Energiron at a glance

Pioneering achievements since 1957

Energiron products

Energiron plants

Plant & process economics

Energiron process

HYL HYTEMP® system

Energiron and steelmaking plant integration

Advanced automation systems

Energiron and the environment

Global project execution

Quality manufacturing

Construction capability

Customer training and assistance

Most recent projects

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THE SMART CHOICE

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Energiron is as strongas the name suggestsand the unique productof this technologyis more than justDirect Reduced Ironit’s Energy combinedwith Iron for thelowest cost and highestquality steelmakingapplications.

Competitive CAPEX and OPEX solutions from Energiron:

_ Integration withEAF thanks to DRIhot charge viaHYTEMP® system

_ Integration withBF shops forreduced carbonfootprint orincreased liquidsteel production

_ Safe-to-transporthigh carbon DRIfrom stand aloneplant

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Energiron at a glance

Since its establishment in February2006, the Energiron alliance hasbrought to the market the mostrevolutionary technology which stronglycontributed to change the DRI worldscenario, as confirmed by the severalEnergiron DRP assigned.

The largest capacity DR plants in theworld are now Energiron Zero-Reformerplants: Suez Steel in Egypt (2.0 Mtpy)and Nucor, USA (2.5 Mtpy). Moreover,since 2009 Emirates Steel in Abu Dhabihas been operating the two mostefficient hot DRI Energiron units, each ofwhich will reach a capacity of 2.0 Mtpy.

As a consequence, after six years ofsuccessful collaboration, Danieli andTenova HYL reconfirmed their exclusivealliance for an additional 10 years. With this background and these longterm prospectives, Danieli and TenovaHYL will continue to offer theircombined experience to support thecompetitiveness of the steel producersand to enhance raw material quality and availability.

EAF steelmaking continues to grow inthe production of higher quality steels,including specialty steel products.Energiron responds to the need for

Energiron is the result of a strategic alliancebetween Tenova HYL andDanieli to competitivelyserve the DR plant market. Under the alliance, the two companies havecombined their know-howand technology for thedesign and construction of gas-based DR plants,offered worldwide underthe Energiron trademark.

a premium raw material for competitiveand quality clean steel production.

Steel production cost is a combinationof raw material, energy and labor cost.There are areas where DRI productionis naturally more convenient due to theavailability of energy and iron ore at lowprices. Energiron plant configurationscan be designed to be competitiveeven in those areas where Natural Gasis not economically available, by usingother sources of reducing gas, such asCoke Oven Gas (COG), CoalGasification Gas (SYNGAS) and others.

Energiron DRI is a highly metallizedproduct with controllable carboncontent in the range of 1.5 to 4.0%which generates chemical energy in the EAF melting process.

In DRI-based integrated minimills theuse of the HYL HYTEMP® systemallows the delivery of hot DRI directly to the EAF, thus further reducing electricenergy consumption and tap-to-tap time.

The uniquely stable characteristic ofEnergiron DRI, makes it a product whichcan be safely and easily transportedwithout briquetting, following standardIMO guidelines.

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

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High process flexibility with proven technology

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

High product flexibility

Controlled carbon content -0.8 to 4%- for best EAF steelmakingperformances, comparable to hot metal practice.HYTEMP® system for hot DRI charge into the EAF, providing additionalenergy 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 anythingfrom the basic technology package to local equipment supply and erectionup to full turnkey projects. Energiron team support runs from processtechnology through operations and maintenance training and technicalassistance, not only in the DR plant but in the steel mill as well. Further,Danieli and Tenova can provide complete steel mill projects coveringmaterials handling, direct reduction, EAF meltshop, casting and rolling and product finishing lines.

What makes Energironunique:

_No raw materials limitation _Best Carbon-Iron units mix_Lowest OpEx in EAF melting

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Sustainable production thanks to the lowest carbon footprint

Energiron plants are ecologically friendly and meet the most stringentenvironmental regulations; because of the unique features of thistechnology, 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 theair pollutants like NOx and SOx. Additionally the water by-product of thereduction 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 (200,000tpy), 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 standardequipment of smaller size throughout the plant significantly reduces thecost of maintenance. Further, Energiron plants are controlled by a highlyautomated system providing Level 2 automation, requiring minimal humanintervention and providing high plant availability and reliability.

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

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Pioneering achievements since 1957

1957Startup of the world’s firstcommercially successful gas-baseddirect reduction plant, Hylsa 1M,using the HYL process.Production of flat products via theEAF, based on the use of DRI.

1958Batch charging of DRI to the EAF at 600 °C.

1965Use of more than 30% DRI in an EAFcharge, eventually increasing in stagesup to 100% by 1972.

1968Continuous feeding of DRI to the EAF.Computerize process control systemput into use.

1969Use of foamy slag practices.

1970Design of pellets for direct reduction.First full scale testing and use of DRI as a BF-BOF feed.

1972Production of extra-deep drawingsteels in EAF using DRI.

