Direct Reduction Technology: Danieli and Energiron A History of Success Supporting The Future Challenges

DANIELI AND ENERGIRON
DIRECT REDUCTION TECHNOLOGY

A HISTORY OF SUCCESS
SUPPORTING THE FUTURE CHALLENGES
2011
With the latest two
2.5-Mtpy DRI
module orders in force
(+3 awarded),
Energiron technology
confirms its leadership
in the ironmaking
industry. In the past
five years 12.75
Mtpy of new DRI
capacity added
with the Energiron
plants changed
the world scenario
EMIRATES STEEL INDUSTRIES:

THE PLANTS WITH THE HIGHEST PRODUCTIVITY RATE WORLDWIDE
Two Energiron DR plants enable today the Emirates

Steel Industry to produce more than 3 Mtpy of Hot DRI.
Starting from the completion of the Hot Commissioning,
the DRP has scored some remarkable achievements.
> 2009
Commissioning of the first ESI Energiron plant
successfully completed at the end of December
with a production higher in quality and quantity
than the guaranteed one and with the consumption
parameters well below the contractual limits.
> 2010
Several remarkable achievements collected by
the first Energiron plant in operation at ESI, including:
new world record for daily production with 5895 t/day
of Hot DRI (245.63 t/h) on February 1st;
new world record for monthly production with 134,951
tons (plant availability higher than 97%) in June.
> 2011
On May 24 the second Energiron DRP successfully
passed the 7 day Performance Test recording
an average metallization of 95.61% and an average
production exceeding 200 tonnes/h. Further 10-day
test proved the efficient integration of the Energiron
DRP with the meltshop: 41,000 tons of saleable billets
produced in 275 heats which is 10% above target.
Layout of a typical
Danieli Energiron
Direct Reduction plant.
1 Incoming oxide
storage area
2 Direct reduction plant
3 Iron oxide day bins
4 Product storage
open yard
5 Product storage
silos for cold charge
6 Water treatment plant
6
4
3
2
DANIELI AND ENERGIRON DR

TECHNOLOGY A HISTORY
OF SUCCESS SUPPORTING
THE FUTURE CHALLENGES
Danieli excellence in DRI technology
In the recent years, the increasing price of reducing

agents and the restrictions imposed by the
environmental regulations induced the steelmaking
industry to adopt alternative solutions.
The high performance parameters, both in terms
of efficiency and productivity, reached with the
Energiron direct reduction technology set a
new benchmark for the ironmaking industry.
Focusing on the DRP market, the world scenario
shows a strong change when this innovative
technology has been created merging Tenova HYL
& Danieli technologies (2005).
> High DRI quality with different raw

materials (iron ore pellet, lump ore,
BF pellet, or mix)
> High degree of metallization and control

of carbon content, according to
requirement of the final use of DRI
> Maximum process flexibility -with

or without external reformer- and maximum
production flexibility, from 0.2 to 2.5 Mtpy
of cold or hot DRI
> Optimized energy consumptions
> Improved environmental parameters
(Selective elimination of CO2, Removal
of sulphur from gaseous emissions,
Low NOx emissions, Zero make-up water
requirements)
Effect of the Energiron alliance

and the worldwide commercial network of Danieli.
(based on tpy of installed capacity)
> Advanced automation systems

> High ramp-up performances (97%
of the monthly operating time reached
in less than 1 month; 92% of the nominal
plant production reached in less than
5 months)
DRP built from

1957 to 2005
before HYL-Danieli
alliance.
HYL
Others
New Energiron
DRP installed
and/or under
construction since
2006, after
Danieli-Tenova HYL
alliance.
Others
ENERGIRON
Customer
Location
Emirates Steel Industry I
UAE
Mtpy
1.6
Gulf Sponge Iron
UAE
0.2
Emirates Steel Industry II
UAE
1.6
Suez Steel
Egypt
1.95
Ezz Rolling Mills
Egypt
1.9
(*)
Far East
0.5
Nucor Steel
USA
2.5
Jindal Steel & Power
India
2.5
Total new projects capacity
12.75
DANIELI
AUTOMATION
INNOVATIVE
DIRECT
REDUCTION
PLANT PROCESS
CONTROL SYSTEM
The control system
architecture includes a Level 1
for equipment and system
control and a new Level 2
designed not only
for process supervision,
data traking and reports
generation but also
for optimization of the process.
New functionalities installed
in the Level 2 include
a Process Reconstruction
Model that uses
instrumentation signal coming
from the PLC and physical
equations in order
to provide a full description
of the plant status.
HOT DRI CHARGE INTO THE EAF
E (kWh/tLS)
When DRI with a temperature of 600 C is melted in the EAF,

the savings in electric energy are up to 141 kWh/tLS with
an increase in productivity of up to 22% for a practice of 90%
hot-10% cold DRI.
700
600
500
400
300
200
100
0
100
200
300
400
DRI temperature (C)
500
600
EZZ Rolling Mills

Plant capacity: 1.9 Mtpy
ENERGIRON technology
with an external reformer
for production of cold DRI
DANIELI AND ENERGIRON / PROJECTS UNDER CONTRUCTION,

TARGETING OVER 2.5 MTPY IN A SINGLE REACTOR
Suez Steel Co.

Plant capacity: 1.95 Mtpy
World biggest DR plant
in a single module
ENERGIRON technology
without external reformer
for production of hot and cold
DRI, equipped with pneumatic
transport for hot DRI
DANIELI CONSTRUCTION
HIGH CONSTRUCTION
AND ERECTION CAPABILITY
Danieli Construction International operates worldwide covering full services
from soil improvement, civil works, material and equipment handling,
electromechanical installations, piping prefabrication, HVAC. The company
operates synergically with Danieli Group technology divisions involved
in the project, with the aimof providing total customer satisfaction with quality
and on-time performances.
DANIELI
YEAR 2011

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DANIELI AND ENERGIRON

DIRECT REDUCTION TECHNOLOGY

EMIRATES STEEL INDUSTRIES:

Two Energiron DR plants enable today the Emirates

DANIELI AND ENERGIRON DR

Danieli excellence in DRI technology

In the recent years, the increasing price of reducing

> High DRI quality with different raw

> High degree of metallization and control

> Maximum process flexibility -with

Effect of the Energiron alliance

> Advanced automation systems

DRP built from

Emirates Steel Industry I

Gulf Sponge Iron

Emirates Steel Industry II

Ezz Rolling Mills

Jindal Steel & Power

Total new projects capacity

HOT DRI CHARGE INTO THE EAF

When DRI with a temperature of 600 C is melted in the EAF,

DRI temperature (C)

EZZ Rolling Mills

DANIELI AND ENERGIRON / PROJECTS UNDER CONTRUCTION,

Suez Steel Co.

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