Setting the new standard: DR technology for North America

Setting the new standard:
DR technology for North America
P R E S E N T E D AT
DRI & MINI-MILLS CONFERENCE
NEW ORLEANS, LOUISIANA , USA
10 – 11 SEPTEMBER 2013
BY: M A R K B O E D E C K E R , P L A N T S A L E S M A N A G E R
MIDREX TECHNOLOGIES, INC.
© 2013 Midrex Technologies, Inc. All rights reserved
© 2012 Midrex Technologies, Inc. All rights reserved.
A Re-Introduction
 Midrex Technologies, Inc. - The Technology Leader in Direct Reduction
 Providing technology solutions to steelmakers around the world through practical
innovations and continuous technology improvement
 Solutions engineered for specific steelmaker needs with flexibility to achieve more
 The leading DRI process technology provider in the world. More than 60 plants operating
and even more currently under construction- including LGOK 3 & voestalpine Texas.
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© 2013 Midrex Technologies, Inc. All rights reserved
Description of the
MIDREX® NG Process
 Simple, energy
efficient closed loop
gas system.
 Iron ore reduction to
metallic (elemental) Fe
occurs in MIDREX®
Shaft Furnace
 Reducing gases
generated in MIDREX®
Reformer
 Simple design,
minimized moving
parts and unit
operations, and no
steam system results in
very high availability
© 2013 Midrex Technologies, Inc. All rights reserved.
MIDREX® Process
Simplicity
 Low pressure - less complex operation
 MIDREX® Reformer- Unique to MIDREX® Process
Eliminates need for CO2 Removal System, Process Gas Heater, steam
generation, etc.
 Fast start-up
Reliability
 Proven long term availability demonstrated by the annual production of
MIDREX® Plants worldwide –Actual Data NOT extrapolated data
 Built on State-of-the-Art technology - provides Reliable Operation,
Increased performance while minimizing capital & operational costs
 Ongoing technology development allows older plants to expand capacity
and remain competitive.
Flexibility
 Widest range of oxide pellets and lump
 Production of CDRI/HDRI without interruption of process or product
output
 3 hot transport solutions for variety of site layouts all of which minimize
fines generation
© 2013 Midrex Technologies, Inc. All rights reserved.
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MIDREX® Process

An elegant and simple process that
is proven to consistently produce
highly metalized quality product

Process gas experience allows for
use of: Natural Gas, syngas from
coal, pet coke, refinery bottoms,
coke of gas (COG) and off gases
from technologies such as COREX®
and FINEX®.

MIDREX® is the only DRI process
that provides the ability to
simultaneously produce any
combination of product types

Hotter Higher Quality HDRI with less
fines due to mechanical conveying
solution.

Less fines Produced is crucial to
CDRI & HBI yield

More flexibility than any other
process Technology available
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© 2013 Midrex Technologies, Inc. All rights reserved.
MIDREX® Shaft Furnace
 Capable of producing high quality
Iron Oxide
cold DRI (CDRI), hot DRI (HDRI), and
hot briquetted iron (HBI)
 The MIDREX® Furnace can discharge
hotter with less oxide coating producing higher temperature HDRI
and export quality HBI
Upper Seal Leg
 Low pressure inherently safer -
operation allows gravity feed into and
out of Shaft Furnace without
requiring lockhoppers
 Packed bed reactor design results in
Top Gas Outlet
Reducing
Gas
Inlet
high efficiency and productivity.
 Higher and more consistently
metallized DRI produced due to
uniform solids flow and gas flow
inside Shaft Furnace.
DRI
© 2013 Midrex Technologies, Inc. All rights reserved.
MIDREX® Reformer
 Proven Reliable
Operation &
Dependable
Performance
 Very high reforming
rate of CH4, CO2, and
H2O into CO and H2.
 The MIDREX® process
can handle any Natural
Gas source regardless of
sulfur or heavy
hydrocarbon content
Reaction
CH4 + CO2  2CO + 2H2
CH4 + H2 O  CO + 3H2
© 2013 Midrex Technologies, Inc. All rights reserved.
Heat
Endothermic
Endothermic
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Description
CO2 reforming
H2O reforming
MIDREX® Reformer
the best use of NG for DRI Production
 Not a typical steam
reformer
Flue Gas Collection Header
 MIDREX® Reformer-
Reducing Gas Collection Headers
Reforms natural gas and
CO2
 Eliminates need for CO2
Removal System, Process
Gas Heater, steam
generation, etc.
 Tubular type reformer,
specifically designed to
operate at low pressure
Reformer Box
Feed Gas / Air / Top Gas Fuel Headers
© 2013 Midrex Technologies, Inc. All rights reserved.
MIDREX® Environmental
 MIDREX® Plants are designed to minimize water, noise and air pollution.
 MIDREX® Plants meet applicable US standards and more importantly, Midrex will
provide DR Plants designed to meet any local emissions or environmental standards
regardless of location.
 Environment – setting the standard. The voestalpine Texas HBI plant will be the most
environmentally conscious HBI plant in the world; including control for dust emissions
and air emissions.
 Full range of Technologies/Innovative Equipment to handle Dust, reduce emission and
improve water quality and maximize water usage/ recycle.