1980Start up of the HYL continuousshaft reactor process in Monterrey.

1984First HYL pilot operation of a directreduction plant without external gasreformer.

1988Use of coating of pellet/lump ores fordirect reduction.

1993HYTEMP

®pneumatic transportation

system and hot DRI feeding to the EAF.

1993First Zero kWh direct reduction plantbegins operation at Vikram Ispat HYL IIIplant, India.

1994HYL begins producing high carbon DRIwith 3.0 to 5% carbon content.

1995Production of ultra thin (< 1mm) hotrolled coils based on 100% DRI, withHYL plant and Hylsa CSP minimill.

1997World’s first dual-discharge (DRI andHBI) plant design put into operation,Vikram Ispat (now Welspun Maxsteel)HYL plant, India.

2006 marked theestablishment of theEnergiron alliance: Tenova HYL and Danieliteam up to promote and develop the newEnergiron technology for direct reduction plants.

HYL experience in DRtechnology dates back tothe fifties and since thenoriginal continuous shaftreactor and zero reformerprocesses and the HYLHYTEMP® pneumatictrasportation system weredeveloped.

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1998Startup of first commercial scaleHYL Zero Reformer Process plant,Hylsa 4M, Monterrey. Hot and coldDRI charging to the world’s largesttwin-cathode DC EAF.

1999HYL III Plant with water producingoption starts up at Hadeed, KSA.

2000First plant to use 100% lump orecharge successfully on a routine basis(Usiba HYL plant, Brazil). Vikram Ispatbecomes second in 2006.

2001Successful economical design of Micro-Module (200,000 tpy) plants based onHYL ZR reformerless technology.

2003Successful design of HYL ZR processplants based on coal gasification andCOG.

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

2006First 1.6 Mtpy Energiron DR plant withHYTEMP® system order from EmiratesSteel, UAE.

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

2008Second 1.6 Mtpy Energiron DR plantwith HYTEMP® system ordered byEmirates Steel, UAE.

20091.9 Mtpy Energiron plant for productionof Cold DRI for Ezz Rolling Mill, Egypt.

2009First new generation 1.95 Mtpy ZeroReformer Energiron plant for productionof hot and cold DRI for Suez Steel, Egypt.

2010The world biggest Energiron DRplant in a single module suppliedfor Nucor Steel with a 2.5 Mtpydesign capacity.

2013Excellent production ramp-up andlearning curve at Emirates Steel DRplant #2 leading to full productivityduring second year of operation.

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Energiron products

DRI Direct Reduced Iron

DRI is reduced iron pellet and/or lump,which is cooled and discharged at low(ambient) temperatures. The processcharacteristics allow for independentcontrol of the DRI metallization andcarbon levels. Metallization can beadjusted at will, typically around 94%and higher._ DRI carbon levels can be selected inthe range of 1.5 - 4.0%, most of whichis in the form of iron carbide._ The high iron carbide contentprovides the unique stabilitycharacteristic of this product. EnergironDRI is safe to transport and store undernormal established procedures.

HYTEMP® Iron

Hot DRI is discharged continuouslyfrom the reactor at > 700 °C to apneumatic transport system. The product is transported by means ofa carrier gas to surge bins locatedabove the meltshop for controlledfeeding to the electric arc furnace. HYTEMP® iron, like cold DRI can beproduced to high levels of metallizationand carbon, in order to satisfy meltshoprequirements for greater economy andefficiency. The HYTEMP® system is the world’sfirst proven technology for continuoushot discharge, transport and feeding ofquality DRI to the electric furnace shop.It is completely proven and reliable, withabsolutely no downtime since its firstimplementation in 1998.

HBI Hot Briquetted Iron

Reduced pellet or lump is discharged at temperatures > 700 °C into hotbriquetting presses located below thereactor discharge area. Briquettes arecompressed, cut and cooled to makeHBI, typically for merchant sale overlong distances. As with DRI, HBI isproduced in controlled metallizationranges around 94% and higher. HBIcan be easily charged to an EAF as partof a standard scrap bucket charge toreduce scrap residual levels. It isadditionally an excellent charge inintegrated mills as a coolant to thebasic oxygen furnace.Carbon for HBI is typically 1.5%, higherthan other HBI products that often haveless than 1% carbon. Work is underwayto develop HBI at even higher carbonlevels.

Our technology offers three productoptions from the same reductionprocess - DRI, HYTEMP® iron and HBI,each of which can be produced todifferent metallization and carbon levels.

Energiron plants efficiently reduce any iron pellet or lump into “energized” hot or cold Direct Reduced Iron or Hot Briquetted Iron with controlledmetallizationand carbon levels.

