The midrex process the worlds most reliable and productive. The midrex process the worlds most reliable and productive direct reduction ironmaking technology. It is basically a countercurrent process where a hot and highly reducing gas 95vol. Midrex and hyl energiron are the leading technologies in shaft furnace direct reduction, and they account for about 76% of worldwide production. Metallic iron used in steel industries is mostly obtained from a direct reduction process. Innovative uses of hydrogen in steelmaking presentation by jayson ripke, midrex technologies, inc. Using the cost analysis method, the costs of the blast furnacebasic oxygen furnace, midrex, and hyl were calculated over a period of 25 years. The midrex plant is constructed near the city of corpus christi, texas.
The increasing role of direct reduced iron in global. The use of hot riquetted iron hi in the last furnace f for hot metal production hi can be used as blast furnace burden material with the following environmental, productivity and cost benefits. It is designed to produce two million metric tons of hot briquetted iron hbi per year. The hot transport conveyor option continuously transports hdri from the discharge of the midrex shaft furnace via an inclined bucket conveyor into inerted storage bins located directly above the eaf. Flexibility of direct reduction technology the midrex way. This furnace will be the indias largest blast furnace to date. Midrex plants commonly operate in excess of 8000 hrs per year. Technical developments in the middrex process abhilasha gulhane, gaurav kumar. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper.
Coke constitutes the major portion of ironmaking cost and its production causes the severe environmental concerns. Midrex offers hotlink, hot conveyor, and hot container to transport the hot dri to the eaf while tenova hyl offers hytemp system. Resources trend and use of direct reduced iron in steelmaking. Potential for co2 emissions reduction in midrex direct.
Alternative methods known as direct reduction are used in over a score of countries, but less than 5 percent of iron is made this way. Danieli corus has enjoyed an incredible journey with indian steel industry over the years. Blast refers to the combustion air being forced or supplied above atmospheric pressure in a blast furnace, fuel, ores, and flux are continuously supplied through the top of the furnace, while a hot blast of air sometimes with. Midrex technology which is the most important gasbased direct reduced iron dri process in the world, includes reduction, transition and cooling zones.
Furnace turnaround this technical document will focus primary on furnace charging, melting, and refining, and will discuss these operations in detail in the sections that follows. Hot charging dri to the eaf options direct from midrex 2 nd quarter 2007 11 get it while its hot carbon emissions can be further reduced by hot charging the dri to the eaf midrex has developed three methods for discharging the dri at elevated temperature, transporting it hot to the meltshop, and charging it to the eaf at 600700 c. Outotec direct reduction technologies include solutions for the full range of plant types, and have been developed through extensive research and testing with a wide range of raw materials and process parameters. The reduction zone considered as a counter current gassolid reactor. Directreduced iron an overview sciencedirect topics. Futhermore, a bigger dr ironmaking capacity is now available up to around 2 million tons per year. Hotlink, hot transport conveyor htc and hot transport vessel htv. Our innovations focus on improving plant performance, reliability, and sustainability, while reducing capital investment and. Aftermarket group dedicated to continual support of your midrex plant. The rated capacity of this furnace is 9,500 tons of hot metal per day with pulverized coal injection system of 200 kgthm. Midrex ng process first plant built in 1969 over 70 units constructed worldwide over a. The increasing role of direct reduced iron in global steelmaking. The midrex process performs the iron ore reduction activities inside a tall vertical reactor called the midrex shaft furnace.
Midrex is an innovative ironmaking process, developed for the production of directreduced iron dri from iron ores and primarily natural gas. Using the cost analysis method, the costs of the blast furnace basic oxygen furnace, midrex, and hyl were calculated over a period of 25 years. Double bustle allows better distribution of the reducing gas when compared with a single bustle. Request pdf shaft furnace direct reduction technology midrex and energiron coke constitutes the major portion of ironmaking cost and its production causes the severe environmental concerns. Midrex process accounts for about 60% of global production. The order value for the consortium is in the three. In the area of gaseous emissions, the kyoto protocol has put great pressure on the industrialized countries. The reducing gas from 1020% co and 8090% h2 is produced from natural gas. At the most favorable operation conditions using 400 kgthm of dri thm ton of produced hot metal, the co2 emissions of the blast furnace can be reduced by up to 26.
