BHUBANESWAR INSTITUTE OF INDUSTRIAL TECHNOLOGY

Seminar onHYL Process

Presented by Ghanesh Kumar Mahanta

Branch-Metallurgical and Materials Engineering

Registration no-1001365015

IntroductionThe HYL process was developed by Hojalata y Lamina S.A. (HYLSA) of Monterrey, Mexico in the HYL process, lump ore and fired plates are produced in the fix bed retorts by performed natural gas.

The first commercial HYL plant was installed at Monterrey and started production late in 1957.

Why HYL

There are many process are there for production of DRI like MIDREX Process, Rotary Klin Process etc.

Generally all process are used the coal for reduction of iron ore.

In substitution of coal we can use the natural gas and some fuel gas for reduction of iron ore and production of DRI commercially in HYL.

What is DRI

DRI is the Direct reduction of Iron Ore by some reductant.

The Reductant may be the Solid or Gas.

Depending upon the Reductant Process are differents.

Different Process

ReductantNon-Coking Coal

ReductantNatural Gas,Gassified

Coal

DRI/HBI/HDRIGas Based Process

DRI

TechnologyShaft Furnace (Moving Bed)

1. Midrex 2. HYL-III

3. NSC 4. Iron carbide

5. Ghaem 6. Circored

TechnologyKiln Process

1. Krupp Rein 2. Krupp CODIR

3. SL/RN (Outocompu) 4. ACCAR

5. DRC

DRI vs. HBI

Two different forms of the same product:

•DRI is the traditional form, in either pellet or lumpore form

•HBI is compressed DRI Two different uses

(theoretically) :•DRI is for onsite production and

use in EAF melt shops•HBI is for commercial shipment

to customers worldwide, usually by sea

Gas Based Processes

In the gas based processes, the reduction of iron oxide is carried out by a mixture of CO & H2 at a temperature of about 750-950°C.

The reducing gas is produced by reformation of natural gas. The reformation is partial oxidation of hydro-carbons. To enhance the reformation process, normally a catalyst is used.

Major Facility in Gas Based Process

a) Direct reduction furnace b) Hot briquetting system (OPTIONAL) c) Process dust collection system d) Reformer e) Recuperator and flue gas system f) Gas scrubber and cooler g) Process gas compressors and blowers h) Water system i) Effluent treatment system

Major Facility in Gas Based Process

j) Natural gas system k) Inert gas/seal gas system l) Compressed air system m) Steam facilities (for HYL-III plant only) n) Electrical equipment o) Instrumentation p) Raw material, product storage & handling system q) Repair shop and laboratory r) Ventilation and dedusting system

Raw MaterialsSL. NO ITEM PELLET IRON ORE LUMP

1 Fe 66.57% 66.50%

2 SiO2 2.25% 0.71%

3 Al2O3 0.28% 1.66%

4 P 0.017% 0.015%

5 S 0.011% 0.005%

6 CaO 2.10% _______

7 MgO 0.08% _______

Quality of Products

SL.NO ITEM DRI HBI

1 Fe total, % 90-91 90-91

2 Degree of metallisation, %

92-94 92-94

3 Carbon, % 1.5-2.5 1.0

4 Gangue, % 3.5-4.0 3.5-4.0

5 Bulk density, t/m3

1.8 2.7

6 Nominal volume, cm3

_______ 30X60X100 or, 30X60X90

HYL Process

Reactions in HYL

3Fe2O3 +H2 = 2Fe3O4+ H2O

3Fe2O3 + CO = 2Fe3O4 + CO2

Fe3O4 + H2 = 3FeO +H2O

Fe3O4 + CO = 3FeO + CO2

FeO + H2 = Fe + H2O

FeO + CO = Fe + CO2

HYL Process Cont.

1. Pre-heating of the charge along with partial (secondary)reduction by hot gases coming out of the primary reductionstep.2. Primary reduction, where the partially (secondary) reducedcharge is further reduced by the strong reducing gas comingfrom the cooling stage.3. Cooling of the reduced charge by fresh gas which itself getspre-heated and is available for primary reduction. This stepcompletes reduction and allows controlled carbon deposition(1.5-2.25%).4. Discharging the sponge and re-charging the reactor with freshcharge to start the process all over again.

HYL II

HYL II is the Development process of HYL where (1) use high temperature alloy tube in the reducing gas reheating furnace, which permits heating the gas to the higher temperature, and (2) reduced the number of heating furnace for the original four units to two units.

In the HYL II process reducing gas (rich in carbon monoxide and hydrogen) is generated, typically by nickel based catalytic reforming.

HYL III

HYL III process, a single shaft furnace with a moving bed is used in place of the four original fixed bed reactors.

The main equipment of HYL-III comprises a DR shaft furnace, a gas reformer, and a gas reheated. The principles of operation of the furnace are similar to the midrex shaft furnace.

HYL III Process

Available Module Size

Typically HYL offers the following module sizes : i) 250,000 tpa module ii) 500,000 tpa module iii) 750,000 tpa module iv) 1,000,000 tpa module

ADVANTAGESProduct flexibility: High-C, Cold and/or Hot DRI, HBIHigher product qualityHigh-Carbon content DRIDirect use of hot DRI in the EAFFlexibility to process a wide range of iron oresHYL R & D and steelmaking supportMinimum reducing gas requirementsHigher metallic yieldLower production costUse of alternative reducing gasesLow environmental impact

Conclusion

The HYL Micro-Module is a low cost, high quality option for small steel producers or merchant suppliers to produce high quality, High Carbide Iron.The independent operation of the HYL Process has enable this dramatic reduction in DR plant size, while maintaining quality and reliability.