Ammonia removal systems
Baghouse Charge hopper dust collection
De-Sulfurization systems
Innovative burner systems to reduce NOx emissions/lower CO emmisions
Sea Water Heat Exchangers to minimize water consumption
© 2013 Midrex Technologies, Inc. All rights reserved.
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MIDREX® CO2 Capture
 When there is a market to sell CO2 – very site specific for
large quantities of CO2
 Addition of CO2 capture will give clients up to 20%
additional production
 Midrex has experience with VPSA, PSA and Ammine-
based CO2 removal systems
 System can be taken offline without stopping production
© 2013 Midrex Technologies, Inc. All rights reserved.
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voestalpine Texas HBI Plant
Project to use MIDREX® Technology for 2.0
MTPY HBI facility

Annual capacity of two million tons of hot briquetted iron
(HBI)

The largest single HBI producing Plant in the
world

Most environmentally conscious HBI Plant to date;
incorporates the latest air & dust emission technologies

The consortium of Siemens and Midrex will provide
engineering, supply of mechanical and electrical
equipment as well as site services for the MIDREX® Plant.

Designed with considerations for future CO2 capture
“With Siemens and Midrex, we will have highly competent partners with a tried and tested technology at our side.
By choosing a U.S. partner company, we are also making a significant contribution to the desired local value added,”
- Wolfgang Eder, CEO and Chairman of the Management Board of voestalpine AG.
© 2013 Midrex Technologies, Inc. All rights reserved.
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DRI for the sake of Steelmaking
A balanced system.
Each unit operation is sized to fit the others.
Mining
Ore
preparation
Ironmaking
(DRIorBF)
Steelmaking
(BOF or EAF)
Casting
Rolling
Finishing
A system with a bottleneck at the Ironmaking stage.
All ensuing operations are restricted by the shortage of capacity at Ironmaking and you, the owner,
are left paying for all fixed and related costs of the down unit, loss of profits AND possibly a down
stream customer!
Mining
Ore
preparation
Ironmaking
(DRIorBF)
Steelmaking
(BOF or EAF)
Casting
Rolling
Finishing
= Missed Expectations, Non-Productive Assets , Labor and Other Fixed Costs, + Lost Profits
© 2013 Midrex Technologies, Inc. All rights reserved.
Plant Performance
Measured in Actual Results
80 hours of total unscheduled down time
between both modules in 2012
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© 2013 Midrex Technologies, Inc. All rights reserved.
MIDREX® Innovation/Results
The three newest MIDREX® Plants in MENA Region have notably
outperformed the three newest plants by a competing technology
MIDREX®
120%
high pressure
technology
Capacity Utilization
110%
100%
90%
80%
70%
60%
50%
2011
2012
A
94.3%
108.5%
B
110.4%
96.8%
C
97.7%
97.6%
© 2013 Midrex Technologies, Inc. All rights reserved.
A
80.4%
74.3%
B
80.0%
89.8%
C
55.4%
75.1%
MIDREX® Innovation/Results
 40 years of the Technology improvement
 MIDREX® Plants built 30 years ago are producing double capacity.
 MIDREX® Plants hold the yearly production records for shaft furnace-based
production of HDRI, HBI and CDRI.
© 2013 Midrex Technologies, Inc. All rights reserved.
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The New Age of DRI
 The growth and increasing sophistication of the world steel industry has created an
escalating demand for higher quality iron products.
 Shale Gas in North America, growing movement for DRI
 Lack of low cost NG in certain regions is driving new DR technologies solutions to
utilize coal and coke oven Gas
 New applications for DRI usage being
adopted by the Integrated industry
 Environmental benefits
 Requirement for Advanced Technology that
solves immediate solution while positing
companies for the future
© 2013 Midrex Technologies, Inc. All rights reserved
Designed for Today,
Engineered for Tomorrow™
Thank you
Visit www.midrex.com for more technical presentations
and the 2012 World Direct Reduction Statistics Booklet
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© 2013 Midrex Technologies, Inc. All rights reserved.
© 2013 Midrex Technologies, Inc. All rights reserved.