Use of drihbi in ironmaking and steelmaking furnaces. The reducing gas from 1020% co and 8090% h2 is produced from natural gas using midrexs co2 reforming. Conventionally, the dri was discharged after cooling. Hot dri hdri can be transferred from the dri plant to the meltshop by hot transport vessels, hot transport conveyors or pneumatic transport, depending on the distance between the dri plant and the melt shop, or by direct gravity feeding in the case of a closecoupled reduction furnace and eaf. Midrex is a gasbased shaft furnace process that converts iron oxides in the form of pellets or lump ore into direct reduced iron dri. Cost effectiveness analysis of hyl and drex dri te chnologies for the iron and steelking industry pa ge 2 acknowledgements i am thankful for the wonderful support shown to me by my advisor, dr. The conventional way of iron and steel making consumes high fuel and even causes emission of carbon dioxide. Manufactured for easier handling and transocean shipping, the majority of this product has been melted in electric arc furnaces eafs. Bfbof route, midrex performed a detailed analysis of various steelmaking methods, including the blast furnacebof and the eaf fed with various mixes of scrap plus alternate iron dri, hbi, and pig iron. Worldwide, there is an increasing emphasis on environmental issues. It is designed to produce two million metric tons of hot briquetted iron hbi per year, making it the largest single module of this type worldwide. Either lump ore, or pellets prepared for direct reduction ironmaking, are charged as raw material from the top of a shaft furnace.
So lower energy consumption, lower co2 emission and waste recycling are driving the iron and steel industry to develop alternative, or cokefree, ironmaking process. Proprietary engineering, key process equipment supply, bulk material supply, field services, training. The ore is reduced inside the furnace and the reduced iron is discharged from the bottom of the. Midrex shaft furnaces can be equipped with one of three systems to transfer hdri to a steelworks meltshop. Nonblast furnace iron making technology total materia. Ironmaking in the rotary hearth furnace rhf is a direct reduction process which utilizes noncoking coal for the reduction of iron ore. However, the proportion of blast furnace bf basic oxygen furnace bof steelmaking could drop to 40 % in 2050 from the current level of 60 % as the blast furnace ironmaking proportion falls from around 95 % to 60 % of the total iron ore processed. We work with you to decide on the solution that most precisely corresponds to your requirements. The focus of this study is to simulate the furnace of the midrex technology. The rotary kiln, shaft furnace, and the traveling bed reactor vass produce the highest metallization.
Midrex has the only commercial scale shaft furnace technology that is using syngas derived from coal to produce dri this plant has been successfully operating since 1999 h2co ratio 0. Paul wurth designs its valves to meet and exceed the most severe operating conditions to be expected in blast furnace operation. Key points midrex plants located next to a steel mill eaf should charge hdri to take advantage of the sensible heat 500. Hot direct reduced iron hdri is dri that is transported hot, directly from the reduction furnace, into an electric arc furnace, thereby saving energy. The midrex process is a shafttype direct reduction process where iron ore pellets, lump iron ore or a combination are reduced in a vertical shaft reduction furnace to metallic iron by means of a reduction gas see figure 1. The roof and electrodes are raised and are swung to the side of the furnace to allow the scrapcharging crane to move a full bucket of scrap into place over the furnace. In the midrex process, the main purpose of the reduction zone is to metallize the iron to the desired product metallization using reductants co and h 2 produced by. Blast furnace top charging technology ironmaking our.
Blast furnaces are used to produce pig iron from iron ore for subsequent. The midrex technology is highly adaptive to our customers. These advantages help in increasing the shaft furnace productivity. Midrex and hyl energiron are the leading technologies in shaft furnace direct reduction, and they account for. High carbon dri 34% also provides more chemical energy in eaf steelmaking. The primary objective of iron making is to release iron from chemical combination with oxygen, and, since the blast furnace is much the most efficient process, it receives the most attention here. The rotary fireplace furnace has the fastest procedure clip. Midrex the worlds leading directreduced iron production. This furnace is designed for a twenty year campaign. Direct reduction process an overview sciencedirect topics.