COLD DRI

HOT DRI

BRIQUETTED IRON

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Unique to Energiron DRI

High carbon DRI - iron carbideA unique benefit of the ZR process isthe DRI that it produces. As comparedwith DRI from other processes, hisproduct typically has a metallization of95% and a carbon content controlled ina range between 1.5 to 4% in the formof combined carbon. This type ofproduct yields significant benefits in theelectric furnace that no other process todate has been able to achieve.Carbon in the DRI, mostly as ironcarbide (Fe3C) is derived mainly frommethane (CH4) and to a lesser extentfrom CO. The level of carbon isadjusted by controlling the reducing gascomposition and/or oxygen injection.DRI produced with the ZR scheme ischaracterized by higher stability thanDRI typically obtained in other DRprocess schemes. The reason for this isthe high cementite or Fe3C content,

which inhibits the re-oxidation ofmetallic iron in contact with air. For acarbon content of 4%, approximately95% is present as Fe3C. In general,every 1% of combined carboncorresponds to 13.5% of Fe3C.Therefore, a DRI with 4% Carboncontains more than 50% of Fe3C.The high percentage of Fe3C in the DRImakes the product very stable.

DRI stabilityExtensive tests were conducted todetermine whether the combinedcarbon in DRI was a factor in improvingproduct stability over that ofconventional DRI, whether produced byEnergiron plants or other processtechnologies. In general, High-CarbonDRI is more stable than conventionalDRI. This has been proven in specifictests that were performed for DRI beingproduced at the Ternium 3M5 plant,before and after its conversion to the

ZR Process scheme. Since stabilityitself is not measured but ratherreactivity of the product in three distinctenvironments, tests were conducted inthe presence of air, air plus water andair plus salt water to determine whichtype of DRI is more stable. The testresults indicate that reactivity to air,water and salt water is significantly lessover time for DRI containing highpercentages of carbon as iron carbide.Currently, all or most direct reductiontechnologies carry out reductionreactions at very high temperatures –from 920 to 980 °C. The high reductiontemperature is one of the factorsdetermining the DRI stability.Nevertheless a more significant factor is the carbon content of DRI. DRI,which has high levels of carbon in theform of iron carbide or cementite, formsa quality of DRI pellet which, while stillrequiring proper handling procedures, is much safer than ever before.

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Energiron plants

Energiron plants are designed formaximum savings in both investmentand operating costs. Multiple reductionreactors can share a common reducinggas source. Auxiliary systems andmaterials handling equipment can becommon to several modules. With theZR process configuration, furthereconomies are obtained based on thesmaller overall plant size and equipmentrequirement.

Micro-moduleThis basic plant design concept wasdeveloped specifically for marketswhere small volumes of DRI areneeded, and where coal-basedtechnologies have until now been theonly option. The highly functional, no-frills version of the traditional plantprovides the highest quality DRIavailable to companies requiring annualcapacities in the range of 200,000 tpy.

Mini-moduleThis is the optimum sized DR plant forthe typical steel mill producing qualityproducts. It’s a 500,000 tpy DR plantwith the reliability and quality for whichHYL is renowned. A totally re-engineered DR module,designed with the latest technologysuch as reformerless (ZR) reduction andproduction of High Carbide Iron. The Mini-Module takes advantage ofmodular design for a constructionschedule that means shorter projectimplementation and a faster startup.

Custom modulesEnergiron plants can be designed toincorporate a variety of technologies,depending on the particular needs of aclient or project. Plant capacities canrange anywhere up to 2.5 Mtpy in asingle reactor, to multiple reactor plantsof several million tons per year capacity.

Micro-module0.2 Mtpy

Mini-module0.5 Mtpy

Custom modules0.5 Mtpy / 2.5 Mtpy

Next challenge3.0 Mtpy

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

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

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Plant and process economics

Both capital and operating expenses for Energiron plants are extremely low.For equivalent production capacity, aZR plant requires barely half the landarea needed for other processes. And because the process ispressurized, overall equipment sizes are smaller, for even greater savings.

Operating expenses are low as well,given the flexibility to use lower-costores, the inherent low gas and powerrequirements, and the best ore to-product yield of any DR process (1.38 tscreened). These savings in energyrequirements and also raw materialconsumption amount to a significantadvantage for the Energiron technologyof more than US$ 10 per ton in loweroperating expenses. For a million tonper year plant, that means US$ 10million savings every year.The composition, final quality and costof any DRI is dependent on the qualityof the iron ores used for reduction.

Energiron plants offer the flexibility tooperate with a wide variety of oxidepellets, lump ores or mixtures of both.This flexibility includes the possibility

of using low grade iron ore feedstocks,an advantage in places such as Chinaor India where huge amounts of iron oreare available, but with high percentagesof silica and alumina.There is no practical limitation regardingthe chemical composition of the ironore. In particular since gas is notrecycled back to a reformer, theprocess is very flexible for using highsulfur iron ores.

Moreover, due to the lower gasvelocities through the reactor, the use of hydrogen-rich gases and themechanical system sealing devices,

the use of friable lump ores can bemaximized. Maintenance costs are also minimal.

Low maintenace costsThe HYTEMP® system has virtually nomaintenance at all, unlike mechanicalsystems with lower availability.

