DRI UPDATENOVEMBER | 20200

Editorial

Dear Readers,
We are once again presenting the new edition of our in house magazine “DRI UPDATE”. In our previous
edition of September, 2020, I have given a rough sketch of iron ore scenario and expressed my worries
about the shortage of iron ore and its impact on DRI and steel industry. If we look into the AprilSeptember, 2020 production scenario from these mines , there was hardly 4 million tonnes production compared toabout 36 million tonnes corresponding to the previous period of last year. Therefore, there was a gap of 32 million
tonnes from these mines. In spite of this gap, shortage of iron ore was not felt too much because of various reasons
like lack of steel demand, existing inventory with DRI and steel producers, additional production of non auctioned
mines and auction of iron ore fines by SAIL etc. However, with the improvement of steel demand and inventory dryup, producers are now facing acute shortage of iron ore. SIMA has been drawing the attention of the state andcentral authorities about this situation and its likely adverse impact on DRI and steel production in the country. If thissituation continues to persists, I am afraid we will lose the tag of world’s largest DRI producer and Iran will take alead over India.
Energy scenario in India is changing very fast. There is a serious discussion of exploring the possibility of increased
use of natural gas, syn gas, hydrogen gas for production of DRI and steel basically to reduce carbon footprints. Steelproducers all over the world are under pressure to be carbon neutral. We have to start thinking in this direction. It
may be mentioned here that The Energy and Resources Institute (TERI) is of the opinion that coal based DRI plants
may not have any future after 25 years. Recently, Hon’ble Union Minister of Coal has stated that India’s window forusing coal resources may last 20-30 years.
In this edition we have mentioned the DRI and steel scenario from April – September, 2020 which indicate that India’s
crude steel and DRI production have shown negative growth of about 21% each and steel consumption by 30%.
However, the current festival season has brought the smile on the faces of DRI and steel producers. We hope that
this scenario will continue to the rest of this financial year.

I wish all the readers a very Happy and Prosperous Deepawali.
Deependra Kashiva
Executive Director

1Coal Gasification: To Fast Track India’s Economic Prosperity
Damodar Mittal, Jindal Steel & Power Ltd. Angul
Coal is an important natural fuel resource available in India in abundance, with accumulative
total reserve of approximately 307 Billion tonnes, estimated up to the maximum depth of
1200m. India has the world’s 3rd largest coal reserve.
India is presently dependent upon imports to meet its requirements of metallurgical Coal,petroleum and natural gas. However, the abundant reserve of thermal coal in India has thepotential to meet all of its energy requirements.
In India, historically coal has been used for its Thermal Energy properties only. However, coal canbe and should be used for its Chemical properties also to produce more value-added
downstream organic and inorganic products.
At present, the majority of the available Indiancoal is consumed by the power producing
units. While a small proportion is being used by
the steel & cement industry, thus producing alarge amount of CO2 and other gases,
potentially damaging the environment.
Hon’ble Prime Minister Shri Narendra Modi
during his visit to the USA in Sept 2019 told
the Bloomberg Global Business Forum that theGovernment is looking at ways to use
technology in coal gasification to ensure thatthe natural resource is used by the country in aclean and environment-friendly manner tomeet its energy requirements.
He had further said “The solution is coalgasification. By doing coal gasification we
can get clean energy. We are inviting othercountries to come with their technology foruse in coal gasification,”

Why Coal Gasification for India:
 Clean Energy Technology to Harness
Huge High Ash Coal Reserve.
 To make India “AatmNirbhar” by
Import Substitution Provide Energy
Security.
 Minimise Current Account Deficit(CAD)
 Convert Low Value Feed of Thermal
Coal to High Value Products Bring Prosperity & Development atremotely located coal mines by way
of Job creation and economic
development.

