Energiron DR Technology-July 2007

from Tenova HYL and Danieli & C.
2006 Danieli & C.; HYL Technologies - This document contains proprietary information of DANIELI & C. S.p.A., and HYL Technologies, S.A. de C.V.; not disclosable, not reproducible. All Rights Reserved.
Danieli and Tenova HYL Alliance

The New Strength in Direct Reduction
Tenova HYL - Danieli Alliance

HYL Technologies, the pioneer of DRI Technology now known as Tenova HYL, has joined with Danieli to create the new Key Player in 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 will have the strong and flexible position for offering any project approach; from any size DR plant to a complete integrated minimill facility; from technology packages to EPC turn-key projects.

The combined resources and potentials of these partners in the field of DRI include:
A heritage of over 40 direct reduction modules including the first commercial plant worldwide, built in 1957. A major steel maker, the Techint Group, with a production of over 7.5 Mtpy DRI and HBI, and over 15 Mtpy of steel production. Patented DR technologies of HYL and Danieli as well as future developments. Impressive plant making capabilities and powerful international networks of Danieli and Tenova.
The new ENERGIRON trademark highlights the high energy content of the final product from the offered technologies, which are also able to process multiple typologies of iron ore, including high sulfur ores and employ reducing gases as different as natural gas, syngas and coke oven gas.

The first achievement of this new alliance is a turn key contract for the supply of a steel complex for the production of 1,4 Mtpy of Long rolled products recently signed by Danieli with General Holding Corporation, in Abu Dhabi, with the cooperation of HYL and Techint. One of the key plants of this steel complex is the new HYL module for the production of 1,6 mtpy of DRI. This plant will also be equipped with the HYTEMP technology, the state of the art pneumatic system for the continuous transportation and charge of hot DRI into the EAF; this same system has been successfully in operation for more than 6 years at Ternium-Hylsa in Monterrey, Mexico.
GHC Abu Dhabi Project:

DR Plant of 1.6 M t/y Hot DRI with HYTEMP System for long steel products Minimill
Technical Overview
Process Overview
The process converts lump ore, iron oxide pellets or pellet / lump ore mixtures into highly metallised, stable iron product. The most common types of iron ores have the composition of hematite (Fe2O3) and contain about 30% of oxygen. In the ENERGIRON process this chemically bonded oxygen is removed by means of a reducing gas mix at high temperature. The reducing gas is a mix of carbon monoxide (CO), hydrogen (H2) and methane (CH4). These gases react with the oxygen contained in iron ore giving carbon dioxide (CO2) and steam (H2O(g)) as products. In an ENERGIRON plant the reducing gas is produced in two ways:
in an external steam reformer and/or directly in the shaft reactor by means of in situ reforming reactions.
Process Overview
N.G.
Reformer size & C content vs. "In-situ" reforming
600
water
CO2
H2O
500
Reform (Nm er 3/t)
Carbon: 2.0 4%
400
Carbon: 1.5 3%
N.G.
CO2
H2O
200
Carbon: 0.8 2.2%
300
O2
100
H2O
10 20 30 40 50 60
NG
Oxygen Injection (Nm3/t)
CO2
O2 Oxygen
Process Overview
The ratio between reforming and in situ reforming can be varied to balance production and investment costs exigencies. The reducing gas mix extracts from iron oxide the chemically bonded oxygen. The overall reduction reactions are: (1) (2) Fe2O3 + 3 H2 2 Fe + 3 H2O Fe2O3 + 3 CO 2 Fe + 3 CO2
moreover there is an additional reduction given by the following reaction: (3) FeO + CH4 Fe + CO + 2H2 3Fe + CH4 Fe3C + 2H2
Reaction (3) is part of the in situ reforming reactions. The high carbon DRI produced with the ENERGIRON plant has a very high metallization and a controlled carbon content (between 1 4%), according to EAF requirements, in the form of Fe3C.
Process Overview
This reaction is important because it is the basis for the production increase given by the coupled reactions of reforming and reduction which shift the chemical equilibrium towards a better gas exploitation. Reaction (3) is highly endothermic and is catalyzed by Fe (met) in the reduction zone where also the other intermediate reaction occurs. Reaction (3) generates high carbon DRI (mostly in the form of the stable Fe3C-cementite) with a high degree of metallization, and also the reducing gas that will be used by the system in the pre-reduction reactions taking place in the upper zone of the shaft. To provide the necessary energy, the temperature of the Reducing Gas entering into the furnace is increased by means of O2 injection. Additionally, the implementation of the HYTEMP pneumatic transport system allows the exploitation of the hot DRI directly charged in the EAF for a final energy optimization.
Process Overview
Oxygen injection for in-situ Reforming
Iron Ore Temperature: 930C Pressure: 6 barA Reducing gas from heater Partial Combustion/ Reforming 2H2 + O2 2CH4 + O2 CH4 + H2O CO2 + H2 2 H2O 2 CO + 4H2 CO + 3H2 CO + H2O DRI
Partial Combustion/ Reforming: Oxygen is injected in the transfer line to the DR reactor. This partial combustion, besides adding thermal energy to the reducing gas, promotes to some degree the reforming reactions.
T: 1085C
Oxygen
Process Overview
In-situ Reforming
Iron Ore CO2 H2O In-situ Reforming: Conditions for natural Reducing gas gas reforming: to reactor Oxidants (H2O + CO2), high temperature and presence of catalyst. In the lower part of the reactors reduction zone, these conditions are present, making possible in-situ reforming. Oxygen Reforming Reduction
In-situ Reforming CO + 3H2 CH4 + H2O CH4 + CO2 2CO + 2H2 Reduction Fe2O3 +3CO 2Fe + 3CO2 Fe2O3 +3H2 2Fe + 3H2O Carburization 3Fe + CH4 Fe3C + 2H2 DRI
Process Overview
Flexibility for: Energy sources and Product type
Iron Ore
Reducing gas sources Natural Gas Reformed Gas Coal Gasification COG others
CO2
H2O
Only for cold DRI
fuel
O2
HYTEMP Iron Optional DR products: DRI HBI EAF
Technical Overview
Main Features of ENERGIRON Technology
Scheme The ENERGIRON scheme permits the direct utilization of any source of reducing gas, such as:
Reformed gas Natural gas Coke Oven Gas Syn-gas from coal gasification Exhaust gases from smelters etc.
Technical Overview
Main Features of ENERGIRON Technology Scheme
The basic process configuration is unchanged for any energy source application
Scheme flexibility to process different gas analysis
Ref. Gas NG COG Syngas
Iron Ore
H2O
CO2
Humidifier Fuel
Oxygen
H2O
DRI NG COG Syngas
Technical Overview
Main Features of ENERGIRON Technology Process
Always the same basic configuration of the reduction loop. Flexibility to produce high quality DRI from any source of gas such as Natural gas, Reformed gas, Coke Oven Gas, Syn-gas, etc., while maintaining the same proven process configuration. Selective elimination of H2O and CO2 Optimization of reducing gas requirements and complete control of the gas chemistry entering the DR Reactor. Gas Temperature: 950C. The use of Oxygen allows high temperature operation and higher process efficiency. Gas Pressure from 2.5 to 6 bars. Smaller equipment, high process efficiency, low power consumption.
Technical Overview
Main Features of ENERGIRON Technology
Product Product flexibility:

Cold DRI, HBI and Hot DRI (HYTEMP) in every modality. The product quality can be adjusted to best fit the client needs.
Product quality:
High metallization, high-carbon DRI. It is the only DR technology currently capable of producing High Carbon DRI with more than 90% of the Carbon as Iron Carbide.
Technical Overview
Main Features of ENERGIRON Technology The physical and chemical characteristics of high carbon DRI especially its chemical energy contribution given by the high percentage of Fe3C, make it a high-performance metallic source for electric steel-making allowing the production of even the most demanding steel grade thanks to its high purity and to the total absence of tramp elements. A very important feature to be stressed is the stability of the product.
This product is safe to store and transport without any inert atmosphere or briquetting, with relevant savings in production and transport costs. The same product can therefore be directly used in an adjacent EAF or transported and sold elsewhere.
Technical Overview
Plant configuration: Scheme with Reformer
Iron Ore
water Steam Turbines
~
PG Compressor
H2O PG Heater
Reduction Fe2O3 + 3H2 Fe2O3 + 3CO Reactor 2Fe + 3H2O 2Fe + 3CO2
Natural gas
fuel
CO2
H2O
Fuel
Oxygen
Steam Reforming CH4 + H2O CO + H2O CO + 3H2 CO2 + H2
DRI
Electricity optimization Hot and/or Cold DRI production Carbon content: 0.8% 3.5%, depending on the extent of in-situ reforming with NG
Technical Overview
Plant configuration: Scheme w/o Reformer
The Scheme w/o Reformer is characterized by the following features:
Partial combustion of the reducing gas. In-situ reforming of CH4 in the lower part of the reactors reduction zone. Adjustable composition of the reducing gas to control DRI metallization and carbon. Natural gas optimization Hot and/or Cold DRI production Carbon content: 2.0% 4.0%
DRI
CO2 H2O
Iron Ore
NG
Humidifier Fuel
Oxygen
Technical Overview
Consumption Figures
Item Plant capacity Metallization Carbon (controlled) Inputs Iron ore t/t Unit t/a 200,000 - 2,000,000 93% 0.8% - 5% Specific Consumption 1.38 - 1.40 2.3 - 2.6
depending on DRI Carbon depending on: DRI Carbon & Temperature, extent of "insitu" reforming and power co-generation depending on power cogeneration depending on extent of "insitu" reforming depending on the water recovery system depending on plant size for cold DRI - hot DRI depending on extent of "insitu" reforming
Remark
Natural gas
Gcal/t
Electricity Oxygen Water Labor Maintenance
kWh/t Nm3/t m3 m-h/t US$
0 - 85 0 - 50 0 - 1.3 0.11 - 0.17 3 - 3.3
Technical Overview
The ENERGIRON process is the most competitive way to produce the best virgin iron source for the Electric Arc Furnace in order to optimise the liquid steel production cost. The exploitation of the in-situ reforming principle allows to optimise the investment and production cost 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.
Technical Overview
Low Environmental Impact
The low dust carry-over determined by the low gas velocity into the shaft furnace, The high efficiency of the selected dedusting system, The low suspended solid content of water, The re-utilisation of the exhaust gas as burner gas (no gas is burned in flare system) greatly reduce the environmental impact of the ENERGIRON plant site, Selective removal and potential use of CO2, as by-product, to decrease emissions of gases related to greenhouse effect, Low NOx emission.
Technical Overview
Low maintenance and high availability
The elimination of the reformer (for 100% in-situ reforming) or small reformer size (less than 500 Nm3/t of reformed gas), and the absence of the briquetting machine drastically reduce the maintenance of the plant.
Highly automated process

The plant is controlled by a highly automated system that provides a level 2 automation. The modern control system allows driving the process with minimal human interventions.
Technical Overview
Plant Availability
The ENERGIRON Plant: 7,800 8,000 hr/yr net working time
Technical Overview
Plant sizes Standard Modules Capacity (Mt/year) 200,000 500,000 800,000 1,200,000 1,600,000 2,000,000
Reactor size (approx. nominal ID- m) 2.5 4.0 5.0 5.5 5.7 6.0
(Micro-Module)
Technical Overview
Training Danieli, Techint and HYL Technologies possess a great experience in turn-key plant realization, thanks to their worldwide leadership in mini-mills construction. An important part for the successful implementation of a mini-mill is the presence of fully-qualified personnel. The three companies hence developed a consistent training programme for operation and maintenance personnel. The programme foresees:
Training in Danieli headquarters in Buttrio, Italy and/or in Techint facilities worldwide and/or HYL Technologies in Monterrey, Mexico; On site training; Training in similar plants, i.e. Ternium-Hylsa.
Technical Overview
Manning and crew policy
The usual crew policy is to have 4 complete crews working 6 days in 8-hour shifts and resting 2 days. In this manner, it is possible to run the plant in a 24 hours/day basis without resorting to overtime. Dimensioning of personnel: DR Plant personnel requirements
Per day Administration Plant Operation Process Unit Plant maintenance Total 2 3 4 21 30 Per shift 0 8 2 3 13 Total 2 35 12 33 82
Technical Overview
Raw Materials
Required characteristics for Lump ore and Pellets for Direct reduction are as follows:
Chemical properties
Lump ore % Pellet % w
As high as possible
Chemical characteristics
Fe total Fe++ Na2O + K2O TiO2 LOI
As high as possible
1.00 max 0.10 max 0.20 max 1.50 max
0.10 max 0.20 max -
Metallurgical Properties HYL standards

