December 2011 - SIMA

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e maintained while taking advantage of the moreefficient, higher quality gas-based DRI producingtechnologies.DR Plant configurations for IndiaLooking at the Indian DRI industry some years back,Tenova HYL determined that a solution wouldeventually be needed to replace the existing coalbasedDRI production that faces ever increasingcontrols and regulations because of its environmentalhazards. While the major steel producers are capableof making the large capital investments necessaryfor large scale DRI plants to feed their own steel mills,the smaller coal-based DRI producers don’t have thatluxury. So Tenova HYL decided to engineer a small,efficient, cost-effective gas based DR plant that couldpossibly compete on the smallest production scale.HYL Micro-ModuleThe HYL Micro-Module was developed to produce200,000 tpa of high quality, high carbon DRI usingour Energiron ZR reformerless plant technology. Thefirst of these plants has been installed and put intooperation in Abu Dhabi, UAE and more are underconsideration by various companies in India.The Micro-Module becomes the smallest gas basedDR facility capable of producing high quality productwith a capital cost in the range of $250-300 per tonof product. This of course is higher than the cost of acoal-based plant, but the quality of the DRI producedfar exceeds that of a coal-based unit, while being themost environmentally friendly processes on themarket.Still, in areas where natural gas is either unavailableor the cost is prohibitive, other options must be madeavailable. That is precisely where the flexibility ofthe Energiron ZR process scheme becomes evenmore relevant for India.Energiron ZR using SyngasBecause the Energiron ZR process does not includean integrated gas reformer, it can use any source ofreducing gases to produce high quality DRI. A coalgasification plant can use low grade coals to producethe necessary reducing agents (H2 and CO) for directreduction, and it can do so in a manner that is cleaner200,000 tpa HYL Micro-Module Plant,GSPI, Abu Dhabiand more efficient than the direct use of coal as areductant. Essentially, it allows the use of gas-basedtechnology in areas where natural gas is not anoption, permitting the production of highly metalized,high carbon DRI from gas made from coal.Energiron ZR Process SchemeUsing Syngas as ReductantDECEMBER-2011/28
The first of these plants in India has already beencontracted by JSPL – a 2.5 million tpy Energiron ZRfacility that will use coal gasification as the reducinggas source. Actually, it is the first of four plants agreedon with JSPL for a total of 10 million tons per year ofhigh quality DRI and should be operational by 2014.In large facilities such as the ones being developedby JSPL and others, the coal gasification plants canhave a dual purpose by producing both syngas forthe DR plant as well as power for related facilities.Syngas Micro-Module?The characteristics of the ZR process make the Micro-Module and the large 2.5 million tpy Energiron plantssimilar in every respect except size. Therefore, theMicro-Module could conceivably also use syngasinstead of natural gas – technically there is no difficultyin doing so. However, the capital cost of installing acoal gasification plant is quite high and, in the caseof a Micro-Module plant, would be more expensivethan the DR plant itself. The current state of affairsmakes this an unlikely combination and in fact forDR plants under 1 million tons of annual capacity,the use of a coal gasification plant cannot be easilyjustified. Future developments could change thissituation, but for the present, syngas is an option onlyfor larger scale production units.Recent ProjectsSince 2005, Tenova HYL has started up or is buildingand/or upgrading a significant number of new DRIplants worldwide. The following tables show the latestplants and upgrades.New Projects since end of 2005Plant Country Modules Technology Product Capacity Product Quality(Million ton/yr) Metallization Start UpDesign (Carbon)(a) WelspunMaxsteel Ltd. India 1 ENERGIRON ZR DRI 0.60 94.0 (3.0) 2006 / 2009Emirates Steel 1(GHC) Abu Dhabi 1 ENERGIRON III HYTEMP/DRI 1.60 94.0 (2.0) 2009Gulf Sponge Iron(Al Nasser) UAE 1 HYL-ZR DRI 0.20 93.0 (3.5) 2010Sidor Venezuela 1 HYL III DRI 0.80 94.0 (2.5) 2011Ezz Rolling Mills Egypt 1 ENERGIRON III DRI 1.90 94.0 (2.0) 2011Emirates Steel 2(GHC) Abu Dhabi 1 ENERGIRON III HYTEMP/DRI 1.60 94.0 (2.0) 2011Suez Steel Egypt 1 ENERGIRON ZR HYTEMP/DRI 1.95 94.0 (3.5) 2012Nucor Louisiana USA 1 ENERGIRON ZR DRI 2.50 96.0 (3.5) 2013(b) Jindal Steel& Power India 4 ENERGIRON ZR HYTEMP/DRI 2.50 94.0 (2.5) ContractedNotes:a) 100% lump ore feedb) Syngas based plantsDECEMBER-2011/29
Page 3 and 4: CHAIRMAN’S MESSAGEI am happy that
Page 5 and 6: Target Setting:The methodology for
Page 7 and 8: Energy conservation Opportunities i
Page 9 and 10: MXCOL ® : A BREAKTHROUGH IN COAL-B
Page 11 and 12: MIDREX ® Direct Reduction PlantThe
Page 14 and 15: IRON ORE PELLETS AS THE FUTURE META
Page 16 and 17: Raw material availability:Basic raw
Page 18 and 19: ore also could be intended to gener
Page 20 and 21: AVERAGE PERFORMANCE PARAMETERS:Sl.
Page 22 and 23: CONCLUSION:The salient features of
Page 24 and 25: HARI MACHINES JOINS HANDS WITH RAFA
Page 26 and 27: Indian Reference of RafakoSA - Pola
Page 28 and 29: DECEMBER-2011/26
Page 32 and 33: Plant Upgrades Reference ListPlant
Page 34 and 35: TRI-FLO ® :-THE NEW GENERATION MUL
Page 36 and 37: The ability of the Tri-Flo ® to be
Page 38 and 39: Rejects re-cleaning with a 700 mm I
Page 40 and 41: GREEN FIELD STEEL PROJECT OF JSPLJS
Page 42: DECEMBER-2011/40

December 2011 - SIMA

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