Shaft Furnace Direct Reduction Technology - Midrex and Energiron

2013 ◽  
Vol 805-806 ◽  
pp. 654-659 ◽  
Author(s):  
Xin Jiang ◽  
Lin Wang ◽  
Feng Man Shen
Keyword(s):  
Natural Gas ◽  
Heat Recovery ◽  
Shaft Furnace ◽  
Direct Reduction ◽  
Waste Recycling ◽  
Iron And Steel Industry ◽  
Iron And Steel ◽  
Direct Reduced Iron ◽  
Worldwide Production ◽  
Reforming Gas

Coke constitutes the major portion of ironmaking cost and its production causes the severe environmental concerns. So lower energy consumption, lower CO2 emission and waste recycling are driving the iron and steel industry to develop alternative, or coke-free, ironmaking process. Midrex and HYL Energiron are the leading technologies in shaft furnace direct reduction, and they account for about 76% of worldwide production. They are the most competitive ways to obtain high quality direct reduced iron (DRI) for steelmaking. Therefore, in the present paper, some detailed information about these two processes are given. Much attention has been paid on process scheme, the feedstock, DRI product, heat recovery, reforming gas, hot discharge and transportation, and by-product emission. Its very important for direct reduction development in both natural gas-rich counties and natural gas-poor counties.

scholarly journals Evaluation of biomass-based production of below zero emission reducing gas for the iron and steel industry

2020 ◽  
Author(s):  
Martin Hammerschmid ◽  
Stefan Müller ◽  
Josef Fuchs ◽  
Hermann Hofbauer
Keyword(s):  
Natural Gas ◽  
Direct Reduction ◽  
Economic Assessment ◽  
Air Separation ◽  
Production Costs ◽  
Test Plant ◽  
Separation Unit ◽  
Iron And Steel ◽  
Reducing Gas ◽  
Zero Emission

Abstract The present paper focuses on the production of a below zero emission reducing gas for use in raw iron production. The biomass-based concept of sorption-enhanced reforming combined with oxyfuel combustion constitutes an additional opportunity for selective separation of CO2. First experimental results from the test plant at TU Wien (100 kW) have been implemented. Based on these results, it could be demonstrated that the biomass-based product gas fulfills all requirements for the use in direct reduction plants and a concept for the commercial-scale use was developed. Additionally, the profitability of the below zero emission reducing gas concept within a techno-economic assessment is investigated. The results of the techno-economic assessment show that the production of biomass-based reducing gas can compete with the conventional natural gas route, if the required oxygen is delivered by an existing air separation unit and the utilization of the separated CO2 is possible. The production costs of the biomass-based reducing gas are in the range of natural gas-based reducing gas and twice as high as the production of fossil coke in a coke oven plant. The CO2 footprint of a direct reduction plant fed with biomass-based reducing gas is more than 80% lower compared with the conventional blast furnace route and could be even more if carbon capture and utilization is applied. Therefore, the biomass-based production of reducing gas could definitely make a reasonable contribution to a reduction of fossil CO2 emissions within the iron and steel sector in Austria.

Natural Gas Energy Consumption Strategy by Iron and Steel Industry Enterprises

2020 ◽  
Vol 9 (3) ◽  
pp. 59-64
Author(s):  
V. Koksharov ◽  
I. Kirshina
Keyword(s):  
Energy Consumption ◽  
Natural Gas ◽  
Steel Industry ◽  
Energy Resource ◽  
Iron And Steel Industry ◽  
Conceptual Approach ◽  
Iron And Steel ◽  
Key Factor ◽  
Gas Consumption ◽  
Natural Gas Consumption

The existing modern conceptual approaches to the formation of an assessment of the natural gas consumption strategy in the steel industry do not allow assessing comprehensively all the processes that occur in the enterprise affecting the efficiency of natural gas consumption. Due to the fact that natural gas acts an important role as a universal energy resource, both in the economy and in international politics, the modern strategy for assessing the consumption of natural gas in the steel industry is becoming a key factor in increasing competitiveness and guaranteeing sustainable economic growth of the country's steel industry. The article proposes a conceptual approach to the development of the model in order to assess the strategy of natural gas consumption at iron and steel enterprises, which allows timely management decisions to be taken to increase the organization of efficient energy consumption at the enterprise. Based on the proposed conceptual approach to assessing the strategy of natural gas consumption at the iron and steel industry, it can be stated that this assessment is interconnected with the assessment of the integral criterion for the implementation of the goals of organizing effective energy management.