By-product incomeEnergiron is the only technology thatoffers an additional revenue sourcebeyond the DRI product. CO2 captureand sale to off-takers is a lucrativebusiness, providing millions of dollars inannual income to the DR plant operator.

The overall smaller size of the equipment and land required, alongwith the possibility to use any gas and iron quality,optimum yield andminimum maintenancelead to the lowest marketcapital and operationalexpenses.

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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 sourceto atmosphere and sold to off-takers

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

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Energiron process

General process schemeThe Energiron Direct Reduction Processis designed to convert iron pellet/lumpinto metallic iron by the use of reducinggases in a solid-gas moving bed shaftfurnace. Oxygen is removed from theiron ore by chemical reactions based onhydrogen (H2) and carbon monoxide(CO), for the production of highlymetallized DRI. The technology offersthe flexibility to produce three differentproduct forms, depending on thespecific requirements of each user.

Reducing gases can be generated:- directly, by in-situ reforming of naturalgas inside the shaft furnace,- in an external natural gas/steamreformer, - from gasification of fossil fuels,biomass, etc., as Syngas- from Coke Oven Gas (COG) sources.

In all the above cases, the processconfiguration corresponds to the samebasic proven Zero Reformer (ZR)scheme, adjusting the relative sizes ofequipment for the particular application.For both the in-situ and steamreforming schemes, natural gas analysis(heavy hydrocarbons content) is not alimiting factor.One of the inherent characteristics of

the Energiron process scheme and ofhigh importance environmentally is theselective elimination of both by-products generated from the reductionprocess; water (H2O) and carbondioxide (CO2), which are eliminatedthrough top gas scrubbing and CO2

removal systems, respectively.

Direct use of natural gasThe Energiron ZR process is a majorstep in decreasing the size andimproving the efficiency of directreduction plants. Reducing gases aregenerated in-situ in the reduction shaft,by feeding natural gas as make-up tothe reducing gas circuit.

Since the reducing gases are generatedin the reduction section, optimumreduction efficiency is attained, andthus an external reducing gas reformeris not required. Therefore, the overallenergy efficiency of the ZR process isover 80%, optimized by the in-situreforming inside the shaft furnace, sincethe product takes most of the energysupplied to the process, with minimumenergy losses to the environment.

The impact on plant size of eliminatingthe external gas reformer is significant.For example, a plant of 1-Mtpy capacityrequires only 60% of the area neededby other process plants for the samecapacity. For additional capacity, thearea required is proportionally smaller incomparison. This also facilitateslocating the DR plant adjacent to themeltshop in existing operations. Thisplant configuration has been operatedsuccessfully since 1998 with theTernium DR 4M plant, and also wasincorporated in 2001 to the 3M5 plant,both at the Ternium steel facility inMonterrey, Mexico. The Energiron ZRplants in Egypt and in the USA are afurther reference for this innovativetechnology.

A remarkable advantage of this processscheme is the wider flexibility for DRIcarburization, which allows attainingcarbon levels up to 5%. This is due tothe improved carburizing potential ofthe gases inside the shaft, which allowfor the production primarily of ironcarbide.

Reformed gas, Syngas, COGEnergiron plants can also use theconventional steam-natural gasreforming equipment, which has longcharacterized the process. Otherreducing agents such as hydrogen,gases from coal, pet coke and similarfossil fuels gasifications, and coke ovengas, among others, are also potentialsources of reducing gas, depending onthe particular situation and availability.

This flexibility is made possible preciselybecause the Energiron ZR Process isindependent of the reducing gassource, with no requirement torecirculate gases back to a reformer tocomplete the process chemistry loop.Several projects are currently underdevelopment that will use coke ovengas as the reducing gas source, andprojects using gas from coal gasificationtechnology are also underway.

ReductionInside the shaft furnace vessel, hotreducing gas is fed to the reductionzone and flows upward counter-currentto the iron ore moving bed. The gas distribution is uniform andthere is a high degree of direct contactbetween gas and solids. The exhaust reducing gas (top gas)leaves the reactor at about 400 °C andpasses through the top gas heatrecuperator, where its energy isrecovered to produce steam, oralternatively to preheat the reducing gasstream, and then through thequenching/ scrubbing system.

Energiron is the uniquedirect reductiontechnology that, with the same processscheme configuration, lets you choose the best energy source:natural gas, reformed gas,syngas from a coal gasifieror even coke oven gas,without any modification.

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O2

H2Oremoval

Humidifier

DRreactor

DRI

Iron ore

FiredHeater

Fuel

DRP Tail gas

Top gas heatrecuperator

NGSyngasReformed gasCOG

CO2removalsystem

Cooling

Process GasCompressor

DRreactor

Sinter plant Coke ovenplant

Coal

COG

Coke

Blast FurnacePCI

LumpPellets

HM

Power plant

BFG

BOFG

to in-plant users

Importedscrap

Coolantscrap

Recycle scrap

BOF Steel plantwith treatment

Slab Caster plant

HM desulphurization

DRI

Iron oreENERGIRON DR plantflowsheet for integrated ironmaking plant.

