THE SMART CHOICE

4 Energiron at a glance

10 Pioneering achievements since 1957

12 Energiron products

14 Energiron plants

18 Plant & process economics

20 Energiron process

24 HYL HYTEMP® system

26 Energiron and steelmaking plant integration

30 Advanced automation systems

32 Energiron and the environment

36 Global project execution

38 Quality manufacturing

40 Construction capability

44 Customer training and assistance

46 Most recent projects

2
Energiron is as strong
as the name suggests
and the unique product
of this technology
is more than just
Direct Reduced Iron
it’s Energy combined
with Iron for the
lowest cost and highest
quality steelmaking
applications.
Competitive CAPEX and OPEX solutions from Energiron:

_ Integration with _ Integration with _ Safe-to-transport

EAF thanks to DRI BF shops for high carbon DRI
hot charge via reduced carbon from stand alone
HYTEMP® system footprint or plant
increased liquid
steel production

3
Energiron at a glance

Energiron is the result Since its establishment in February a premium raw material for competitive
2006, the Energiron alliance has and quality clean steel production.
of a strategic alliance brought to the market the most
between Tenova HYL and revolutionary technology which strongly Steel production cost is a combination
Danieli to competitively contributed to change the DRI world of raw material, energy and labor cost.
serve the DR plant market. scenario, as confirmed by the several There are areas where DRI production
Energiron DRP assigned. is naturally more convenient due to the
Under the alliance, availability of energy and iron ore at low
the two companies have The largest capacity DR plants in the prices. Energiron plant configurations
combined their know-how world are now Energiron Zero-Reformer can be designed to be competitive
plants: Suez Steel in Egypt (2.0 Mtpy) even in those areas where Natural Gas
and technology for the and Nucor, USA (2.5 Mtpy). Moreover, is not economically available, by using
design and construction since 2009 Emirates Steel in Abu Dhabi other sources of reducing gas, such as
of gas-based DR plants, has been operating the two most Coke Oven Gas (COG), Coal
offered worldwide under efficient hot DRI Energiron units, each of Gasification Gas (SYNGAS) and others.
which will reach a capacity of 2.0 Mtpy.
the Energiron trademark. Energiron DRI is a highly metallized
As a consequence, after six years of product with controllable carbon
successful collaboration, Danieli and content in the range of 1.5 to 4.0%
Tenova HYL reconfirmed their exclusive which generates chemical energy in
alliance for an additional 10 years. the EAF melting process.
With this background and these long
term prospectives, Danieli and Tenova In DRI-based integrated minimills the
HYL will continue to offer their use of the HYL HYTEMP® system
combined experience to support the allows the delivery of hot DRI directly
competitiveness of the steel producers to the EAF, thus further reducing electric
and to enhance raw material quality energy consumption and tap-to-tap time.
and availability.
The uniquely stable characteristic of
EAF steelmaking continues to grow in Energiron DRI, makes it a product which
the production of higher quality steels, can be safely and easily transported
including specialty steel products. without briquetting, following standard
Energiron responds to the need for IMO guidelines.

4
Proven layout and process integration
for DRI production and electric steelmaking
(DRI-based minimill concept).
Emirates Steel minimills #1 and #2.

5
What makes _No raw materials limitation
Energiron _Best Carbon-Iron units mix
unique: _Lowest OpEx in EAF melting

High process flexibility with proven technology

Energiron is the unique direct reduction technology that, with the same
process scheme configuration, lets you choose the best energy source -
natural gas, reformed gas, Syngas from a coal gasifier or even Coke Oven
Gas without any modification.

High product flexibility

Controlled carbon content -0.8 to 4%- for best EAF steelmaking
performances, comparable to hot metal practice.
HYTEMP® system for hot DRI charge into the EAF, providing additional
energy savings.
Easy to transport passivated cold DRI due to high iron carbide (Fe3C)
content; no need to briquette.x

High project flexibility

To bring it all together, Energiron offers the flexibility of providing anything
from the basic technology package to local equipment supply and erection
up to full turnkey projects. Energiron team support runs from process
technology through operations and maintenance training and technical
assistance, not only in the DR plant but in the steel mill as well. Further,
Danieli and Tenova can provide complete steel mill projects covering
materials handling, direct reduction, EAF meltshop, casting and rolling
and product finishing lines.

6
Sustainable production thanks to the lowest
carbon footprint
Energiron plants are ecologically friendly and meet the most stringent
environmental regulations; because of the unique features of this
technology, it is the lowest carbon footprint of any ironmaking technology,
with the further advantage that selectively removed CO2 can be sold.
Significant achievements have also been reached in the reduction of the
air pollutants like NOx and SOx. Additionally the water by-product of the
reduction reaction, easily condensated and removed from the gas stream,
can be used as cooling water in a zero-water consumption circuit.

The widest range of plant capacities

Energiron plants are available in different modular sizes to meet
the needs of the typical steel mill – either with the Micro-Module (200,000
tpy), or any sized plant up to 2.5 million tpy and larger.
No risk in technology change or scale-up will be present for any size.

Low maintenance and high plant avaibility

The possible elimination of the reformer and the use of standard
equipment of smaller size throughout the plant significantly reduces the
cost of maintenance. Further, Energiron plants are controlled by a highly
automated system providing Level 2 automation, requiring minimal human
intervention and providing high plant availability and reliability.

7
Emirates Steel, UAE. Energiron III (with external reformer) DR plants
for production of 2+2 Mtpy of hot discharged DRI (94% metallization
and 2.5% C). HYTEMP® system for directly feeding hot DRI to the EAF.

