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Henry P. Gaines, Jr PE Christopher Henry P. Gaines, Jr PE Christopher

Henry P. Gaines, Jr PE Christopher - PowerPoint Presentation

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Henry P. Gaines, Jr PE Christopher - PPT Presentation

M Ravenscroft Midrex Technologies Inc Direct Reduction Ironmaking Technologies Trends and Outlook for North America 2014 Midrex Technologies Inc All rights reserved ID: 691730

technologies midrex reserved rights midrex technologies rights reserved 2014 dri hbi furnace plant direct hot production gas capacity plants 100 usa 030

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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