Standard ENERGIRONprocess flowsheet.

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In these units, water produced duringthe reduction process is condensedand removed from the gas stream andmost of the dust carried with the gas isalso separated. Scrubbed gas is thenpassed through the process gasrecycle compressor, where its pressureis increased. Compressed gas, afterbeing sent to the carbon dioxideremoval unit, is mixed with the naturalgas make-up, thus closing the reducinggas circuit.

The furnace operates at a pressure ofaround 7 bar absolute allowing a highreactor productivity of about 9 tph perm2. This results in much higherproduction volumes, of more than 2.5Mtpy in a single module whencompared to ambient pressuresystems. The pressurized operationalso minimizes dust losses through topgas carry-over. This is reflected in lowiron ore consumption, which keeps the

operating cost low. Removal of oxygenfrom the iron ore is accomplished bythe action of the hot reducing gasesand then the product is carburized. Arotary valve, located at the bottom ofthe vessel, regulates the continuousgravity flow of the charge downwardthrough the reduction furnace. DRI isdischarged by automated mechanisms,consisting of pressurized bins andlocks. Specially designed flow feedersinsure the uniform flow of solids withinthe shaft. For cold DRI, a cooling gas isfed to the lower conical part of thefurnace at about 40 °C, flowing upwardcountercurrent to the DRI moving bed.The gas distribution is uniform andthere is a high degree of direct contactbetween the gas and solid, withoutphysical restrictions to the flow of solidsor gases inside the unit. The cooling gas exits from the upperconical part, at about 460 °C, and isthen quenched/scrubbed by means of

cooling water. Scrubbed cooling gaspasses through the cooling gas recyclecompressor to be recycled to thefurnace, after being made-up withnatural gas. Natural gas is injected asmake-up to the cooling gas circuit foroptimum efficiency and control of thecooling and carburization processes.For hot product discharge and use, thecooling circuit is eliminated and hot DRIis continuously discharged at > 700 °C.For the HYTEMP® pneumatic transportsystem, the product is transported bymeans of a carrier gas to the surge binslocated at the meltshop, for a controlledfeeding to the electric arc furnace.For production of HBI, hot DRI iscontinuously discharged at > 700 °C to the hot briquetting machinesarranged below. The HBI is cooled in vibrating coolingconveyors using cooling water and thendischarged to the HBI transportconveyor.

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The HYL HYTEMP®

system

An additional technology that, on itsown provides significant benefits forsteelmakers, is the HYTEMP®

pneumatic transport system for sendinghot DRI from the reduction reactor tothe EAF shop. When combined with theEnergiron ZR Process, the benefitsincrease substantially by bringing hot,high carbide iron to directly feed themelting furnaces. The HYTEMP®

system involves an Energiron hotdischarge direct reduction reactorconnected to an adjacent electricfurnace mill by means of a pneumatictransport system. HYTEMP® iron is DRIproduced at high temperature (700 °C)and which is pneumatically transportedfrom the reactor discharge to themeltshop for direct feeding to the EAF.In this manner, the energy value of thehot DRI is capitalized in the EAF.

This process scheme offers the mostadequate arrangement for integratedsteelmaking facilities due to theimportant benefits capitalized in theEAF. Hot DRI is sent to the meltshop,where it is temporarily stored ininsulated inert storage bins for feedingto the furnace by continuous injectionmechanisms which deposit the materialdirectly in the metallic bath surface.

Currently the Ternium Monterrey 4M,Emirates Steel and Suez Steel DRplants produce hot-discharge DRI,

Virtually maintenance-free and with no fines normetallization losses, thelow OpEx HYTEMP® inertpneumatic charge systemallows safe hot DRI feedand energy savings intothe EAF.

HYTEMP® DIRECT CHARGE

INTO THE EAF

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using the HYTEMP® system for hot DRItransport to the meltshop. Cold DRI isalso produced via an external cooler ifrequired. The product is transported to thefurnace by means of a carrier gas, via the interface bin where the carriergas is separated from the hot DRI and where depressurization also takesplace. Hot DRI is discharged to the EAF surge bin, which feeds the EAF. The carrier gas is separated from the hot DRI in the pressurized interfacebins, and it is passed through a quenching/scrubbing system forcooling and cleaning. Then, the carriergas is recycled to the pneumatictransport circuit by means of therecycle compressor, thus closing thepneumatic transport loop.

According to the particularrequirements of the steelmakingfacilities, an off-line discharge for DRIcooling can be used during EAF

downtime, or an external cooler can beincorporated for cold DRI production, or a briquetting machine can beinstalled in case that part of theproduction is being sent for export.As the DR plant designed for HYTEMP®

iron production is linked to steelmakingfacilities, the reactor tower, pneumatictransport system and EAF feeding binscan be arranged in the most adequatelayout to minimize distances and tomatch the continuous DRI output withthe batch consumption of themeltshop.