8
9
Pioneering achievements
since 1957

HYL experience in DR 1957 1993

Startup of the world’s first First Zero kWh direct reduction plant
technology dates back to commercially successful gas-based begins operation at Vikram Ispat HYL III
the fifties and since then direct reduction plant, Hylsa 1M, plant, India.
original continuous shaft using the HYL process.
reactor and zero reformer Production of flat products via the 1994
EAF, based on the use of DRI. HYL begins producing high carbon DRI
processes and the HYL with 3.0 to 5% carbon content.
HYTEMP® pneumatic 1958
trasportation system were Batch charging of DRI to the EAF at 600 °C. 1995
Production of ultra thin (< 1mm) hot
developed. 1965 rolled coils based on 100% DRI, with
Use of more than 30% DRI in an EAF HYL plant and Hylsa CSP minimill.
charge, eventually increasing in stages
2006 marked the up to 100% by 1972. 1997
establishment of the World’s first dual-discharge (DRI and
Energiron alliance: 1968 HBI) plant design put into operation,
Continuous feeding of DRI to the EAF. Vikram Ispat (now Welspun Maxsteel)
Tenova HYL and Danieli Computerize process control system HYL plant, India.
team up to promote put into use.
and develop the new
Energiron technology 1969
Use of foamy slag practices.
for direct reduction plants.
1970
Design of pellets for direct reduction.
First full scale testing and use of DRI
as a BF-BOF feed.

1972
Production of extra-deep drawing
steels in EAF using DRI.

1980
Start up of the HYL continuous
shaft reactor process in Monterrey.

1984
First HYL pilot operation of a direct
reduction plant without external gas
reformer.

1988
Use of coating of pellet/lump ores for
direct reduction.

1993
HYTEMP® pneumatic transportation
system and hot DRI feeding to the EAF.
10
 2003
Successful design of HYL ZR process
plants based on coal gasification and
COG.

2005
First coal gasification-based Energiron
DRI plant for Jindal Steel, India. This
2 Mtpy module is the largest plant of
this kind ever to be built in the world.

2006
First 1.6 Mtpy Energiron DR plant with
HYTEMP® system order from Emirates
Steel, UAE.

2006
First HYL Micro-Module plant built,
GSPI, Abu Dhabi, UAE.

2008
Second 1.6 Mtpy Energiron DR plant
with HYTEMP® system ordered by
Emirates Steel, UAE.

2009
1.9 Mtpy Energiron plant for production
of Cold DRI for Ezz Rolling Mill, Egypt.
1998
Startup of first commercial scale 2009
HYL Zero Reformer Process plant, First new generation 1.95 Mtpy Zero
Hylsa 4M, Monterrey. Hot and cold Reformer Energiron plant for production
DRI charging to the world’s largest of hot and cold DRI for Suez Steel, Egypt.
twin-cathode DC EAF.
2010
1999 The world biggest Energiron DR
HYL III Plant with water producing plant in a single module supplied
option starts up at Hadeed, KSA. for Nucor Steel with a 2.5 Mtpy
design capacity.
2000
First plant to use 100% lump ore 2013
charge successfully on a routine basis Excellent production ramp-up and
(Usiba HYL plant, Brazil). Vikram Ispat learning curve at Emirates Steel DR
becomes second in 2006. plant #2 leading to full productivity
during second year of operation.
2001
Successful economical design of Micro-
Module (200,000 tpy) plants based on
HYL ZR reformerless technology.
11
Energiron products

Energiron plants HYTEMP® Iron

COLD DRI
efficiently reduce Hot DRI is discharged continuously
any iron pellet or lump from the reactor at > 700 °C to a
into “energized” pneumatic transport system.
hot or cold The product is transported by means of
a carrier gas to surge bins located
Direct Reduced Iron above the meltshop for controlled
or Hot Briquetted Iron feeding to the electric arc furnace.
with controlled HYTEMP® iron, like cold DRI can be
metallization produced to high levels of metallization
and carbon, in order to satisfy meltshop
and carbon levels. requirements for greater economy and
efficiency. HOT DRI
The HYTEMP® system is the world’s
first proven technology for continuous
Our technology offers three product hot discharge, transport and feeding of
options from the same reduction quality DRI to the electric furnace shop.
process - DRI, HYTEMP® iron and HBI, It is completely proven and reliable, with
each of which can be produced to absolutely no downtime since its first
different metallization and carbon levels. implementation in 1998.

DRI Direct Reduced Iron HBI Hot Briquetted Iron

DRI is reduced iron pellet and/or lump, Reduced pellet or lump is discharged
at temperatures > 700 °C into hot BRIQUETTED IRON
which is cooled and discharged at low
(ambient) temperatures. The process briquetting presses located below the
characteristics allow for independent reactor discharge area. Briquettes are
control of the DRI metallization and compressed, cut and cooled to make
carbon levels. Metallization can be HBI, typically for merchant sale over
adjusted at will, typically around 94% long distances. As with DRI, HBI is
and higher. produced in controlled metallization
_ DRI carbon levels can be selected in ranges around 94% and higher. HBI
the range of 1.5 - 4.0%, most of which can be easily charged to an EAF as part
is in the form of iron carbide. of a standard scrap bucket charge to
_ The high iron carbide content reduce scrap residual levels. It is
provides the unique stability additionally an excellent charge in
characteristic of this product. Energiron integrated mills as a coolant to the
DRI is safe to transport and store under basic oxygen furnace.
normal established procedures. Carbon for HBI is typically 1.5%, higher
than other HBI products that often have
less than 1% carbon. Work is underway
to develop HBI at even higher carbon
levels.