2Given the potential of
converting indigenous coal toenergy and useful chemicals,
NITI Aayog has setup a
Technical Committee to discussand suggest a roadmap withsuitable technology fordevelopment of Surface Coal
Gasification (SCG) in Indian
conditions. The committee will
also look at a suitable businessmodel for the development of
SCG in the country. The Union
Government has already set atarget to gasify 100 MT of coal
under four major projects withan overall investment of Rs
20,000 crore by 2030.
Jindal Steel & Power Ltd (JSPL)
installed state-of- the-art
and the World’s First DRI Plant(1.80 Million Tonne per Annum
capacity) based on

Mr Naveen Jindal Dreamt
of producing Steel from
Swadeshi Raw material inEnvironment friendly mannerin 2000, thus making India
AatmNirbhar“Coal Gasification technology” located at Angul-Odisha which being operated using
SWADESHI high ash non-coking coal available in abundance in the State of Odisha.
The SynGas Project at JSPL Angul started in 2007 and was commissioned in 2014 making India
AtmaNirbhar by way of Import substitution of Metallurgical Coal, thus saving precious
foreign exchange. Coal gasification is a potential long-term solution to India’s energy
requirements, in an environment-friendly manner. Adoption of this technology will immensely
help India to achieve the targets set during COP21 to reduce Greenhouse emissions by 30%. The
National Steel Policy envisages production of 300 Million tonnes of crude steel by 2030 and3the success of Coal Gasification technology will create a new segment of capacity additionin India which will be based on domestic coal, thereby minimizing the need of imported coking
coal. This will also save our precious foreign exchange.
JSPL has installed Coal Gasification Plant (CGP) with technological support from M/s Lurgi– Germany. In CGP, synthesis gas (“Syn-gas”) is produced by using high ash coal as a fueland the Syn-Gas is used as a reducing agent in gas based vertical shaft kiln for making DRI.
JSPL Angul CGP - DRI Configuration: The process is named as MAXCOL Process.

Advantage of Gas Based Vs Coal Based DRI Production:GAS BASED

COAL BASED

1. Clean Technology.

1. Prone to Pollution

2. Energy Requirement is 20% less than thatof rotary kiln based plant.

2. High Energy Requirement.

3. Product suits best steel making qualities.

3. For making High quality steel additional
refining set up investment and cost to be
incurred.

4. DRI fines (-5mm) generated is 5%. Thus,
Loss in SMS are less due to low % of fines.
5. - Sulphur content in DRI is in range of
0.003-0.01% which is very low.
6. Average Metallization is 92-94%

4. DRI fines (-3mm) generated is 30-40%.
Thus, Loss in SMS are more due to highpercentage of fines.
5. Sulphur in coal is partly absorbed by DRI and
partly goes to atmosphere as SO2 contributing
to air pollution.
6. Average Metallization is 86-90%
4

Today, the world’s first CGP-DRI plant at
JSPL Angul has become a “Technology
Demonstrator”
being
frequently
quoted by industry participants, studied
across the world by various institutes of
repute including Harvard, and isfrequently visited by national andinternational dignitaries.
Various global companies have also visitedthe facility and they have shown interest,
installing similar gasification based
facility to produce DRI/HBI, Chemicals
and other downstream industries fordomestic and international markets.

Potential Forex Saving for the Country through Steel
Making:a) Forex Saving through reduced coking coal imports at
Current level of Steel Production:
 India’s current Steel Production: 110 MTPA


30% via CGP-DRI Route

Potential Forex Saving on coking coal: $3.5 Billionb) By 2030: 300 MT of Steel Production

30% via CGP-DRI Route

Potential Forex Saving: $9.4 Billion

We also expect substantial FDI in the sector as many multinational companies would like toinstall a gasification facility to produce DRI/HBI in India for domestic and international
markets. However, it is a proven fact that the success of coal gasification technology
depends strictly on coal quality and consistent supply from a single source. The performanceof gasifier is highly sensitive to the feed coal quality & certain other parameters and it
has been seen that best utilisation of this technology can be ensured by providing dedicatedlinkage of coal from a single source.
Coal Gasification Plant and use of by-products:
At Angul, the Syngas produced contains methane, carbon monoxide and hydrogen. Comparedto the coal combustion process – the CO2 emitted in the gasification process is entirely
absorbed back in to the process and the Hydrogen Sulphide emitted is entirely converted into
Sulphur production.
Hence, it ensures energy efficiency and is environment friendly. Besides, all the by–products of the Syngas plant are being recycled through internal use or by sale to external
parties. This ensures health and safety of employees as well as local communities and also
ensures environmental protection.