Study on the Reduction of Oolitic Hematite Ores in N2-CO Atmosphere

2014 ◽  
Vol 968 ◽  
pp. 198-201
Author(s):  
Guang Long Jin ◽  
Jin Zhu Zhang ◽  
Ben Jun Xu ◽  
Song Yang
Keyword(s):  
Carbon Monoxide ◽  
Steel Industry ◽  
Iron Ore ◽  
Direct Reduction ◽  
Iron And Steel Industry ◽  
Iron And Steel ◽  
Reduction Time ◽  
Potential Source ◽  
Maximum Value ◽  
Metallization Rate

The oolitic hematite will be a potential source of raw iron ore for the Chinese iron and steel industry. Up to now, the oolitic hematite have hardly been utilized effectively by any single traditional technology. The direct reduction may be a practical technology for the exploitation of oolitic hematite. The results show that the metallization rate of the HeZhang oolitic hematite increases with both the partial pressure of CO increase and the reduction time lasted, and the maximum value of the metallization rate is obtained at 35% carbon monoxide in the N2-CO atmosphere and 4h reduction time at 1050°C with 10% calcium oxide in the oolitic hematite. The diffusion may be the primary factor controlled the metallization rate in the later stage of reduction.

scholarly journals Highly efficient CO2capture with simultaneous iron and CaO recycling for the iron and steel industry

2016 ◽  
Vol 18 (14) ◽  
pp. 4022-4031 ◽  
Author(s):  
Sicong Tian ◽  
Jianguo Jiang ◽  
Feng Yan ◽  
Kaimin Li ◽  
Xuejing Chen ◽  
...  
Keyword(s):  
Steel Industry ◽  
Steel Slag ◽  
Steel Production ◽  
Waste Recycling ◽  
Iron And Steel Industry ◽  
Capture Process ◽  
Iron And Steel ◽  
Highly Efficient ◽  
Calcium Looping ◽  
Iron And Steel Production

A highly efficient CO2capture process integrating calcium looping and waste recycling into iron and steel production is proposed, which can also valorize the waste steel slagviaa simultaneous iron and CaO recycling.

scholarly journals Review on the Use of Alternative Carbon Sources in EAF Steelmaking

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 222
Author(s):  
Thomas Echterhof
Keyword(s):  
Steel Industry ◽  
State Of The Art ◽  
Carbon Sources ◽  
Melting Process ◽  
Iron And Steel Industry ◽  
Iron And Steel ◽  
Direct Reduced Iron ◽  
Current State ◽  
Carbon Neutral ◽  
Reduction Of Co2

Steelmaking in the electric arc furnace (EAF), either scrap-based or based on hydrogen direct reduced iron, will in future contribute substantially to the reduction of CO2 emissions in the iron and steel industry. However, there still will be the need to introduce carbon into the EAF process either to carburize the steel or to create foaming slag to improve the energy efficiency of the melting process. So, to reach the emission reduction goals set around the world, it will be necessary to substitute fossil charge and injection carbon used in EAF steelmaking with alternative carbon sources. This review presents the recent research on carbon-neutral biomass-based and circular rubber or plastics-based carbon sources and their potential to substitute fossil charge or injection carbon in the EAF process. It also discusses the current state-of-the art and suggests further opportunities and needs for research and development to use alternative carbon sources to produce a really green and carbon neutral and/or fully circular steel.

scholarly journals Adaptation of the Rist Operating Diagram as a Graphical Tool for the Direct Reduction Shaft

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 1953
Author(s):  
Thibault Quatravaux ◽  
Jose Barros ◽  
Pascal Gardin ◽  
Gabriel Lucena
Keyword(s):  
Blast Furnace ◽  
Shaft Furnace ◽  
Direct Reduction ◽  
Industrial Process ◽  
Sensitivity Study ◽  
Direct Reduced Iron ◽  
Graphical Tool ◽  
The Impact ◽  
Minimum Quality

The blast-furnace operating diagram proposed by Rist was revised to direct reduction and was specifically applied to the Midrex NGTM process. The use of this graphical tool in the study of an industrial process highlighted the staggered nature of the reduction in the shaft furnace with, in particular, the existence of a prereduction zone in the upper part where metallization is thermodynamically impossible. A sensitivity study also showed the impact of the in situ reforming rate on the ability of the gas to completely reduce iron oxides. Finally, we graphically defined the minimum quality required for the top gas to produce direct-reduced iron.

Experimental and numerical study of the rib effect in a gas-gas heat exchanger performance used in a sponge iron production plant (MIDREX)

2021 ◽  
pp. 095765092110079
Author(s):  
AM Hosseini ◽  
A Faghih Khorasani
Keyword(s):  
Carbon Dioxide ◽  
Heat Exchanger ◽  
Heat Recovery ◽  
Numerical Study ◽  
Direct Reduction ◽  
Carbon Dioxide Production ◽  
Production Plant ◽  
Height Range ◽  
Iron And Steel ◽  
Steel Industries

Heat loss is a leading cause of heightened global temperatures and carbon dioxide. The energy crisis has raised concerns on addressing heat recovery, especially in iron and steel industries. Iron and steel industries are consuming roughly 10 to 15 percent of the world’s energy. Increasing the production of heat recovery can reduce carbon dioxide production, which in effect decreases the overall cost of production. This article evaluates heat recovery in a gas-gas heat exchanger of a sponge production using the direct reduction by gas method in the MIDREX process. In this research a numerical and experimental study on ribs placed on the chosen heat exchanger in the MIDREX process has been performed. Based on results obtained from the other study, a reasonable width and height range was selected for the ribs. The best performance evaluation criterion (PEC) based on the numerical results was obtained at the lowest width and highest height of the rib. The best value for PEC was found at 1.15.

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