12
Unique to Energiron DRI which inhibits the re-oxidation of ZR Process scheme. Since stability
metallic iron in contact with air. For a itself is not measured but rather
High carbon DRI - iron carbide carbon content of 4%, approximately reactivity of the product in three distinct
A unique benefit of the ZR process is 95% is present as Fe3C. In general, environments, tests were conducted in
the DRI that it produces. As compared every 1% of combined carbon the presence of air, air plus water and
with DRI from other processes, his corresponds to 13.5% of Fe3C. air plus salt water to determine which
product typically has a metallization of Therefore, a DRI with 4% Carbon type of DRI is more stable. The test
95% and a carbon content controlled in contains more than 50% of Fe3C. results indicate that reactivity to air,
a range between 1.5 to 4% in the form The high percentage of Fe3C in the DRI water and salt water is significantly less
of combined carbon. This type of makes the product very stable. over time for DRI containing high
product yields significant benefits in the percentages of carbon as iron carbide.
electric furnace that no other process to DRI stability Currently, all or most direct reduction
date has been able to achieve. Extensive tests were conducted to technologies carry out reduction
Carbon in the DRI, mostly as iron determine whether the combined reactions at very high temperatures –
carbide (Fe3C) is derived mainly from carbon in DRI was a factor in improving from 920 to 980 °C. The high reduction
methane (CH4) and to a lesser extent product stability over that of temperature is one of the factors
from CO. The level of carbon is conventional DRI, whether produced by determining the DRI stability.
adjusted by controlling the reducing gas Energiron plants or other process Nevertheless a more significant factor
composition and/or oxygen injection. technologies. In general, High-Carbon is the carbon content of DRI. DRI,
DRI produced with the ZR scheme is DRI is more stable than conventional which has high levels of carbon in the
characterized by higher stability than DRI. This has been proven in specific form of iron carbide or cementite, forms
DRI typically obtained in other DR tests that were performed for DRI being a quality of DRI pellet which, while still
process schemes. The reason for this is produced at the Ternium 3M5 plant, requiring proper handling procedures,
the high cementite or Fe3C content, before and after its conversion to the is much safer than ever before.

13
Energiron plants

Custom modules from

0.2 to 2.5 (3.0) Mtpy.
Compact plants
for several millions tpy
capacity, using different
gas sources.
No scale-up risk
for different plant sizes.

Micro-module Mini-module Custom modules Next challenge

0.2 Mtpy 0.5 Mtpy 0.5 Mtpy / 2.5 Mtpy 3.0 Mtpy

Energiron plants are designed for Mini-module

maximum savings in both investment This is the optimum sized DR plant for
and operating costs. Multiple reduction the typical steel mill producing quality
reactors can share a common reducing products. It’s a 500,000 tpy DR plant
gas source. Auxiliary systems and with the reliability and quality for which
materials handling equipment can be HYL is renowned.
common to several modules. With the A totally re-engineered DR module,
ZR process configuration, further designed with the latest technology
economies are obtained based on the such as reformerless (ZR) reduction and
smaller overall plant size and equipment production of High Carbide Iron.
requirement. The Mini-Module takes advantage of
modular design for a construction
Micro-module schedule that means shorter project
This basic plant design concept was implementation and a faster startup.
developed specifically for markets
where small volumes of DRI are Custom modules
needed, and where coal-based Energiron plants can be designed to
technologies have until now been the incorporate a variety of technologies,
only option. The highly functional, no- depending on the particular needs of a
frills version of the traditional plant client or project. Plant capacities can
provides the highest quality DRI range anywhere up to 2.5 Mtpy in a
available to companies requiring annual single reactor, to multiple reactor plants
capacities in the range of 200,000 tpy. of several million tons per year capacity.

14
15
Suez Steel, Egypt. Energiron ZR (without external reformer)
DR plant for production of 1.95 Mtpy of hot and cold
discharged DRI (94% metallization and 3.5% C).
HYTEMP® system for directly feeding hot DRI to the EAF.

16
17
Plant and process
economics

The overall smaller size

of the equipment
and land required, along
with the possibility to use
any gas and iron quality,
optimum yield and
minimum maintenance
lead to the lowest market
capital and operational
expenses.

Both capital and operating expenses

for Energiron plants are extremely low.
For equivalent production capacity, a
ZR plant requires barely half the land
area needed for other processes.
And because the process is
pressurized, overall equipment sizes
are smaller, for even greater savings.

Operating expenses are low as well,

given the flexibility to use lower-cost
ores, the inherent low gas and power
requirements, and the best ore to-
product yield of any DR process (1.38 t
screened). These savings in energy of using low grade iron ore feedstocks, the use of friable lump ores can be
requirements and also raw material an advantage in places such as China maximized. Maintenance costs are
consumption amount to a significant or India where huge amounts of iron ore also minimal.
advantage for the Energiron technology are available, but with high percentages
of more than US$ 10 per ton in lower of silica and alumina. Low maintenace costs
operating expenses. For a million ton There is no practical limitation regarding The HYTEMP® system has virtually no
per year plant, that means US$ 10 the chemical composition of the iron maintenance at all, unlike mechanical
million savings every year. ore. In particular since gas is not systems with lower availability.
The composition, final quality and cost recycled back to a reformer, the
of any DRI is dependent on the quality process is very flexible for using high By-product income
of the iron ores used for reduction. sulfur iron ores. Energiron is the only technology that
offers an additional revenue source
Energiron plants offer the flexibility to Moreover, due to the lower gas beyond the DRI product. CO2 capture
operate with a wide variety of oxide velocities through the reactor, the use and sale to off-takers is a lucrative
pellets, lump ores or mixtures of both. of hydrogen-rich gases and the business, providing millions of dollars in
This flexibility includes the possibility mechanical system sealing devices, annual income to the DR plant operator.

