Ironmaking and steelmaking technologies presented at DIM 2024

The session consisted of presentations and discussions on ore processing, ironmaking and steelmaking, DRI production, with a special focus on intelligent, competitive, green technologies including advanced automation, use of hydrogen, and water treatment.

Iron ore beneficiation: excellence begins in the mine. Efficient ore comminution and beneficiation contribute greatly to economically viable iron and steel production: it offers great benefits when compared to processing lower grade ores in metals production, e.g. since it allows for the use of renewable energy sources. This is what was highlighted in the opening of the ironmaking and steelmaking session.

It is a matter of fact that Energiron is the most flexible, competitive DRI production technology.

A well-consolidated process successfully operating in multiple scenarios, that produces high-quality DRI from different grades of iron pellets.

The same Energiron process scheme can be applied for: production of high-quality cold / hot DRI, production ofHBI and having a product with adaptable metallization and carbon content; processing a wide variety of iron oxides including DR-grade pellets and BF-grade and lump ore; the use of reducing gas of any quality and chemistry, including NG, syngas, reformed gas, coke oven gas and hydrogen.

Green steel projects to be implemented in phases, using natural gas G today and eventually switching to hydrogen, with no changes to the equipment.

A carbon-capture system is embedded in the Energiron process, therefore up to approx. 60% of the CO2 generated can be utilized for CCU/CCS.

This operational flexibility comes with no compromises on energy efficiency, which leads to the lowest OpEx.

Net-Zero CO2 emissions in DRI production is possible by making use of hydrogen, but also switching the heating of process gas to full electrification, removing the combustion from the process.

Energiron® DRI plants are hydrogen-ready by design, and allow flexible gas switch without any configuration change.

Energiron is the innovative DRI technology jointly developed by Tenova and Danieli, selected for 11 projects over the last four years.

Low-carbon footprint steel production is becoming a reality – even for the traditional BF–BOF route.

The Danieli Corus “Low Emission Action Program” for decarbonization of integrated steel production seeks to lower emissions by 40% to retain the BF-BOF route viability and its economic advantages.

Two major steps are to eliminate 25% of emissions by raising BOF scrap input by 20%, and to eliminate sintermaking for another 8% emission reduction. The specific blast furnace emissions can be reduced further by up to 200 kgCO2/tls using electrical process gas heaters, top-gas recycling, and modern injection practices, with or without generating reducing gases in a reformer.

Danieli Corus hot blast system technology enables stove campaigns up to 50 years, with its design details that overcome the challenges connected to hot-blast generation and its high–temperature cyclic nature, such as refractory expansion and inter-crystalline stress corrosion. The latest developments in hot-blast stove burner design and tuyere stock assemblies offer greatly improved efficiency, reducing emissions associated with hot blast generation for blast furnace ironmaking.

With its improved energy efficiency, lower cost, reduced plot space, and practically eliminated water consumption, Danieli Corus patented dry blast-furnace gas cleaning is now the only acceptable solution for many steel producers, especially where space or water is scarce.

Utilizing DRI from low-grade pellets in the EAF to obtain high-grade steel was discussed and proved by Danieli experience, process design and controls, achieving automotive and quality steels from different DRI grades.

Regarding iron and steelmaking automation, Q-Set for Level-2 DRI process control with advanced data analysis for optimal setpoint generation was revealed.

Q-Compass is the new-generation integrated steel plant automation platform dealing with plant logistics as well as process control, reducing waiting times and associated temperature losses. In addition to its value in day-to-day operations and scheduling, the system can also be used for establishing new best practices for any plant and assessment of plant reconfiguration and design for projects related to e.g. decarbonization programs.

Shifting from product-based to service-based models, Danieli Automation native-designed, advanced monitoring and maintenance services offer servitization to the metals industry.

By remotely monitoring the performance and condition of the assets, it is possible to detect early signs of equipment failure, schedule proactive maintenance, and minimize the impact of any breakdown to customer operations.

You can read about the breakthrough Digimelter and Q-One power feeder in the next NewsFlash that will report on the “EAF meltshop and casting” session.