a) Swelling index (% weight) At 800 C b) Reducibility index (k x 10-2 min-1)** At 800 C At 950 C c) Low temperature disintegration (% wt.) 500 C, +6.3 mm 500 C, -3.2 mm
Lump ore
Pellet
3.0 min 4.0 min 70 min 20 max
15 max 3.0 min 4.0 min 80 min 10 max
Metallurgical characteristics
Technical Overview
Raw Materials
Physical and Mechanical Properties
a)Size distribution after screening - 42.0 + 31.8 mm +31.8 mm + 15.9 mm - 9.5 mm - 6.3 mm - 3.2 mm a)Porosity (%) a)Mechanical Strength Tumbler index (% w, +6.3 mm) Compression strength
(kg/pellet, +10 mm 16 mm)
Lump ore
% weight 5.0 max
Pellet
% weight 0 0
Physical characteristics
8.0 max 2.0 max -
5.0 max 15.0 max 1.0 max 0 20.0 min
90 min -
93 min 200 min
High Carbon DRI Benefits
Effect of High-Carbon
100*Combined Carbon/Total Carbon Combined Carbon (cementite or iron carbide - Fe3C) in DRI from HYL Self-Reforming Process 100 95 90 85 80 75 70 2 3 4 5 6 7 % Total Carbon in DRI
A DRI with 4% Carbon contains more than 50% of Fe3C. The high percentage of Fe3C in the DRI of the 4M plant makes the product very stable. Most of the Carbon in the DRI is present as Fe3C, for a Carbon content of 4% approx. 95% of it is present as Fe3C. Every 1% of combined Carbon corresponds to 13.5% of Fe3C.
DRI Analysis 4M Plant: Metallisation 94% Carbon 4% Fe 83.0% Fe Total 88.3% Fe3C 55.1% Gangue 6.2%
DRI Stability
REACTIVITY OF DRI IN CONTACT WITH AIR
6 5 HYL DRI Characteristics: DRI -ZR Mtz. = 94%, C = 4% (> 90% as Fe3C) DRI -w/Reformer Mtz. = 94%, C = 2%
60 50 HYL DRI Characteristics: DRI -ZR Mtz. = 94%, C = 4% (> 90% as Fe3C) DRI -w/Reformer Mtz. = 94%, C = 2%
REACTIVITY OF DRI IN CONTACT WITH AIR+WATER
LTS O2/TON HR
LTS O2/TON HR
4 3 2 1 0 0 0.5
40 30 20 10 0
1.5
HYL ZR HYL III
0.5
1.5
HYL ZR HYL III
TIME (DAYS)
TIME (DAYS)
In general, High-Carbide DRI is more stable than conventional DRI. This has been proven in specific tests that were performed for DRI being produced at the 3M5 plant, before and after its conversion to the ZR scheme, for two levels of Carbon.
DRI Stability
REACTIVITY OF DRI IN CONTACT WITH SALTY WATER + AIR
70 60
Lts O2/Ton-Hr
These test results, specifically with salty water, are of relevant importance due to the low risks for High-Carbon DRI overseas transportation.
50 40 30 20 10 0 0 2 4 6 8
HYL ZR Salty Water+Air
HYL III w/Reformer Salty Water+Air 10 12
Time (Hrs)
In the EAF
Carbon in Fe3C form
Chemical Energy Contribution
The conversion of Fe3C into iron and carbon is an exothermic reaction which improves the thermal efficiency in the EAF.
Efficient use of carbon in EAF

The combined carbon is totally used, minimizing external carbon (graphite) additions.
Higher stability during handling

Iron carbide is more stable and is safer to be stored and transported.
In the EAF
Easy foamy slag generation:
As high carbon DRI enters in contact with free or combined oxygen.
Carbon and DRI are fed at the same time:

The same system controls the feeding rate of metallic charge and carbon additions.
Easier operation with intensive oxygen use:

As DRI feeding rate is varied, carbon is varied as well and, as a consequence, oxygen use is varied.
Specific Savings
High temperature and High C in DRI
35 4
Electric power savings (kWh/TLS)
30
30 27
3.5 3 2.5
25 20 15 10 5 0
2.5 2.1 12
2 1.5 1
0.9
0.5 0
100C
1% C
1% Met
Power on time savings (min/heat)
HYTEMP System For Hot DRI
HYL Process
HYTEMP System for hot DRI Charging to EAF
Iron Ore
Reducing gases Possible sources Natural Gas Reformed Gas Syngas (coal) COG others
H2O CO2
Reactor
HYTEMP System
O2
fuel
Hot DRI
Transport Gas Make up EAF
External Cooler
Cold DRI
HYTEMP System
Only proven technology for continuous transport/feeding of hot DRI to EAF

Pneumatic transport of hot DRI to EAF Flexible configuration and layout Simple operation
Totally enclosed from ore to liquid steel Savings of power related costs in EAF EAF productivity increase
HYTEMP System
Hot DRI-EAF Performance
550
DRI: 94% Metz. and 3.7% C.
270 250
Energy (kWh/t LS)
500 230 450 210 190 400 170 350

50 100 150 200 250 300 350 400 450 500 550 600
150
DRI Temperature (C)

kWh/t LS tonnes/hr
Melting rate (t LS/hr)
HYTEMP System
Industrial Installation
Ternium Hylsa is currently feeding two EAFs with Hot DRI. The Danieli EAF is fed with up to 100% HighCarbon, Hot DRI More than 6 million tons of Hot-High Carbon DRI already transported
EAF No.1
22 m
EAF No. 2
83 m
4M DR Plant
72 m
10 m
53 m
HYTEMP System
Reactor Tower
HYTEMP System
For a new project, the proposed general scheme is same as that of Ternium-Hylsas 4M DR Plant, with the following main characteristics:
Reactor for hot DRI discharge, same as 4M, but incorporating flow feeders in case of larger dimension reactor. External cooler for production of cold DRI preferably by pneumatically fed or alternatively by gravity fed, depending on capex and/or height limitations. Capacity for 100% cold DRI or 100% hot DRI production or any combination. HYTEMP System to transport hot DRI to EAF charging system.
HYTEMP System
Cooler Feed by Pneumatic Transport
7000 (REF.) 7000 (REF.) 7000 (REF.) 7000 (REF.) EL. 82.500
3 2 1 1 0
REACTOR RE 221-D
F.L. 74.415
ELEVATOR FLEXOWALL
MIN 3 00 120 OTE N M IMU
RE 221-D
STAIRS
REDUCTION TOWER
EL. 70.765 TOP OF BIN
7000 NOTE 5
4500 (REF.)
4500 (REF.) EL. 57.750
4500 (REF.)
4500 (REF.)
REACTOR HEAT RECUPERATOR PG 221-C EMERGENCY DUMP 7000 NOTE 5
F.L. 55.062
60 cm
50
40
30 20
10
2000
4500
9000
DRI COOLER CG 121-D
EL. 40.022 TRANSFER LINE
4500
TO COLD DRI STORAGE YARD
R E A C TO R
PTS PELLETS TRAP PH 651-G
4500
4500 9000
"A"
FL. EL. 20.212
FL. 17.634
E L E V A T O R
A B
D R I C O O LER C G 1 2 1 -D
RE 251-F
R E A C TO R
TS MP F RO GASATER HE
1 0 1 2 3 3 1 2 1 0
M .R .
B
B C A A C B
EL. 6.520
C G 1 55 -F 11
EL. 0.000 FLOOR LEVEL
A-A
B-B
C G 155-F 12
HYTEMP System
Specific Advantages Production of hot or cold DRI.
Flexibility for carbon control in DRI (2.5 4%)
High C, hot DRI to EAF:

Power savings of more than 130 kWh / t LS in EAF. Potential EAF decrease on power on time of about 30% Potential EAF net productivity increase of about 20%
Technology Advantages
ENERGIRON Technology
Advantages Most advanced current and proven technology available in the market:
In-situ reforming and HYTEMP System since 1998 at industrial scale.
High and flexible DRI quality:

DRI is produced with high and uniform quality. Metallization and carbon can be independently adjusted to meet any steel specification:
Metallization: > 93%. Carbon: from 0.8 4%.
Lower iron ore and energy consumption figures as compared to competing DR processes.
Advantages Optimised DR plant design:
High operating pressure (> 5 bars) which reduces equipment size and power consumption (Dp). Selective removal of oxidants from the reduction process: H2O and CO2: Optimization of Reducing gas make-up.
Flexibility to fulfil customer requirements:

Zero kWh scheme: Grasim (India), 2P5 (Mexico), partialLebGOK(Russia) and PSSB (Malaysia). Zero Water consumption: Hadeed (Saudi Arabia). CO2 as by-product for sale: 3M5 & 4M (Mexico). Plants are designed to comply with the local environmental regulations.
Raw Materials Experience and Flexibility
up to 100% lump ore in Usiba and Vikram Ispat-Grasim
Pellets Source Alzada CMP CVRD GIIC Hierro Peru IMEXSA Kudremukh LKAB Mandovi Pea Colorada Samarco Sicartsa SIDOR Ferrominera Lebedinsky Country Mexico Chile Brazil Bahrain Peru Mexico India Sweden India Mexico Brazil Mexico Venezuela Venezuela Russia Lump ores Source Bailadhila Alegra Corrego El Pao Esperanca Feijao Ferteco G.G. Brothers Mineral Sales Mutuca NMDC Sishen Country India Brazil Brazil Venezuela Brazil Brazil Brazil India India Brazil India South Africa
Pioneering Experience Since 1957
Not only technology supplier but overall experience as DR technology developer within a steel company. Committed to R&D. Laboratory and Pilot Plant facilities to perform iron ores test works. Proven and reliable DR Technology:
Currently about 11 MM t of DRI/HBI are yearly produced in HYL plants worldwide for a total accumulated production of over 150 MM t.
Flexibility to offer any combination of proven Plant Configurations, depending on specific customer requirements:
Cold (Low or High-Carbon) DRI Hot (Low or High-Carbon) DRI HBI
Reference Lists
HYL I / HYL II Plants
Plant
Hylsa 1M Hylsa 2M Tamsa Hylsa 1P Usiba Hylsa 3M Sidor I Hylsa 2P PTKS I PTKS II PTKS III PTKS IV Sidor II SEIS I SEIS II ASCO
Country
Mexico Mexico Mexico Mexico Brazil Mexico Venezuela Mexico Indonesia Indonesia Indonesia Indonesia Venezuela Iraq Iraq Iran
Units
1 1 1 1 1 1 1 1 1 1 1 1 3 2 2 3
HYL Design Capacity Product Scheme million tonne/y

HYL-I HYL-I HYL-I HYL-I HYL-I HYL-I HYL-I HYL-I HYL-I HYL-I HYL-I HYL-I HYL-II HYL-I HYL-I HYL-I DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI 0.10 0.19 0.28 0.25 0.23 0.42 0.36 0.63 0.56 0.56 0.56 0.56 2.11 0.54 0.93 1.03
Status
dismantled converted closed dismantled converted converted closed converted shutdown shutdown operating converted 2-operating 1-shutdown closed closed operating
Start Up
1957 1960 1967 1969 1974 1974 1976 1977 1978 1978 1981 1981 1981 1988 1989 1993
Reference Lists
HYL III / ZR Plants
Plant
Hylsa 2M5 Hylsa 3M5 Mittal Steel-1 Mittal Steel-2 Vikram Ispat PTKS PSSB Usiba Hylsa 2P5 Hylsa 4M Hadeed Lebedinsky Matesi
Country
Mexico Mexico Mexico Mexico India Indonesia Malaysia Brasil Mexico Mexico S. Arabia Russia Venezuela
Units
1 1 2 2 1 2 2 1 1 1 1 1 2
HYL Scheme
Product
Capacity, million tonne/y Design Achieved

0.25 0.50 1.00 1.00 0.75 1.35 1.20 0.31 0.61 0.68 1.10 0.90 1.50 closed 0.63 1.20 1.20 0.90 1.35 1.20 0.35 0.65 0.93 1.10 1.09 1.50
Product quality Metallization Carbon