Aug 21, 2015 metallic iron used in steel industries is mostly obtained from a direct reduction process. Double bustle also allows higher flows of the reducing gas to the furnace without local fluidization of the dri. This is accomplished as the continuously fed iron oxide, which is similar in size and shape to marbles, flows downward through the shaft furnace by gravity, countercurrent to the hot. Pdf the iron and steel production processes are characterized by a considerable environmental impact. The rhf is the process reactor which consists of a flat, refractory hearth rotating inside a stationary, circular tunnel kiln. The newly reformed gas, containing 9092 percent h2 and co, is then fed hot directly to the shaft furnace as reducing gas. Blast furnace valves ironmaking our activities site. Shaft furnace direct reduction technology midrex and energiron. Nov 05, 2015 midrex is an innovative ironmaking process, developed for the production of directreduced iron dri from iron ores and primarily natural gas.
The performance of midrex plants typically exceeds nominal capacity ratings. Abstract this paper presents an overview of the history of the technical developments in midrex process, as well as the latest developments in this field. The main dri technologies in use are those of midrex and hyl, but. Carbon in the midrex direct reduction process and the act technology in the midrex shaft furnace, carbon is added to dri in three places see figure 3. Dri, whereas the product of the blast furnace is referred to as hot metal in the molten state, or pig iron in the solidified form. The reaction in the blast furnace creates a molten metal known as hot metal. Modeling and simulation of the midrex shaft furnace. This is the only alternative to the conventional blast furnace route consisting of sinter plant, coke oven. The hot blast is directed into the furnace through watercooled copper nozzles called tuyeres near the base. The use of hot riquetted iron hi in the last furnace f. The midrex shaft furnace can use natural gas or a syngas from coal or coke oven gas as its reductant. The hot blast temperature can be from 900 c to 0 c 1600 f to 2300 f depending on the stove design and condition.
The increasing role of direct reduced iron in global steelmaking by f. Minnitt synopsis direct reduced iron dri, produced by the reaction between iron ore and reducing gasses, is used as a source of lowresidual iron, in addition to ferrous scrap and pig iron, in the production of steel mainly through the electric arc. The eaf options included 80% cold dri20% scrap, 80% hot dri20% scrap, 30% cold dri70% scrap, 30% hbi70% scrap, 30% pig iron70% scrap. The tuyeres are used to implement a hot blast, which is used to increase the efficiency of the blast furnace. The gas is heated and reformed as it passes through the tubes. Your partner for contracting to commissioning direct reduced iron plants. The midrex technology is highly adaptive to our customers needs, which is reflected in a broad variety of configurations. In a midrex hot discharge plant, hdri can be transferred by one of three methods to an eaf meltshop. Outotec direct reduction technologies are based on almost 50 years experience of delivering solutions for customers in the ferrous direct reduction sector, encompassing the full range of plant types. Pdf use of drihbi in ironmaking and steelmaking furnaces. Heat recovery the thermal efficiency of the midrex reformer is greatly enhanced by the heat recovery system. This plant is north americas firstever hbi facility and is the largest of its kind. Dr plant was envisaged to supply hot dri to adjacent melt shop along with extra cold dri to be available for sale in gcc market. For this hot transport mode, the midrex shaft furnace discharge can be at a significantly lower elevation than the eaf.
Blast furnace, a vertical shaft furnace that produces liquid metals by the reaction of a flow of air introduced under pressure into the bottom of the furnace with a mixture of metallic ore, coke, and flux fed into the top. The plant is also unique in that it is the first hbi plant built based on blast furnace demand rather than the electric arc furnace eaf. The most popular on the market right now is the midrex shaft furnace with about 60 % of the market portion of dri production table 1. Shaft furnace direct reduction technology midrex and. Hot metal is further processed in a basic oxygen furnace where pure oxygen is charged into the furnace to oxidize the impurities in the metal. State of direct reduction and reduction smelting processes j. Coal gasification for dri production an indian solution. Our knowledge gained from about 700 installations, combined with the operational experience.
Primetals technologies and consortium partner midrex technologies, inc. Overview of sulb dr plant in 2010 sulb company made a contract with kobe steel, ltd. Hot briquetted iron hbi is a compacted form of dri designed for ease of shipping, handling and storage. Blast furnace steelmaking uses iron ore, coke, and limestone in a blast furnace heated from the bottom with oxygen and air. The direct reduction process uses pelletized iron ore or natural lump ore.
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