M Ravenscroft Midrex Technologies Inc Direct Reduction Ironmaking Technologies Trends and Outlook for North America 2014 Midrex Technologies Inc All rights reserved ID: 691730
Download Presentation The PPT/PDF document "Henry P. Gaines, Jr PE Christopher" is the property of its rightful owner. Permission is granted to download and print the materials on this web site for personal, non-commercial use only, and to display it on your personal computer provided you do not modify the materials and that you retain all copyright notices contained in the materials. By downloading content from our website, you accept the terms of this agreement.
Slide1
Henry P. Gaines, Jr PE
Christopher M. RavenscroftMidrex Technologies, Inc.
Direct Reduction Ironmaking: Technologies, Trends and Outlook for North America
© 2014 Midrex Technologies, Inc. All rights reserved. Slide2
WHY Direct Reduced Iron?Why so much interest?
© 2014 Midrex Technologies, Inc. All rights reserved.
The versatile Ore-based metallicSlide3
DRI Products Versatile Ore-based Metallics
CDRI: Cold Direct Reduced IronHDRI
: Hot Direct Reduced I
ron charged directly into a melter without cooling
HBI
: Hot Briquetted Iron is direct reduced iron discharged from the shaft furnace at ≥650°C
and compacted to a density ≥
5 gm/cc
© 2014 Midrex Technologies, Inc. All rights reserved
.Slide4
IntegratedOperational Value
© 2014 Midrex Technologies, Inc. All rights reserved.4
EAF Steelmaking
Operational Value
Low residuals
Uniform chemical
composition
Lower emissions
EAF can produce
steel grades
unattainable
with 100%
scrap
Low NG energy costs particularly in
USA
HDRI is a lower cost feed to the EAF than pig
HBI can be an economical means to increase BF productivity or to replace purchased scrap in the BOF
…
Increasing need for MetallicsSlide5
element content (%) in scrap and HBI/DRI
Typical levels of residual elements in scrap and
HBI/DRI
© 2014 Midrex Technologies, Inc. All rights reserved.
5
%Cu
%Sn
%Ni
%Cr
%Mo
%Mn
%S
%P
%Si
No. 1 Bundles
0.07
0.008
0.03
0.04
0.008
0.03
0.02
0.01
0.005
Shredded0.220.030.110.180.020.40.040.0250.01No.1 HMS0.250.0250.090.10.030.30.40.020.01No. 2 Bundles0.50.10.10.180.030.30.090.030.01No. 2 HMS0.550.040.20.180.040.30.070.030.01DRI/HBI0.002trace0.0090.003trace0.06-0.100.01-0.030.07-0.09***Both Phosphorus and Silica are contained in the oxide form; they are not in the elemental form.
Virgin Iron SourceSlide6
Benefits of charging HBI to a blast furnace (BF) are
:
Greater productivity
Lower blast furnace fuel
consumption
Lower coke consumption, and
therefore
g
reatly
decreased CO
2
emissions
for
ironmaking
HBI has been used as part of the regular, routine operation of a commercial blast furnace in North America for
more than 25 years as well as other blast furnaces around the world.HBI will play a future roll in the integrated steel industry6© 2014 Midrex Technologies, Inc. All rights reserved.
Charging of 30% HBI yields approximately a 24% increase in production.Slide7
More DR Capacity is On the Way© 2013 Midrex Technologies, Inc. All rights reserved.
7Midrex expects USA production of DRI to surpass ten million tons per year sometime near the end of this decade. This means additional plants need to be permitted and contracted within the next 2 to 4 years.Slide8
More DR Capacity is On the Way© 2013 Midrex Technologies, Inc. All rights reserved.
8Midrex expects USA production of DRI to surpass ten million tons per year sometime near the end of this decade. This means additional plants need to be permitted and contracted within the next 2 to 4 years.Slide9
More DR Capacity is On the Way© 2013 Midrex Technologies, Inc. All rights reserved.
9Midrex expects USA production of DRI to surpass ten million tons per year sometime near the end of this decade. This means additional plants need to be permitted and contracted within the next 2 to 4 years.Slide10
Module size: are mega modules the way forward for US DRI?© 2014 Midrex Technologies, Inc. All rights reserved.