18
Typical consumption figures

Item Remark
Plant capacity (Mtpy) 0.2 - 2.5 world’s smallest and largest capacities
Metallization (%) ≥ 93 adjustable to suit meltshop needs
Carbon (controlled) (%) 1.5 - 4 depending on extent of “in-situ” reforming

Inputs Specific consumption

Iron ore (t/t) 1.38 - 1.40 depending on DRI carbon
Natural gas (Gcal/t) 2.24 - 2.60 depending on DRI carbon and temperature,
extent of in-situ reforming and power co-generation
Electricity (kWh/t) 0 - 85 depending on power co-generation
Water m3/t) 0 - 1.3 depending on the water recovery system
Labor (m-h/t) 0.11 - 0.17 depending on plant size
Maintenance (US$/t) 3.0 - 3.3 for cold-hot DRI

Technological characteristics

Others ENERGIRON ZR ENERGIRON ZR advantages

CapEx Large plant area, No reformer Less land required,
includes integrated reformer more efficient plant design
Non-pressurized system Pressurized system Smaller size equipment

OpEx Requires top-grade DR pellet feed Can use any pellet, lump or mix, Lowest possible iron metallics cost
even high sulfur per ton of product

Higher fines loss to process off-gas Lower velocity, lower fines loss Higher yield per ton of ore
Custom reformer catalyst No reformer, no catalyst No maintenance cost
for replacing damaged catalyst
CO2 not recovered, fully released CO2 can be selectively captured Lucrative additional revenue source
to atmosphere and sold to off-takers

19
Energiron process

Energiron is the unique the Energiron process scheme and of A remarkable advantage of this process
direct reduction high importance environmentally is the scheme is the wider flexibility for DRI
selective elimination of both by- carburization, which allows attaining
technology that, products generated from the reduction carbon levels up to 5%. This is due to
with the same process process; water (H2O) and carbon the improved carburizing potential of
scheme configuration, dioxide (CO2), which are eliminated the gases inside the shaft, which allow
lets you choose through top gas scrubbing and CO2 for the production primarily of iron
removal systems, respectively. carbide.
the best energy source:
natural gas, reformed gas, Direct use of natural gas Reformed gas, Syngas, COG
syngas from a coal gasifier The Energiron ZR process is a major Energiron plants can also use the
step in decreasing the size and conventional steam-natural gas
or even coke oven gas, improving the efficiency of direct reforming equipment, which has long
without any modification. reduction plants. Reducing gases are characterized the process. Other
generated in-situ in the reduction shaft, reducing agents such as hydrogen,
by feeding natural gas as make-up to gases from coal, pet coke and similar
General process scheme the reducing gas circuit. fossil fuels gasifications, and coke oven
The Energiron Direct Reduction Process gas, among others, are also potential
is designed to convert iron pellet/lump Since the reducing gases are generated sources of reducing gas, depending on
into metallic iron by the use of reducing in the reduction section, optimum the particular situation and availability.
gases in a solid-gas moving bed shaft reduction efficiency is attained, and
furnace. Oxygen is removed from the thus an external reducing gas reformer This flexibility is made possible precisely
iron ore by chemical reactions based on is not required. Therefore, the overall because the Energiron ZR Process is
hydrogen (H2) and carbon monoxide energy efficiency of the ZR process is independent of the reducing gas
(CO), for the production of highly over 80%, optimized by the in-situ source, with no requirement to
metallized DRI. The technology offers reforming inside the shaft furnace, since recirculate gases back to a reformer to
the flexibility to produce three different the product takes most of the energy complete the process chemistry loop.
product forms, depending on the supplied to the process, with minimum Several projects are currently under
specific requirements of each user. energy losses to the environment. development that will use coke oven
gas as the reducing gas source, and
Reducing gases can be generated: The impact on plant size of eliminating projects using gas from coal gasification
- directly, by in-situ reforming of natural the external gas reformer is significant. technology are also underway.
gas inside the shaft furnace, For example, a plant of 1-Mtpy capacity
- in an external natural gas/steam requires only 60% of the area needed Reduction
reformer, by other process plants for the same Inside the shaft furnace vessel, hot
- from gasification of fossil fuels, capacity. For additional capacity, the reducing gas is fed to the reduction
biomass, etc., as Syngas area required is proportionally smaller in zone and flows upward counter-current
- from Coke Oven Gas (COG) sources. comparison. This also facilitates to the iron ore moving bed.
locating the DR plant adjacent to the The gas distribution is uniform and
In all the above cases, the process meltshop in existing operations. This there is a high degree of direct contact
configuration corresponds to the same plant configuration has been operated between gas and solids.
basic proven Zero Reformer (ZR) successfully since 1998 with the The exhaust reducing gas (top gas)
scheme, adjusting the relative sizes of Ternium DR 4M plant, and also was leaves the reactor at about 400 °C and
equipment for the particular application. incorporated in 2001 to the 3M5 plant, passes through the top gas heat
For both the in-situ and steam both at the Ternium steel facility in recuperator, where its energy is
reforming schemes, natural gas analysis Monterrey, Mexico. The Energiron ZR recovered to produce steam, or
(heavy hydrocarbons content) is not a plants in Egypt and in the USA are a alternatively to preheat the reducing gas
limiting factor. further reference for this innovative stream, and then through the
One of the inherent characteristics of technology. quenching/ scrubbing system.
20
Standard ENERGIRON H2O Top gas heat
process flowsheet. removal recuperator

Process Gas
Compressor Iron ore

Cooling
Fired
CO2 Heater
DR
removal reactor
system

NG
Syngas Humidifier
Reformed gas
COG O2
DRP Tail gas

Fuel
DRI

ENERGIRON DR plant Iron ore

flowsheet for integrated iron Coal
making plant.