The HYTEMP® system was not only the first successful continuous hot DRIcharging system, having been inoperation since 1998, but it is easily the most efficient and productive, withno fines losses from the system.HYTEMP® is virtually maintenance-freewith no recorded downtime in any ofthe plants using the system since it firststarted up over 15 years ago.

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Energiron and steelmaking plant integration

Energironimproves steelmakingThe virtual absence of residual elementsmakes DRI the ideal complement toEAF scrap charges, as well as therecommended charge material forproducing most high grades of steel.Additionally, DRI and HBI serve asquality metallic sources for blast furnaceand BOF shops. DRI can becontinuously charged for even greateradvantages. The use of this qualityfeedstock in the EAF provides numerousadvantages in steelmaking, including:

_ Greater uniformity and predictability;_ Better slag foaming;_ Increased efficiency and productivity,especially when using High-Carbide DRI;_ Lower total steel cost.

The perfect integration between thedirect reduction plant and the meltshop,achieved through the combination ofthe HYTEMP® system and a properlydesigned EAF, is presently a provenconcept as previously indicated.

In particular, when DRI with atemperature of 600 °C is directly meltedin the EAF, all the thermal energy of theDRI, discharged hot from the DirectReduction Reactor, is completelyrecovered in the EAF. Immediatebenefits are recorded at the melt-shopin terms of both electrical energyconsumption and tap-to-tap time, ifcompared to the traditional solutions of

charging only cold DRI. For example inEmirates Steel Industry Phase 1&2plants, feeding the EAF their typical mix(90% hot +10% cold DRI), it is possibleto save about 26 kWh/tls for every 100°C increase in the DRI temperature.

Together with the savings in electricity,the EAF productivity increases with theDRI temperature. The tap-to-tap timedecreases about 5% and theproductivity increases accordingly perevery 100 °C increase in the DRItemperature. For this reason, when DRIwith a temperature of 600 °C is meltedin the EAF, the savings in powerconsumption are up to 141 kWh/tLSwith an increase in productivity of up to22% for a practice of 90% hot+10%cold DRI.

Further benefits can be achieved byusing high-carbon hot DRI in meltshop

operations, as also widelydemonstrated in the Ternium MonterreyEAF. The diagrams show the effect ofDRI temperature inside the EAF, whenusing 100% DRI feed. Data are takenfrom industrial installation records,sorted by DRI average metallization,with a carbon content consistently inthe range of 2.2 to 2.5%.

Effect of high carbon (as Fe3C)Chemical energy contributionThe conversion of Fe3C into iron andcarbon is an exothermic reaction whichimproves the thermal efficiency in theEAF, by means of oxygen injection to the furnace.

Efficient use of carbon in EAFThe combined carbon is totally used,minimizing external carbon (graphite)additions, since it is a part of the DRIbeing fed.

Wide technology and fieldexperience in DRI andelectric steelmaking lead to the most efficienttechnical solutions for acompetitive high qualityliquid steel production.

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Pow

er-O

n Ti

me

(min

/hea

t)

DRI Temperature (°C)

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60% DRI 2.2 %C, 25 Nm3/tls

60% DRI 4.0 %C, 42 Nm3/tls

100% DRI 2.2 %C, 25 Nm3/tls

100% DRI 4.0 %C, 42 Nm3/tls

Higher stability during handlingIron carbide is more stable and is saferto be stored and transported.

Easy foamy slag generationAs high carbon DRI enters in contactwith free or combined oxygen.

The future of integratedsteelmakingEnergiron direct reduction plants havereached a stage where they canconceivably compete with thetraditional integrated steel mill in termsof size and production capacity. Theconventional wisdom has been that foran integrated mill, capacities of blastfurnace ironmaking need to be greaterthan 2 Mtpy of hot metal. Below thatlevel, the capital cost associated withthe BF/BOF installation would be toohigh on a per-ton of steel basis. Whilefew new integrated mills have been builtin the past decade or so, most havebeen in the range of 2 to 3 million tonsper year of hot metal. Today’s state-of-the-art EAF mill, with the use of oxygenlancing and carbon input (either fromcoal or graphite, or from high carbonDRI from Energiron plants) relies moreand more on chemical energy as wellas electrical energy. Using low residualmetallic feedstocks, including DRI orHBI, allow EAF mills to produce thesuperior steel grades demanded bysuch users as automotive, special andtool steels that were previously onlypossible in integrated mills. So in termsof quality, the DR-EAF route is certainlynot limited to producing simplycommercial steel grades. Add to thisthe ability to now produce DRI incapacities exceeding 2.5 million tonsper year, and coupling this type of plantwith a modern EAF meltshop, we caneasily see a new type of “integrated”mill for the near future: a high volume,integrated DR-EAF mill, capable ofcompeting in both quality and cost.

The diagrams show the effect of DRI temperature inside the EAF,when using 100% DRI feed. Data are taken from industrial installationrecords, sorted by DRI average metallization, with a carbon contentconsistently in the range of 2.2 to 4.0%.