94.0 94.0 94.8 94.8 93.6 93.3 95.0 91.3 93.3 94.4 94.4 95.1 93.0 2.7 3.9 2.1 2.1 1.1 2.3 2.0 2.8 3.4 3.6 2.4 1.1 1.8
Start Up
1980 1983 1988 1991 1993 1993 1993 1994 1995 1998 1999 1999 2004
HYL III DRI HYL-ZR DRI HYL III DRI HYL III DRI HYL III HBI/DRI HYL III DRI HYL III DRI HYL III DRI HYL III DRI HYL-ZR HYTEMP/DRI HYL III DRI HYL III HBI HYL III HBI
Reference Lists
New Projects
By HYL/Techint
Plant
Al Nasser Vikram Ispat Mittal Steel Sidor
Country
UAE India Mexico Venezuela
Units
1 1 1 1
Scheme
System
Capacity, million tonne/y Design Status

0.20 0.50 + 20% 0.80 Under construction Under execution Successful start-up Under execution
Product quality Metallization Carbon

93.0 94.0 94.0 94.0 3.5 3.0 2.0 2.0
Start Up
2007 2007 2007 2008
High-C DRI Micro-Module High-C DRI Mini-Module
Expansion CO2 absorption Cold DRI Conversion
By HYL - Danieli
Plant
GHC
Country
Abu Dhabi UAE
Units
1
Scheme
System

1.60 Under construction
Product quality Start Up Metallization Carbon

94.0 3.0 2008
Hot, High-C HYTEMP/DRI DRI
By Danieli (support from HYL)

Plant
Jindal Ceara
Country
India Brazil
Units
1 1
Scheme
System

1.70 1.70 Under execution Under execution
Product quality Start Up Metallization Carbon

94.0 94.0 2.0 2.5 2008 2008
Coal gasification HYTEMP/DRI Hot DRI High-C DRI -

Energiron DR Technology-July 2007

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from Tenova HYL and Danieli & C.

Danieli and Tenova HYL Alliance

Tenova HYL - Danieli Alliance

Tenova HYL - Danieli Alliance

Tenova HYL - Danieli Alliance

GHC Abu Dhabi Project:

Reform (Nm er 3/t)

Carbon: 0.8 2.2%

Oxygen Injection (Nm3/t)

Only for cold DRI

HYTEMP Iron Optional DR products: DRI HBI EAF

DRI NG COG Syngas

Product Product flexibility:

Steam Reforming CH4 + H2O CO + H2O CO + 3H2 CO2 + H2

Electricity Oxygen Water Labor Maintenance

kWh/t Nm3/t m3 m-h/t US$

0 - 85 0 - 50 0 - 1.3 0.11 - 0.17 3 - 3.3

Highly automated process

The ENERGIRON Plant: 7,800 8,000 hr/yr net working time

Fe total Fe++ Na2O + K2O TiO2 LOI

1.00 max 0.10 max 0.20 max 1.50 max

0.10 max 0.20 max -

Metallurgical Properties HYL standards

3.0 min 4.0 min 70 min 20 max

15 max 3.0 min 4.0 min 80 min 10 max

8.0 max 2.0 max -

5.0 max 15.0 max 1.0 max 0 20.0 min

93 min 200 min

High Carbon DRI Benefits

REACTIVITY OF DRI IN CONTACT WITH AIR+WATER

HYL ZR Salty Water+Air

HYL III w/Reformer Salty Water+Air 10 12

Efficient use of carbon in EAF

Higher stability during handling

Carbon and DRI are fed at the same time:

Easier operation with intensive oxygen use:

Electric power savings (kWh/TLS)

Power on time savings (min/heat)

HYTEMP System For Hot DRI

Transport Gas Make up EAF

Energy (kWh/t LS)

500 230 450 210 190 400 170 350

DRI Temperature (C)

Melting rate (t LS/hr)

EL. 70.765 TOP OF BIN

4500 (REF.) EL. 57.750

REACTOR HEAT RECUPERATOR PG 221-C EMERGENCY DUMP 7000 NOTE 5

DRI COOLER CG 121-D

EL. 40.022 TRANSFER LINE

TO COLD DRI STORAGE YARD

PTS PELLETS TRAP PH 651-G

FL. EL. 20.212

EL. 0.000 FLOOR LEVEL

High C, hot DRI to EAF:

High and flexible DRI quality:

Flexibility to fulfil customer requirements:

HYL Design Capacity Product Scheme million tonne/y

Capacity, million tonne/y Design Achieved

Product quality Metallization Carbon

Capacity, million tonne/y Design Status

Product quality Metallization Carbon

High-C DRI Micro-Module High-C DRI Mini-Module