Coke
Sinter plant Coke oven
plant COG

Lump
Pellets

DR
reactor
Blast Furnace

BFG
Power plant

PCI BOFG
DRI

to in-plant
HM users

HM BOF Steel plant Slab Caster

desulphurization with treatment plant

Coolant Recycle scrap

Imported
scrap scrap
21
22
In these units, water produced during operating cost low. Removal of oxygen cooling water. Scrubbed cooling gas
the reduction process is condensed from the iron ore is accomplished by passes through the cooling gas recycle
and removed from the gas stream and the action of the hot reducing gases compressor to be recycled to the
most of the dust carried with the gas is and then the product is carburized. A furnace, after being made-up with
also separated. Scrubbed gas is then rotary valve, located at the bottom of natural gas. Natural gas is injected as
passed through the process gas the vessel, regulates the continuous make-up to the cooling gas circuit for
recycle compressor, where its pressure gravity flow of the charge downward optimum efficiency and control of the
is increased. Compressed gas, after through the reduction furnace. DRI is cooling and carburization processes.
being sent to the carbon dioxide discharged by automated mechanisms, For hot product discharge and use, the
removal unit, is mixed with the natural consisting of pressurized bins and cooling circuit is eliminated and hot DRI
gas make-up, thus closing the reducing locks. Specially designed flow feeders is continuously discharged at > 700 °C.
gas circuit. insure the uniform flow of solids within For the HYTEMP® pneumatic transport
the shaft. For cold DRI, a cooling gas is system, the product is transported by
The furnace operates at a pressure of fed to the lower conical part of the means of a carrier gas to the surge bins
around 7 bar absolute allowing a high furnace at about 40 °C, flowing upward located at the meltshop, for a controlled
reactor productivity of about 9 tph per countercurrent to the DRI moving bed. feeding to the electric arc furnace.
m2. This results in much higher The gas distribution is uniform and For production of HBI, hot DRI is
production volumes, of more than 2.5 there is a high degree of direct contact continuously discharged at > 700 °C
Mtpy in a single module when between the gas and solid, without to the hot briquetting machines
compared to ambient pressure physical restrictions to the flow of solids arranged below.
systems. The pressurized operation or gases inside the unit. The HBI is cooled in vibrating cooling
also minimizes dust losses through top The cooling gas exits from the upper conveyors using cooling water and then
gas carry-over. This is reflected in low conical part, at about 460 °C, and is discharged to the HBI transport
iron ore consumption, which keeps the then quenched/scrubbed by means of conveyor.
23
The HYL HYTEMP®
system

Virtually maintenance-free
and with no fines nor
metallization losses, the
low OpEx HYTEMP® inert
HYT
pneumatic charge system E
INT MP ® D
OT IRE
allows safe hot DRI feed HE C
EAF T CHA
RGE
and energy savings into
the EAF.

An additional technology that, on its

own provides significant benefits for
steelmakers, is the HYTEMP®
pneumatic transport system for sending
hot DRI from the reduction reactor to
the EAF shop. When combined with the
Energiron ZR Process, the benefits
increase substantially by bringing hot,
high carbide iron to directly feed the
melting furnaces. The HYTEMP®
system involves an Energiron hot
discharge direct reduction reactor
connected to an adjacent electric
furnace mill by means of a pneumatic
transport system. HYTEMP® iron is DRI
produced at high temperature (700 °C)
and which is pneumatically transported
from the reactor discharge to the
meltshop for direct feeding to the EAF.
In this manner, the energy value of the
hot DRI is capitalized in the EAF.

This process scheme offers the most

adequate arrangement for integrated
steelmaking facilities due to the
important benefits capitalized in the
EAF. Hot DRI is sent to the meltshop,
where it is temporarily stored in
insulated inert storage bins for feeding
to the furnace by continuous injection
mechanisms which deposit the material
directly in the metallic bath surface.

Currently the Ternium Monterrey 4M,

Emirates Steel and Suez Steel DR
plants produce hot-discharge DRI,
24
using the HYTEMP® system for hot DRI downtime, or an external cooler can be
transport to the meltshop. Cold DRI is incorporated for cold DRI production,
also produced via an external cooler if or a briquetting machine can be
required. installed in case that part of the
The product is transported to the production is being sent for export.
furnace by means of a carrier gas, As the DR plant designed for HYTEMP®
via the interface bin where the carrier iron production is linked to steelmaking
gas is separated from the hot DRI facilities, the reactor tower, pneumatic
and where depressurization also takes transport system and EAF feeding bins
place. Hot DRI is discharged to the EAF can be arranged in the most adequate
surge bin, which feeds the EAF. layout to minimize distances and to
The carrier gas is separated from match the continuous DRI output with
the hot DRI in the pressurized interface the batch consumption of the
bins, and it is passed through meltshop.
a quenching/scrubbing system for
cooling and cleaning. Then, the carrier The HYTEMP® system was not only
gas is recycled to the pneumatic the first successful continuous hot DRI
transport circuit by means of the charging system, having been in
recycle compressor, thus closing the operation since 1998, but it is easily
pneumatic transport loop. the most efficient and productive, with
no fines losses from the system.
According to the particular HYTEMP® is virtually maintenance-free
requirements of the steelmaking with no recorded downtime in any of
facilities, an off-line discharge for DRI the plants using the system since it first
cooling can be used during EAF started up over 15 years ago.
25
Energiron
and steelmaking plant
integration

Wide technology and field

experience in DRI and
electric steelmaking
lead to the most efficient
technical solutions for a
competitive high quality
liquid steel production.

