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PRESENTED BY CHRISTOPHER RAVENSCROFT MIDREX TECHNOLOGIES, INC. 2017 SEAISI CONFERENCE & EXHIBITION 22 MAY 2017 - 25 MAY 2017 RESORTS WORLD SENTOSA SINGAPORE Status of Direct Reduction Ironmaking: New Trends, Technologies, and Applications for Steelmakers © 2017 Midrex Technologies, Inc. All rights reserved.

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Page 1: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

P R E S E N T E D B Y

C H R I S T O P H E R R AV E N S C R O F T

M I D R E X T E C H N O L O G I E S , I N C .

2 0 1 7 S E A I S I C O N F E R E N C E & E X H I B I T I O N2 2 M A Y 2 0 1 7 - 2 5 M A Y 2 0 1 7

R E S O R T S W O R L D S E N T O S A S I N G A P O R E

Status of Direct Reduction Ironmaking:New Trends, Technologies, and Applications for

Steelmakers

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 2: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

2

• Process gas experience allows for use of: natural gas, syngas from coal, pet coke, refinery bottoms, coke oven gas (COG) and off gases from technologies such as COREX®

and FINEX®

• MIDREX® is the only DRI process that provides the ability to simultaneously produce any combination of product types

• Low fines produced (crucial to CDRI & HBI yield)

• Provides maximum flexibility

MIDREX® Process

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 3: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

Kobe Steel as a DR technology leader

Since its founding in 1905, Kobe Steel, Ltd. (KSL) has pursued “monozukuri” — a Japanese approach to quality manufacturing — across a broad range of fields, supplying outstanding products and technologies that contribute to the advancement of industry and the promotion of a prosperous society

Kobe Steel, LTD (KSL) is the owner and Licensor of the MIDREX® Direct Reduction Process - the world’s most reliable and productive Direct Reduction Technology

Technology innovation is Fundamental to Success and KSL’s continuous R&D has kept the MIDREX® Technology number 1.

Plants using the MIDREX Process are the world’s largest, most flexible and longest running Direct Reduction (DR) plants.

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 4: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

DRI Products

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 5: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

DRI Production & Usage

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 6: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

2016 WORLD DRI PRODUCTION

6 © 2017 Midrex Technologies, Inc. All rights reserved.

Page 7: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

2016 World DRI Production – 72.76 mt

© 2017 Midrex Technologies, Inc. All rights reserved.

0

10

20

30

40

50

60

70

80

HDRI

HBI

CDRI

Page 8: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

2016 World DRI Production – 72.76 mtProduction by Region

© 2017 Midrex Technologies, Inc. All rights reserved.

34.19

19.18

9.19

5.73.2

0.7 0.6

MiddleEast/North

Africa

Asia/Oceania LatinAmerica

CIS/EasternEurope

NorthAmerica

Sub-SaharanAfrica

WesternEurope

mil

lio

n t

on

s p

er

ye

ar

2016 World DRI Production by Region (Mt)

Page 9: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

2016 World DRI Production by Process

MIDREX®64.8%

HYL/Energiron17.4%

Other Gas0.3% Coal-based

17.5%

2016 World DRI Production by Process

MIDREX®

HYL/Energiron

Other Gas

Coal-based

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 10: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

© 2017 Midrex Technologies, Inc. All rights reserved.10

EAF Steelmaking -HDRI

Page 11: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

More Merchant HBI…

© 2016 Midrex Technologies, Inc. All rights reserved. © 2017 Midrex Technologies, Inc. All rights reserved.

Page 12: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

voestalpine Texas, LLC -2.0 MTPY Merchant HBI

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 13: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

LGOK III – 1.8 MTPY Merchant HBI

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 14: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

© 2016 Midrex Technologies, Inc. All rights reserved.

14

voestalpine Texas -World’s Largest HBI Plant Built

for the Blast Furnace

Overview

• Capacity: 2,000,000 tons/year

• Location: Corpus Christi, Texas

• Product: HBI

• Start-up: 2016

Driving Forces

• 1 million tons of HBI will be shipped to

voestalpine’s integrated mills

• Increase blast furnace productivity in

the Linz and Donawitz (Austria)

• Decrease specific CO2 emissions

• Provide additional HBI for merchant market

• Leverage low cost NG in USA

Page 15: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

HBI is expected to see significant growth for use in Blast Furnaces increases productivity

decreases fuel consumption per ton

of hot metal (less coke)

decreases the overall CO2 footprint

HBI can also be used instead of

purchased scrap as a coolant in

the BOF

BF/BOF Steel

Page 16: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

Coal Gas/Shaft Furnace Production

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 17: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

MIDREX® Plant Capacities

Scale up factor 1.17

1.8 MPTY 2.5 MPTY

Scale up factor 1.09

1.0 MPTY

5.15 m

2 modules under construction

2.0 MPTY

19 modules

5.56 m 6.65 m 7.65 m7.15 m

4 modules 28 modules21 modules

Page 17

Scale up factor 1.08

Scale up factor 1.10

Page 18: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

Algerian Qatari Steel

2.5 MTPY MIDREX®

HDRI/CDRI Plant

• Midrex and Paul Wurth awarded project

for HDRI/CDRI combination facility in

2016

• AQS is a joint venture between Sider Co.

and National Investment Fund (51%) and

Qatar Steel International (49%)

• Located in Bellara Algeria, 375 km east of

Algiers

• The MIDREX® Plant will be part of the

overall steel complex that will produce 2.0

million tonnes of re-bar and wire rod

finished products

Page 19: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

Tosyali Algeria

2.5 MTPY HDRI/CDRI Plant

located in Bethioua (Oran), Algeria

HDRI will be fed via an Aumund hot transport conveyor to a new EAF meltshop located adjacent to the MIDREX® DRI Plant allowing for greater EAF productivity and energy savings

CDRI can also be produced for additional onsite use.

Page 20: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

DRI production and capacity will continue its growth as the product evolves its role in Global Steelmaking

EAF & BF Steelmaking are fueling growth

Realization of Technologies; increase in shaft furnace adoption

Innovations need to serve the industry; provide options and operational flexibility to steelmakers

Final thoughts

© 2017 Midrex Technologies, Inc. All rights reserved.

Page 21: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

THANK YOU

© 2017 Midrex Technologies, Inc. All rights reserved.

Designed for Today,Engineered for Tomorrow™

Visit www.midrex.com for more technical presentations and the 2016 World Direct Reduction

Statistics Booklet

Page 22: Status of Direct Reduction Ironmaking - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session7B Paper1.pdf · 2 • Process gas experience allows for use of: natural gas,

© 2014 Midrex Technologies, Inc. All rights reserved.

The Biggest driver for DRI demand is the growth of global EAF steelmaking.

DRI use offers consistent and predictable EAF operations