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Innovative IronmakingTechnologies for the
Growing MENA and Asian Markets
By John Kopfle
“They must often change who would be constant in
happiness or wisdom.”Confucius, Analects
Presentation ContentsMENA and Asia steel and DRI productionAdvantages and challenges for the regionsInnovative ironmaking technologies to utilize the advantages and address the challenges
MENA and Asia steel and DRI production
Steel Production2011 vs. 2010
Region/country through April
MENA +2.5%India +8.0%China +8.3%Other Asia +8.5%
Source: Worldsteel
Even withpolitical situation
These countries account for 66% of total world production and their economies are growing
faster than N. America, Europe, and Japan
DRI Production
Source: Midrex
Region/country 2010 production (Mt)MENAAbu Dhabi 1.18Egypt 2.86Iran 9.35Libya 1.27 Qatar 2.16Saudi Arabia 5.51
Subtotal 22.32
AsiaIndia 23.42Indonesia 1.36Malaysia 2.39
Subtotal 27.17
These countries accounted for 70% of total world production
Continued Growth in World DRI Production, Driven by Emerging Markets
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14019
70
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MidrexProjections
Advantages and challenges for MENA and Asia
Advantages for MENA and Asia Iron and Steel Industries
1. Economic growth – drives steel demand and most of these countries are expected to expand at 5-10%/yr. in future
2. Capital – economic growth is generating investment funds
3. Raw materials and energy – natural gas in MENA, iron ore and coal in China, India, and other countries
4. Operating expertise – skilled workforce, good performance in many steelmaking and direct reduction facilities
Challenges for MENA and Asia Iron and Steel Industry
1. Coking coal – spot prices of $300/t and higher. China is only Asian country that has significant reserves and those are being depleted.
2. EAF feedstock – scrap generation is still low, supplemental iron is required
3. Emissions – CO2, NOx, SOx, and particulates are a concern for blast furnace and rotary kiln operations
4. Energy use – China shut down steel mills in late 2010 to achieve energy consumption targets
New ironmaking technologies to utilize the advantages and address
the challenges
MXCOL®
Use of coal syngas in a MIDREX ® Plant (from gasifier, coke oven gas, BOF gas, etc.).Enables use of lower quality domestic coal or integrated mill offgases.
Jindal Steel & PowerWorld’s First MXCOL Plant
Using a Coal GasifierAngul, Odisha, India
SUPER MEGAMOD®
MIDREX® SUPER MEGAMOD with capacities up to 2.5 Mtpy. Economical DRI production to supplement scrap in EAFs.
Three options for discharge and transport of hot DRI and charging to EAF at up to 600º C. Provides increased productivity, energy savings, and lower emissions.
Hot transport conveyorHadeed Module E
Saudi Arabia
Hot transport containersLion DRIMalaysia
HOTLINK ®
ESISCOEgypt
Hot Discharge/Transport/Charging
Standard MIDREX® Process Using Natural Gas
Low emissions, including CO2, NOx, SO2, particulates.
Show Me the Numbers: Steelmaking CO2 Emissions
for BF/BOF vs. EAF
-50%
EAF using scrap and iron
Reduces CO2 to atmosphere to ~250 kg/t DRI if CO2 is usedfor enhanced oil recovery (EOR) or sequestration.
MIDREX® Carbon Capture
Uses iron oxide fines, avoids need for pellet or sinter plant (lower emissions), uses non-coking coal, produces high quality pig iron product
ITmk3®
Hoyt Lakes
Mesabi Nugget
Mesabi Nugget StatusWorld’s first commercial ITmk3® Plant
Since start-up in January 2010, plant has been increasing its output
Nugget productivity reached 80% and plant availability has improved to 90%. Produced 20,000 tons of nuggets in a 30 day period.
Operations have confirmed that the basic process works well
There were some mechanical issues during initial operations (e.g., coal conveyor system) that are being resolved
Quality of iron nuggets has been very good and they are being used successfully in Steel Dynamics meltshops in Indiana
Based on plant operation to date and improvements underway, Kobe Steel is confident that Mesabi Nugget will achieve the desired results and the ITmk3® Process will provide an economical source of high quality iron for the world’s steelmakers
New MidrexOffice in Shanghai
ConclusionsGrowth in MENA and Asia economies requires increased iron and steel production
The regions’ advantages include strong economic growth, availability of capital, natural resources, and operating expertise
Challenges are coking coal prices and imports, availability of EAF feedstock, gaseous emissions, and energy use
New technologies for MENA and Asia include MXCOL®, MIDREX SUPER MEGAMOD®, DRI hot discharge/transport/EAF charging, MIDREX® Carbon Capture, and ITmk3®