Energiron
improves steelmaking
The virtual absence of residual elements
makes DRI the ideal complement to
EAF scrap charges, as well as the
recommended charge material for
producing most high grades of steel.
Additionally, DRI and HBI serve as
quality metallic sources for blast furnace
and BOF shops. DRI can be
continuously charged for even greater
advantages. The use of this quality
feedstock in the EAF provides numerous
advantages in steelmaking, including:

_ Greater uniformity and predictability; charging only cold DRI. For example in operations, as also widely
_ Better slag foaming; Emirates Steel Industry Phase 1&2 demonstrated in the Ternium Monterrey
_ Increased efficiency and productivity, plants, feeding the EAF their typical mix EAF. The diagrams show the effect of
especially when using High-Carbide DRI; (90% hot +10% cold DRI), it is possible DRI temperature inside the EAF, when
_ Lower total steel cost. to save about 26 kWh/tls for every 100 using 100% DRI feed. Data are taken
°C increase in the DRI temperature. from industrial installation records,
The perfect integration between the sorted by DRI average metallization,
direct reduction plant and the meltshop, Together with the savings in electricity, with a carbon content consistently in
achieved through the combination of the EAF productivity increases with the the range of 2.2 to 2.5%.
the HYTEMP® system and a properly DRI temperature. The tap-to-tap time
designed EAF, is presently a proven decreases about 5% and the Effect of high carbon (as Fe3C)
concept as previously indicated. productivity increases accordingly per Chemical energy contribution
every 100 °C increase in the DRI The conversion of Fe3C into iron and
In particular, when DRI with a temperature. For this reason, when DRI carbon is an exothermic reaction which
temperature of 600 °C is directly melted with a temperature of 600 °C is melted improves the thermal efficiency in the
in the EAF, all the thermal energy of the in the EAF, the savings in power EAF, by means of oxygen injection
DRI, discharged hot from the Direct consumption are up to 141 kWh/tLS to the furnace.
Reduction Reactor, is completely with an increase in productivity of up to
recovered in the EAF. Immediate 22% for a practice of 90% hot+10% Efficient use of carbon in EAF
benefits are recorded at the melt-shop cold DRI. The combined carbon is totally used,
in terms of both electrical energy minimizing external carbon (graphite)
consumption and tap-to-tap time, if Further benefits can be achieved by additions, since it is a part of the DRI
compared to the traditional solutions of using high-carbon hot DRI in meltshop being fed.
26
Higher stability during handling The diagrams show the effect of DRI temperature inside the EAF,
Iron carbide is more stable and is safer when using 100% DRI feed. Data are taken from industrial installation
records, sorted by DRI average metallization, with a carbon content
to be stored and transported. consistently in the range of 2.2 to 4.0%.

Easy foamy slag generation

As high carbon DRI enters in contact
with free or combined oxygen.

The future of integrated 650

steelmaking
Energiron direct reduction plants have 600
Electricity Consumption (kWh/tLS)

reached a stage where they can 550

conceivably compete with the
traditional integrated steel mill in terms 500
of size and production capacity. The
450
conventional wisdom has been that for
an integrated mill, capacities of blast 400
furnace ironmaking need to be greater
than 2 Mtpy of hot metal. Below that 350
level, the capital cost associated with
300
the BF/BOF installation would be too
high on a per-ton of steel basis. While 250
few new integrated mills have been built 0 100 200 300 400 500 600 700
in the past decade or so, most have DRI Temperature (°C)
been in the range of 2 to 3 million tons
per year of hot metal. Today’s state-of-
45
the-art EAF mill, with the use of oxygen
lancing and carbon input (either from
coal or graphite, or from high carbon
40
Power-On Time (min/heat)

DRI from Energiron plants) relies more

and more on chemical energy as well
as electrical energy. Using low residual
metallic feedstocks, including DRI or 35
HBI, allow EAF mills to produce the
superior steel grades demanded by
such users as automotive, special and 30
tool steels that were previously only
possible in integrated mills. So in terms
of quality, the DR-EAF route is certainly 25
not limited to producing simply 0 100 200 300 400 500 600 700
commercial steel grades. Add to this DRI Temperature (°C)
the ability to now produce DRI in
capacities exceeding 2.5 million tons
per year, and coupling this type of plant
with a modern EAF meltshop, we can
easily see a new type of “integrated”
mill for the near future: a high volume,
60% DRI 2.2 %C, 25 Nm3/tls 100% DRI 2.2 %C, 25 Nm3/tls
integrated DR-EAF mill, capable of
competing in both quality and cost. 60% DRI 4.0 %C, 42 Nm3/tls 100% DRI 4.0 %C, 42 Nm3/tls

27
Suez Steel, Egypt. The high process flexibility provided by this Energiron
ZR plant, designed for hot and cold DRI production, makes it possible
to schedule the production according to any actual final user requirement.

28
29
Advanced automation
systems

Energiron plants benefit

from an advanced L2
production and quality
control automation system
developed over decades
of process know how and
research.

