Typical EAF Results Emirates Steel DRI average properties Metallization 94.6% %C 2.3% Average values % Gangue 4.2% Cold DRI 90% Hot DRI % SiO2 2.0% Tapped steel 152 t 152 t EAF inlet T 500 C yield 87.7% 87.8% Tap to tap 53 min 43 min Productivity 172 t/h 212 t/h ELECTRIC ENERGY (kwh/t) 600 550 Daily averages Power-on 45 min 36 min Avg. power 108 MW 107 MW Electric Energy 528 kwh/t 420 kwh/t Oxygen 33 Nm3/t 31 Nm3/t Charged carbon 7 kg/t 4 kg/t 500 Injected carbon 14 kg/t 11 kg/t 450 Slagbuilders 49 kg/t 47 kg/t Tap Temperature 1631 C 1626 C 400 Tap Oxygen 634 ppm 560 ppm Electrodes 1.5 kg/t 1.2 kg/t 350 0% 20% 40% 60% 80% 100% HOT DRI in charge BEST RESULT = 36 heats/day
Recent Plants & Projects Outstanding ENERGIRON Performance
EISC (Gulf Sponge Iron), Abu Dhabi First ENERGIRON Micromodule 200,000 tpa ZR plant for high carbon DRI Started up 2010 Ideal for small steel producers due to low cost natural gas supply
Emirates Steel I and II, Abu Dhabi Twin plants 1.6 mtpa nominal capacity each Both use HYTEMP System to meltshop Module I started 2009 Module II started 2010 Project underway to increase capacity to 2.0 mtpa each, for 4 mtpa total capacity
Suez Steel & Ezz RMS, Egypt Suez Steel-Egypt ZR scheme 1.95 mtpa nominal capacity 94% Mtz; 3.5% Carbon HYTEMP System to meltshop Start-up underway 2013 Ezz Rolling Mill Steel-Egypt 1.90 mtpa nominal capacity Cold, high-carbon DRI 93% Mtz; >3% Carbon Start-up scheduled: pending
Nucor Steel, Louisiana, USA World s largest single DR module 2.5 million tpy capacity ENERGIRON ZR scheme 96% metallization 3.0% carbon Currently in startup
Summing up ENERGIRON Flexibility To build and operate a DR plant of the capacity the customer needs To save money day by day, while producing the highest quality DRI To make more steel, better and more productively
JSPL DR Project, India Tenova HYL together with Danieli & C. signed a contract for the first of four ENERGIRON DR plants for Jindal Steel & Power of India. Main characteristics: DRP capacity: 2,5 million tpa of cold and hot DRI in any combination. Use of syngas from coal gasification and COG as source of reducing gases in any proportion, with energy consumption in the range of 2.2 Gcal/t DRI. DRI Metallization of 94% and carbon of 2-2.5% Use of BOF gas as fuel for the process gas heater and other users.
Where Are We Today? Any reducing gas source can be used Natural gas Syngas COG CO 2 Removal Environmentally friendly Economically attractive by-product ENERGIRON DR plant + EAF meltshop = Top quality steel, economically produced
Potential Growth in DRI Production Source: World Steel Assoc. 2000 2012 ( 70%) 43.8 Mt 74 Mt Shale gas, need to replace coke/bf plants could lead to higher production boost. Means over 3 new 2.0 million tpy plants per year for 12 years
A module for each need For the large, BF-replacing iron production needs, we have 2.5 and soon to be 3.0 million tpy modules For small, specialized needs, we have the Micro- Module and Mini-Modules. With our without hot charging via the HYL HYTEMP System. ENERGIRON has the widest range of capacities from 0.2 to 2.5 Mmtpa.
THANK YOU! www.energiron.com