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

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Advanced automation systems

The Energiron Direct Reduction Processcombines different and complexphysico-chemical processes that haveto be optimized to yield the desired setof chemical reactions and heat andmass exchanges among the variety ofgaseous, liquid and solid phases. Forthis reason, a complete automationsystem is provided that uses the latestavailable technology in the field ofprocess controllers, softwarediagnostics, high availability and fail-safe features.The Energiron control system is basedon an architecture consisting of atraditional Level 1 system for equipmentcontrol with a Distributed ControlSystem, plus a new Level 2, not only forprocess supervision, data tracking andcreation of production reports but alsoprocess optimization.A “Process Reconstruction Model”(PRM) has been developed. It usesinstrumentation signals coming from thePLC and physical equations in order toprovide a full description of the plantstatus. In this way it is possible tocalculate many normally unmeasurableitems such as the top gas compositionand relevant red/ox ratio.

Another target of this PRM is theProduct Quality Prediction; starting fromthe gas composition measured by themass spectrometer, we can predict withsufficient lead time (from 6 to 10 hoursbefore the material is discharged) thecharacteristics of the product, such asmetallization, carbon content and DRItemperature. As a consequence theprocess engineers have a consistentmargin in terms of time to adjust theprocess parameters in order to reachthe desired production both in terms of quality and quantity.

Further innovative Level 2 functionalitiesbased on the Extended Kalman FilterEstimator and the Linear QuadraticGaussian Regulator for calculation ofthe optimal Level 1 set points as afunction of the Level 2 requested inputswill drive the future development of theadvanced DR Process control.

Energiron plants benefitfrom an advanced L2production and qualitycontrol automation systemdeveloped over decades of process know how andresearch.

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Energironand the environment

Energiron plant emissions are inaccordance with the most stringentenvironmental regulations anywhere.This is achieved in large part due to theprocess itself; while other processesrequire heat recovery equipment thattends to increase the NOx levels,Energiron technology is efficient bydesign due to its process configuration.Thus, while achieving high overallthermal efficiency in the plant, there isno significant need for preheating thecombustion air to high temperatures inthe reformer (when used) or in theheater, thus eliminating the possibility ofhigh NOx generation. The NOx emissioncan be additionally reduced byadopting ultra-low NOx burners; in thiscase, the NOx emission can bereduced to values below 25 ppmv (50mg/Nm3 as NO2).A further improvement can be obtainedwith the application of SCR technology,which can be easily installed in existingconvective sections of the heater orreformer. The NOx is reduced to N2 bycatalytic reaction with a commercialsolution of NH2. The evident benefit isthe reduction of NOx emission to valuesbelow 10 ppmv (20 mg/Nm3 as NO2).

Energiron is, without question, thecleanest DR technology available.Depending on the configuration, anEnergiron plant can remove from 60 to90% of total CO2 emissions, which in

Because of the uniquefeatures of this technology,significant achievementshave been reached in terms of greenhousegas emissions and in the reduction of air pollutants like NOx and SO2.

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other technologies are flared or ventedto the atmosphere. Energiron plantsoffer the unique option of selectiverecovery of CO2, which can be cleanedand sold as a cash by-product. The CO2 absorption system not onlycaptures the CO2, but also the sulphur,whenever present in the process gasstream, reducing the overall SO2

emission from the plant by around 99%.

The high operating pressure of theEnergiron shaft and its low gasvelocities, and thus low fluidization anddragging force, results in less finescarry-over by top gas (<1% losses intop gas). This low loss of iron ore finesfrom the reduction process means lessparticle emission, as fines normally haveto be cleaned from the recycle gasstream.

Another advantage of the Energironplant is the possibility to design theprocess for a zero make-up waterrequirement. This is possible mainlybecause water is a by-product of thereduction reaction and it is condensedand removed from the gas stream. As aconsequence, adopting a closed-circuitwater system, based on the use ofsea/river water heat exchangers insteadof conventional cooling towers, there isno need for fresh make-up water andactually a small stream of water is leftavailable at battery limit. This feature isparticularly attractive for locationswhere the water is expensive or notavailable at all.

Emissions

NOx with Ultra Low NOx burners 50 - 80 mg/Nm3

NOx with Selective Catalytic Removal 10 - 50 mg/Nm3

CO 20 - 100 mg/Nm3

Dust from heater/reformer stack 1 - 5 mg/Nm3

Dust from material handling dedusting 5 - 20 mg/Nm3

Carbonin product(DRI/HBI;C=3.5%)

24%

Carbonin non selectiveemissions

31%

Carbonin selectiveemissions

45%

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

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The Energiron alliance offers the uniqueflexibility of providing everything from a basic technology package to fullturnkey projects. Our support runs fromprocess technology through operationsand maintenance training and technicalassistance, not only in the DR plant butin the steel shop as well.In addition to technology licensing and conceptual engineering, we providemaintenance and operations training,project and erection supervision,support during startup andcommissioning, and a wide range of technical services after startup. Our own qualified operations andmaintenance personnel can even takecharge of the operation of a DR facilityon a contract basis, if requested.Our technical staff has years ofexperience providing training andtechnical assistance for meltshop and steel mill personnel, with unequaledsuccess in raising productivity levels in all areas, whether or not the steel millis a DRI-based operation.From mining, pelletizing and materialshandling to steel mill operations andmaintenance, computerized processcontrols, and even includingadministrative and commercialfunctions – we provide technologiesand services for all areas of ironmakingand steelmaking.