The Energiron Direct Reduction Process

combines different and complex
physico-chemical processes that have
to be optimized to yield the desired set
of chemical reactions and heat and
mass exchanges among the variety of
gaseous, liquid and solid phases. For
this reason, a complete automation
system is provided that uses the latest
available technology in the field of
process controllers, software
diagnostics, high availability and fail-
safe features.
The Energiron control system is based
Another target of this PRM is the
on an architecture consisting of a
Product Quality Prediction; starting from
traditional Level 1 system for equipment
the gas composition measured by the
control with a Distributed Control
mass spectrometer, we can predict with
System, plus a new Level 2, not only for
sufficient lead time (from 6 to 10 hours
process supervision, data tracking and
before the material is discharged) the
creation of production reports but also
characteristics of the product, such as
process optimization.
metallization, carbon content and DRI
A “Process Reconstruction Model”
temperature. As a consequence the
(PRM) has been developed. It uses
process engineers have a consistent
instrumentation signals coming from the
margin in terms of time to adjust the
PLC and physical equations in order to
process parameters in order to reach
provide a full description of the plant
the desired production both in terms
status. In this way it is possible to
of quality and quantity.
calculate many normally unmeasurable
items such as the top gas composition
Further innovative Level 2 functionalities
and relevant red/ox ratio.
based on the Extended Kalman Filter
Estimator and the Linear Quadratic
Gaussian Regulator for calculation of
the optimal Level 1 set points as a
function of the Level 2 requested inputs
will drive the future development of the
advanced DR Process control.
30
31
Energiron
and the environment

Because of the unique

features of this technology,
significant achievements
have been reached
in terms of greenhouse
gas emissions
and in the reduction
of air pollutants like
NOx and SO2.

Energiron plant emissions are in

accordance with the most stringent
environmental regulations anywhere.
This is achieved in large part due to the
process itself; while other processes
require heat recovery equipment that
tends to increase the NOx levels,
Energiron technology is efficient by
design due to its process configuration.
Thus, while achieving high overall
thermal efficiency in the plant, there is
no significant need for preheating the
combustion air to high temperatures in
the reformer (when used) or in the
heater, thus eliminating the possibility of
high NOx generation. The NOx emission
can be additionally reduced by
adopting ultra-low NOx burners; in this
case, the NOx emission can be
reduced to values below 25 ppmv (50
mg/Nm3 as NO2).
A further improvement can be obtained
with the application of SCR technology,
which can be easily installed in existing
convective sections of the heater or
reformer. The NOx is reduced to N2 by
catalytic reaction with a commercial
solution of NH2. The evident benefit is
the reduction of NOx emission to values
below 10 ppmv (20 mg/Nm3 as NO2).

Energiron is, without question, the

cleanest DR technology available.
Depending on the configuration, an
Energiron plant can remove from 60 to
90% of total CO2 emissions, which in

32
Carbon Carbon
in product in non selective
(DRI/HBI; emissions
C=3.5%)
24% 31%

Carbon
45% in selective
emissions

other technologies are flared or vented

to the atmosphere. Energiron plants
offer the unique option of selective
recovery of CO2, which can be cleaned
and sold as a cash by-product.
The CO2 absorption system not only
captures the CO2, but also the sulphur,
whenever present in the process gas
stream, reducing the overall SO2
emission from the plant by around 99%.

The high operating pressure of the

Energiron shaft and its low gas
velocities, and thus low fluidization and
dragging force, results in less fines
carry-over by top gas (<1% losses in
top gas). This low loss of iron ore fines
from the reduction process means less
particle emission, as fines normally have
to be cleaned from the recycle gas
stream.

Another advantage of the Energiron

plant is the possibility to design the
process for a zero make-up water
requirement. This is possible mainly
because water is a by-product of the
reduction reaction and it is condensed
and removed from the gas stream. As a
consequence, adopting a closed-circuit
water system, based on the use of
sea/river water heat exchangers instead Emissions
of conventional cooling towers, there is
no need for fresh make-up water and NOx with Ultra Low NOx burners 50 - 80 mg/Nm3
actually a small stream of water is left NOx with Selective Catalytic Removal 10 - 50 mg/Nm3
available at battery limit. This feature is CO 20 - 100 mg/Nm3
particularly attractive for locations
Dust from heater/reformer stack 1-5 mg/Nm3
where the water is expensive or not
available at all. Dust from material handling dedusting 5 - 20 mg/Nm3

33
Nucor Steel (LA), USA. World’s largest single DR module for 2.5 Mtpy
cold DRI production (Energiron ZR - without external reformer).
The plant reached 95% metallization and over 4% C in the first 24
hours of operation. Production rate was as expected since day #1.

34
35
Global project
execution

From basic design through

manufacturing, project
management and
construction and through
to plant startup and
commissioning,
the Energiron team
assures a successful result
in terms of time, quality
and costs.

The Energiron alliance offers the unique

flexibility of providing everything from
a basic technology package to full
turnkey projects. Our support runs from
process technology through operations
and maintenance training and technical
assistance, not only in the DR plant but
in the steel shop as well.
In addition to technology licensing
and conceptual engineering, we provide
maintenance and operations training,
project and erection supervision,
support during startup and
commissioning, and a wide range
of technical services after startup.
Our own qualified operations and
maintenance personnel can even take
charge of the operation of a DR facility
on a contract basis, if requested.
Our technical staff has years of
experience providing training and
technical assistance for meltshop
and steel mill personnel, with unequaled
success in raising productivity levels
in all areas, whether or not the steel mill
is a DRI-based operation.
From mining, pelletizing and materials
handling to steel mill operations and
maintenance, computerized process
controls, and even including
administrative and commercial
functions – we provide technologies
and services for all areas of ironmaking
and steelmaking.
36
37
Quality
manufacturing

The manufacturing
capacity of the Energiron
partners, Danieli and
Tenova, assures quality
and on-time delivery
of the main technological
equipment through
in-house and controlled
facilities.