Meeting Market Demands:Not simply larger capacities but also operational flexibility: Fuels Feed Material
ProductSlide11
Production and Flexibility
© 2014 Midrex Technologies, Inc. All rights reserved.Slide12
Growing
DRI plant Capacityto meet sizes of BF facilities © 2014 Midrex Technologies, Inc. All rights reserved.Slide13
MIDREX
® Plants Meet Demands 2.0 mtpy production is now a reality© 2014 Midrex Technologies, Inc. All rights reserved.
World Record Production for Single DRI Module
Design capacity 1,760,000 tpySlide14
Customer:
voestalpine Texas Llc., USA
Plant Type: 2 mtpy MIDREX®
Direct Reduction HBI Plant
Plant Start-up:
December 2015
Feed material:
100%
pellets (Brazil, Canada)
DR
plant erection:
carried out by a consortium of MIDREX and Siemens
Product:
100% HBI - half to merchant market, half to use in voestalpine BFs in Austria
voestalpine
Texas, LLC
MIDREX® 2.0 MTPY HBI Plant© 2014 Midrex Technologies, Inc. All rights reserved. Slide15
DRI products will play a future roll in the integrated steel industry
Will utilize the low-cost natural gas based on the shale gas production in the USA
Increase blast furnace productivity in
the Linz and Donawitz / Austria
Decrease specific CO
2
emissions
Provide additional HBI for merchant market
Altos
Hornos de Mexico (AHMSA),
has
signed
MOU
to purchase
HBI from voestalpine
Texas
© 2014
Midrex
Technologies, Inc. All rights reserved. Slide16
How easily are plants retrofitted for hot DRI?© 2014 Midrex Technologies, Inc. All rights reserved.
Any hot Discharge MIDREX
®
Plant can easily be configured to transport HDRISlide17
Options for Hot transportCombo Plant design allow for maximum flexibility
© 2014 Midrex Technologies, Inc. All rights reserved.
Temperature dominates.HDRI → Higher Productivity + Lower Power ConsumptionSlide18
© 2014 Midrex Technologies, Inc. All rights reserved
.Lion Case StudyIncreasing Productivity & EfficiencySlide19
Alternative DRI technology: how are alternative technologies developing? What kind of capacities are feasible?
© 2014 Midrex Technologies, Inc. All rights reserved. Technology is being developed and implemented to address market needs such as in areas of the world without NG… Innovation continues that benefits both new and older MIDREX® PlantsSlide20
New Technologies
Innovation that meets industry needs in areas such as IndiaCommercial pairing of MIDREX® Process with a coal sources for direct reduction
ironmakingSame capacities as NG-based PlantsCoal gasification
COREX® Off Gas
Coke Oven Gas (COG)
© 2014
Midrex
Technologies, Inc. All rights reserved
.Slide21
Jindal Steel & Power
Capacity: 1.80
million tpy HDRI Furnace Type: MIDREX
MEGAMOD®
Hot
Discharge Furnace (7.15 m
ID)
Reducing Gas: Coal Gasification
Location:
Angul
,
Odisha,India
World’s First MXCOL
®
Facility
DR Plant + Coal
GasifierJSW STEEL (COREX®/MIDREX®) Capacity: 1.20 million tpy HDRI/CDRI Furnace Type: MIDREX MEGAMOD® Hot Discharge Furnace (7.15 m ID) Reducing Gas: COREX export gas
Products:Hot
DRI (0-100%) and/or
Cold DRI (0-100%)
Location: Toranagallu Karnataka State, India© 2014 Midrex Technologies, Inc. All rights reserved. Slide22
Technology ready for industrial application..Results continue to exceed expectations.
New Technologies – The TRS®© 2014 Midrex Technologies, Inc. All rights reserved.Slide23
THANK YOU
© 2014 Midrex Technologies, Inc. All rights reserved.
Designed for Today,
Engineered for Tomorrow™
Visit
www.midrex.com
for more technical presentations and the
2013
World Direct Reduction Statistics Booklet