1. Iron Reduction Technologies

Iron Reduction Technologies

HYL / ENERGIRON ZR process technology with integrated CO2 absorption system represents with more than 40 references and lowest plant emissions (NOx, SCR, dust) the benchmark in the field of iron reduction technologies.

Tenova HYL and Danieli & C. have formed a partnership for the design and construction of gas-based DR plants under the ENERGIRON trademark. ENERGIRON is the innovative HYL direct reduction technology jointly developed by Techint and Danieli, and whose name derives from the unique DRI product which distinguishes this technology from other available processes.

Plant capacities range from the 200,000 tpa Micro-Module up to 2.5million tpa in a single module. DR plants can be designed to produce cold discharge DRI, hot discharge DRI for direct feeding to an adjacent electric furnace meltshop, or for production of HBI for commercial trade.

The unique High Carbon DRI which characterizes these plants is highly sought after by steel makers for the efficiency it provides in the meltshop and the improved yields, quality, and production costs for liquid steel. Carbon can easily be controlled for any level from 2 to 5%, and since it is in the form of iron carbide (combined carbon), it provides both energy to the EAF as well as stability to the product itself.

The process technology is the most cost effective available anywhere. Using our self-reforming or ZR technology, the typical plant has a small footprint for lower capital expense, and the pressurized operation allows for increased process dynamics and more precise control of process conditions. Because the process is independent of any external gas reforming unit, our DR plants can be designed to use any available reducing gas source. Natural gas, reformed natural gas, syngas from coal gasification units, and coke oven gas can all easily be used to supply the required reducing agents.

In addition to the flexibility for reducing gases, the process can easily handle the widest range of iron ores, including high sulfur ores, in both pellet and lump form or combinations of both.

Environmentally, Tenova HYL has provided "green" technology even before it was a requirement. The ability to selectively recover CO2, lower effluents to water supply, and lower particulate matter waste helps us to consistently register lower-than-accepted levels for environmental permitting.

  • Environment

    Environment

    • Lowest NOx emissions: 0.030 kg NOx/tDRI
    • Selective removal of iron ore reduction’s by-products: H2O & CO2
    • ENERGIRON plant emissions are in accordance with the most stringent environmental regulations anywhere
  • Efficiency

    Efficiency

    • ENERGIRON ZR scheme energy efficiency, which overall energy consumption (as natural gas) of 9,4 GJ/tDRI includes selective CO2 removal
    • More efficient and direct carbon feed to EAF through high-C DRI
    • Decrease of overall energy consumption in EAF (as combined power + oxygen) due chemical input through combustion and dissociation of Fe3C
    • Considering the DRI quality obtained and selective CO2 removal, the plant achieves one of the most efficient NG consumption worldwide; just  ~2.4 Gcal/tDRI
  • Technical Excellence

    Technical Excellence

    • Flexibility in usage of different sources of reducing gases with the same basic scheme
      • Natural Gas
      • Reformed Gas
      • SynGas
      • COG
      • Hydrogen
    • Wide range of raw material quality of iron ore (Sulfur is not a limitation)
    • Flexibility for carbon control: 2,0% - 5,0%

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References

  • Customer
    Project name
    ENERGIRON ZR (MISSING)
    Nucor Louisiana; US
    Nucor Louisiana
    2013

    World's largest DR single modul NUCOR STEEL, LOUISIANA

    • 2,5 Mio tpy – World’s largest single DR module
      ENERGIRON ZR Process
    • High-Carbon DRI:
      Mtz:     96%
      Carbon: 4%
    • Clean CO2 as by-product

    Project figures

    ≥ 300 t/h
    ≥ 96%
    3.6 – 4.0%

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Contact - List

  • Contact Contact Person Position Legal Entity Department Phone Fax E-mail Address
    Hyl Technologies S.A. de C.V
    +52 81 88652801
    +52 81 88652810
    hyl@tenova.com

    Av. Munich, Col. Cuauhtémoc 101

    N.L. 66450 San Nicolás de los Garza

    Mexico

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