Danieli and Tenova firmily believe equipment, flow feeders, rotary valve,
manufacturing is a key factor for a expansion joints, and sealing valves) to
winning project execution and assuring steel structures and pipework.
overall competitiveness. To speed-up construction activities,
Quality procedures and international complete material handling systems
certifications are the basis for the can be produced and pre-assembled
success in the production of the core in our workshops before delivery to the
equipment. Our workshops and project sites. Select qualified external
assembly facilities in Europe, China, workshops cooperate in the successful
Thailand, India and the Americas allow execution of the jobs.
us to optimize the sourcing of quality
raw materials and to take advantage of Employee involvement, quality belief
the most competitive specific skills and and structured management form the
manpower. The manufacturing capacity basis of our manufacturing culture,
ranges from the core area equipment which is widely recognized by the steel
(reactor, process vessels, thermal community.

38
39
Construction
capability

Energiron has the further

advantage of an
international construction
capability within the
alliance, allowing a
constant know how
transfer from engineering
phase to construction
and commissioning phase.

The worldwide presence with own

handling and transportation equipment
and through specialized and trained
people covers full services from soil
improvement, civil works, material and
equipment handling, electromechanical
installations, piping prefabrication, HVAC.

The gained experience proved to be a

valuable asset in different socio-cultural
environments and was developed
during many decades of site activities
carried out all over the world.

40
41
Ezz Steel, Egypt. Installation of a 700-t reactor in a 1.9-Mtpy DRP
(Energiron III, with external reformer; cold discharged DRI: 93%
metallization and 3% C) by means of the new Danieli TCR800 tower
crane, an ideal flexible solution for on-site construction of heavy
DRP or meltshop equipment.

42
43
Customer training
and assistance

Partnership and customer

service are at the basis
of the services offered
along with Energiron
direct reduction plants.
Personnel training,
on-line/on-field assistance,
original spare parts.

Energiron Technical Assistance and

Services are jointly provided by Danieli
and Tenova.
During the project execution phase,
the assistance to the client is mainly
devoted to Multilevel Theoretical and
Practical Training, with classroom and
hands-on activities both in similar
Energiron plants and in the same plant
under execution.
The future plant operators and
managers are accompanied through
a training course which covers a
complete set of topics for each
technical and managerial specialization
to assure a deep knowledge of the
Energiron technology and to develop
the skills necessary to maximize the
productivity and profitability of the DRI
plant.
The range of after-sales activities covers
Management Consulting, Remote
Assistance Services, Production and
Maintenance Service Agreements.
Original Spares and Refurbishments
are assured through the constant
interaction between the plant
management and the Energiron Service
Team. Dedicated preventive and
predictive maintenance tools and Capacity enhancement and Equipment
warehouse management software Technical Improvement analysis can be
can be provided to plan efficiently the provided to the customers to let them
spares resources according to the exploit the latest technological state of
different necessities of each Energiron the art.The success of the Customer is
plant. our pride.
44
45
Most recent
projects

Emirates Steel - ES1

Integrated steel plant 2.0 Mtpy
_ Location: Abu Dhabi, UAE
_ Original design capacity: 1.6 Mtpy
_ Enhance capacity after revamping: 2.0 Mtpy
_ Energiron III (with external reformer)
_ Hot discharged DRI:
93% metallization and 2% C
_ HYTEMP® system for directly feeding
hot DRI to the EAF

Emirates Steel - ES2

Integrated steel plant 2.0 Mtpy
_ Location: Abu Dhabi, UAE
_ Original design capacity: 1.6 Mtpy
_ Enhance capacity after revamping: 2.0 Mtpy
_ Energiron III (with external reformer)
_ Hot discharged DRI:
93% metallization and 2% C
_ HYTEMP® system for directly feeding
hot DRI to the EAF

Al Ezz Rolling Mills - EZZ

1.9 Mtpy
_ Location: Ain Soukna, Egypt
_ Original design capacity: 1.9 Mtpy
_ Energiron III (with external reformer)
_ Cold discharged DRI:
93% metallization and 3% C

46
Suez Steel Company - SSC
Integrated steel plant 1.95 Mtpy
_ Location: Suez, Egypt
_ Original design capacity: 1.95 Mtpy
_ Energiron ZR (without external reformer)
_ Hot or cold discharged DRI:
94% metallization & 3.5% C
_ HYTEMP® system for directly feeding
hot DRI to the EAF

Nucor Steel
2.5 Mtpy
_ Location: Convent (LA), USA
_ Original design capacity: 2.5 Mtpy
_ Energiron ZR (without external reformer)
_ Cold discharged DRI:
96% metallization and 4.2% C

Jindal Steel and Power - JSPL

Integrated steel plant 2.5 Mtpy
_ Location: Angul, India
_ Original design capacity: 2.5 Mtpy
_ Energiron ZR (without external reformer)
with Syngas and COG
_ Hot discharged DRI:
_ 94% metallization and 1.5% C
_ HYTEMP® system for directly feeding
hot DRI to the EAF

47
ENERGIRON
THE INNOVATIVE
DIRECT REDUCTION
TECHNOLOGY
ENERGIRON www.energiron.com info@energiron.com
THE INNOVATIVE
DIRECT REDUCTION
TECHNOLOGY

Danieli headquarters
Via Nazionale, 41
33042 Buttrio (UD) Italy
Tel (39) 0432.1958111
Fax (39) 0432.1958289
www.danieli.com
info@danieli.com

Tenova HYL
Av. Munich 101
San Nicolás de los Garza, N.L.
66450 México
Tel (52) 81.8865.2801
Fax (52) 81.8865.2810
www.tenova.com
hyl@tenova.com