CRISP+

Furnace Solutions
for the Iron & Steel Industry
 Your partner for decarbonizing the iron
and steel value chain
At Hatch we are passionately committed to solving the world’s toughest
challenges and creating a future shaped by a sustainable global society.

We recognize that climate change mitigation pressures are Large scale conversion from coal-based BF to greener,
driving iron and steel producers to implement innovative electric process routes will require an EAF that can
flowsheets to reduce their carbon footprint. Admist the manage a much broader variety of ore qualities and other
transition, they face the need to adapt to raw material metallics than the conventional EAF.
availability and sustainability demands, as well as serve a
Hatch’s advanced Continuous Reduced Iron Steelmaking
growing steel market.
Process (CRISP+) addresses these challenges through the
Iron and steel producers are evaluating options to innovative use of a large, stationary electric furnace for
significantly reduce carbon emissions in the production the continuous melting of DRI and scrap for conversion
of iron that include replacing blast furnace (BF) units with to iron or steel. Steel producers can use the same blast
a direct reduced iron (DRI) – electric arc furnace (EAF) furnace pellets and recycle waste materials to make the
process. Shaft furnace for DRI production using natural entire range of steel products, including high quality,
gas is well proven in the industry and plans are underway low nitrogen grades, and continue to use their existing
to convert these units to hydrogen to further reduce BOF meltshop assets. A discard slag suitable for cement
their carbon footprint. Conventional EAF steelmaking industry applications further improves the sustainable
has traditionally been used to melt DRI produced from approach offered by the CRISP+ technology. When natural
high grade, low gangue pellets. However, this presents gas is replaced by green hydrogen, the CRISP+ furnace can
challenges in dealing with lower grade blast furnace (BF) be transitioned to the direct and continuous steelmaking
pellets and some steel types. mode thereby eliminating the BOF steelmaking step and
further reducing CO2 generation rates.

Current Mid-Term Long Term Vision Applications

Shaft Furnace NG-DRI Shaft Furnace NG - DRI

Blast Furnace
Ironmaking Shaft Furnace Hydrogen-DRI Lower & High Grade Ores

+
CRISP+ Steelmaking
CRISP+ Ironmaking Low & High grade steel
CRISP+ Steelmaking
BOF Steelmaking + Existing & New Facilities
BOF or EAF Steelmaking

2 t*

*tonnes of CO2 per tonne of steel production 0.2 t*

 Key features of the CRISP+ furnace
The CRISP+ electric furnace operates continuously with a similar operating factor to the DRI shaft furnace. Relative to the conventional EAF, CRISP+ provides higher iron yield and lower total
energy requirements. CRISP+ is not limited to processing high grade ores and can process a variety of other materials including fines, mill scale, and scrap. In ironmaking mode, a discard slag
meeting cement industry specifications can be produced. Although new to the steel industry, this type of furnace is well established in other metals industries.

Sealed furnace with reducing atmosphere Hot DRI transfer and feed
• Production of low nitrogen steels • Fully automated, proven, and highly reliable
• Higher quality CO off-gas for capture/mitigation

Effective slag tapping and handling 6-in-line electrode arrangement (vs. 3-delta)
• Higher total power
• Large volumes of slag tapped through low
maintenance tapholes • High efficiency through optimized power/feed control
• Water or air granulation systems
• Heat recovery from air granulation
• Slag suitable for cement market Multiple tapholes arranged on the long wall
• Improved access for tapping operations and
Reliable, efficient power supply maintenance
• Can achieve higher tapping rates (opening multiple
• Lowest maintenance option available in the market; tapholes)
well-proven / reliable system • Fully remote and/or autonomous opening/closing
• High voltage electrical system configured for efficient including lancing
delivery of power to furnace

Robust rectangular furnace crucible

Continuous operation
• Integrated cooling, binding, and refractory
• Power and feed delivered continuously to furnace • Simplified / cost-effective plant layout
• Can be direct coupled to shaft furnace • High availability with long campaign life

Large volume, partially open bath

Integrated automation and digital technology
• Longer residence time improves processing of lower
grade (higher gangue content) direct reduction (DR) • Remote operation and advanced process control
feedstock capable
• Flexibility in processing raw materials (fines, mill scale,
etc.)
• Produces slag at desired chemistry for downstream use

Ironmaking FeNi smelting New Process Development

CRISP+ Ilmenite, iron sands smelting
Prereduction + electric furnace process
Prereduction + electric furnace process (70-80% iron)
Transfer of hot, pre-reduced feed (850+ °C)
Development and optimization of
processes for primary metal production

Experience (iron + TiO2 slag)

Furnace power up to 80 MW
Furnace power proven up to 100 MW

Select References: Select References: Select References:

Leveraging 65+ years of Hatch • Rio Tinto – 13 Furnaces (Iron/Titania) 60-80 MW • Vale Onca Puma - Rectangular 96 MW • CRISP+ steelmaking development and piloting
technology and know-how • New Zealand Steel – 2 Furnaces (Iron) 42 MW • Anglo Barro Alto - Rectangular 85 MW • Conversion of Highveld electric iron furnaces to partially open bath operation
• Highveld – 4 Furnaces (Iron) 36 MW • SNNC – Circular 90MW • Development of shielded arc smelting process for FeNi
• Pronico – Circular 90 MW
 Global Experience
For over 65 years Hatch has provided our furnace technology and know-how to iron and steel producers globally,
partnering with our clients to offer full-service solutions by supporting their upstream and downstream production. With
our innovative technology offerings, specialty engineering services, world renowned smelter subject matter expertise,
and complex project implementation resume, we focus on improving our clients’ business.

Hatch delivers full project life-cycle services from concept development through to implementation and operational
support. We build practical smelter solutions that are safe, sustainable, and fiscally advantageous. By doing our
homework and drawing on our global expertise, we add value to our clients’ operations as we understand their most
significant operational challenges and opportunities.

Legend
Hatch Offices

Hatch Furnace Installations

FeNi Ferrous Metals
Nickel sulfides Other Base Metals
PGM

About Hatch
Whatever our clients envision, our engineers can design and build. With over six decades of business and technical
experience in the mining, energy, and infrastructure sectors, we know your business and understand that your challenges
are changing rapidly. We draw upon our 9,000 staff with experience in over 150 countries to challenge the status quo and
create positive change for our clients, our employees, and the communities we serve.

Find out more on hatch.com.