Global project execution

From basic design throughmanufacturing, projectmanagement andconstruction and throughto plant startup andcommissioning,the Energiron teamassures a successful resultin terms of time, qualityand costs.

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Quality manufacturing

equipment, flow feeders, rotary valve,expansion joints, and sealing valves) tosteel structures and pipework.To speed-up construction activities,complete material handling systemscan be produced and pre-assembled in our workshops before delivery to theproject sites. Select qualified externalworkshops cooperate in the successfulexecution of the jobs.

Employee involvement, quality beliefand structured management form thebasis of our manufacturing culture,which is widely recognized by the steelcommunity.

Danieli and Tenova firmily believemanufacturing is a key factor for awinning project execution and assuringoverall competitiveness.Quality procedures and internationalcertifications are the basis for thesuccess in the production of the coreequipment. Our workshops andassembly facilities in Europe, China,Thailand, India and the Americas allowus to optimize the sourcing of qualityraw materials and to take advantage ofthe most competitive specific skills andmanpower. The manufacturing capacityranges from the core area equipment(reactor, process vessels, thermal

The manufacturingcapacity of the Energironpartners, Danieli andTenova, assures qualityand on-time delivery of the main technologicalequipment through in-house and controlledfacilities.

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The worldwide presence with ownhandling and transportation equipmentand through specialized and trainedpeople covers full services from soilimprovement, civil works, material andequipment handling, electromechanicalinstallations, piping prefabrication, HVAC.

The gained experience proved to be avaluable asset in different socio-culturalenvironments and was developedduring many decades of site activitiescarried out all over the world.

Energiron has the furtheradvantage of aninternational constructioncapability within thealliance, allowing aconstant know howtransfer from engineeringphase to constructionand commissioning phase.

Construction capability

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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 towercrane, an ideal flexible solution for on-site construction of heavy DRP or meltshop equipment.

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Customer trainingand assistance

Energiron Technical Assistance andServices are jointly provided by Danieliand Tenova.During the project execution phase, the assistance to the client is mainlydevoted to Multilevel Theoretical andPractical Training, with classroom andhands-on activities both in similarEnergiron plants and in the same plantunder execution.The future plant operators andmanagers are accompanied through a training course which covers acomplete set of topics for eachtechnical and managerial specializationto assure a deep knowledge of theEnergiron technology and to developthe skills necessary to maximize theproductivity and profitability of the DRIplant. The range of after-sales activities coversManagement Consulting, RemoteAssistance Services, Production andMaintenance Service Agreements.Original Spares and Refurbishments are assured through the constantinteraction between the plantmanagement and the Energiron ServiceTeam. Dedicated preventive andpredictive maintenance tools andwarehouse management software can be provided to plan efficiently thespares resources according to thedifferent necessities of each Energironplant.

Capacity enhancement and EquipmentTechnical Improvement analysis can beprovided to the customers to let themexploit the latest technological state ofthe art.The success of the Customer isour pride.

Partnership and customerservice are at the basis of the services offeredalong with Energiron direct reduction plants.Personnel training, on-line/on-field assistance,original spare parts.

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Emirates Steel - ES1Integrated steel plant

_ 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 - ES2Integrated steel plant

_ 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

_ Location: Ain Soukna, Egypt_ Original design capacity: 1.9 Mtpy _ Energiron III (with external reformer)_ Cold discharged DRI:

93% metallization and 3% C

Most recent projects

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2.0 Mtpy

2.0 Mtpy

1.9 Mtpy

Suez Steel Company - SSCIntegrated steel plant

_ 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

_ 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 - JSPLIntegrated steel plant

_ 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

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1.95 Mtpy

2.5 Mtpy

2.5 Mtpy

ENERGIRONTHE INNOVATIVE DIRECT REDUCTIONTECHNOLOGY

ENERGIRONTHE INNOVATIVE DIRECT REDUCTIONTECHNOLOGY

Danieli headquartersVia Nazionale, 4133042 Buttrio (UD) ItalyTel (39) 0432.1958111Fax (39) 0432.1958289www.danieli.cominfo@danieli.com

www.energiron.com info@energiron.com

Tenova HYLAv. Munich 101San Nicolás de los Garza, N.L.66450 MéxicoTel (52) 81.8865.2801Fax (52) 81.8865.2810www.tenova.comhyl@tenova.com