5 Coal can be used for its Chemical Energy and used to produce more value added
products rather using its thermal energy just for power generation
 ‘A National Policy on Coal Gasification’ should be formulated and promulgated forfaster and smooth implementation of the Coal Gasification technology.
 Coal to be made available 20% lower than Price for “Regulated Sector” (Power)
 Like GoI has offered 20% discount on revenue share for the Coal Gasification and
Liquefaction in the soon to be conducted commercial mining.
 Coal be made available from a Single Source : GoI should hold special auction of Coal Mines for Coal Gasification unit.
 GST Compensation Cess of Rs 400/MT to be waived to further promote theadoption of Gasification.
 A Senior Officer in Ministry of Coal with the charge of Coal Gasification will help theindustry and thus the national mission.

6

Angul : Coal Gasification Complex at a Glance

JSPL Angul Coal Gasification Complex: Night View

7

Gasification Unit

Gasification Unit

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8Experience and Developments of the ENERGIRON DR Technology for H2 Use
Pablo Duarte, Tenova HYL., Mexico.

Abstract
The trend of the steelmaking industry is in the direction of decarbonisation to comply not only withenvironmental regulations but with a sustainable approach for steel production. Current actions ofsteelmaking industry, as part of the decarbonisation of global and specifically Europe’s economy, is towards
intensive steel scrap recycling as part of the circular economy, and to hydrogen-based iron reduction as along-term substitute for carbon-based processes.
The ENERGIRON technology scheme (the innovative DRI Technology jointly developed by Tenova andDanieli) has been characterized by the inspiration of innovation. Starting by installing the first gas based
direct reduction in the 1950’s at industrial scale in Hylsa steelmaking facilities in Monterrey, using H2 richgas (in a ratio of H2/CO ~5) as reducing gas, incorporating selective CO2 removal for increasing processscheme efficiency while reducing energy consumption and providing practical solution for CO 2 capture andcommercialization (CCU), developing the ZR (reformerless) scheme for further process efficiency while
producing high-Carbon DRI (>3%C) since more than 20 years ago, using the breakthrough reliable Hytemp®
System for hot DRI transport and EAF feeding by environmental friendly, totally enclosed pneumatictransport, and developing schemes for intensive H2 use. This paper is focused on the benefits andadvantages on H2 use through the ENERGIRON process for Carbon Direct Avoidance (CDA) as compared toother proposals.

Introduction
As compared to the coal-based BF-BOF route, any energy source providing hydrogen (H2) andcarbon monoxide (CO) can be used as reducing agent for iron oxides reduction in the DR
process. This makes DRI-EAF (or DRI-OSBF) the best available technological solution for
decarbonisation of the steelmaking industry. The simplified process configuration when using
H2, makes the DR process very efficient in terms of energy consumption and scheme simplicity.
The expected energy consumption for the ENERGIRON DR process is reduced from 10,2 GJ/t DRI
with natural gas (NG) to as low as 6,6 GJ/tDRI with H2 for process plus additional 1,6 GJ/tDRI as
fuel and about 25 kWh/tDRI for the core plant. This exceptionally low electricity consumption is
not only because of the H2 use but also due to the high operation pressure of the ENERGIRON
system (≥6 barA @ top gas).
On the other hand, in the EAF meltshop, to overcome the negative effect of the gangue in DRI,
by feeding high-metallised, hot DRI to the EAF, the power consumption is significantly reduced

9

to figures very close to the case of 100% scrap melting, overcoming the negative effect of thegangue content in the DRI. Typical power consumption for a charge of 80% hot DRI and 20%
scrap is about 400 kWh/tLS. Feeding high percentages of DRI is required for production of highend quality steels.
Sustainable H2 generation is based on the application of electrolyzers, using power fromrenewable sources (i.e. eolic, solar PV) and eliminating carbon footprint (CDA) for ironmaking
and steelmaking (Figure 1). For this industrial application, H2 shall be generated by highefficiency electrolyzers, There are different available electrolysers technologies, such as:
Atmospheric Alkaline Electrolysers (AAE), Proton Exchange Membranes (PEM) and High
Temperature Electrolysers (HTE), being the first a mature technology in the MW range forindustrial use.

Figure 1. Carbon-free steelmaking route based on ENERGIRON ZR Process

Reduction of iron ores with H2
The gas reducing agents are CO, H2 and mixtures of both. Thermodynamics of iron oxides,
dealing primarily with equilibrium between iron oxides, CO and H2, provides the potential for a
reduction reaction to occur. This is indicated by the Gibbs Free Energy (G°):

10

Fe2O3 + 3H2  2Fe° + 3H2O

G° @900°C: -11.103,3 kJ/kg mol H2; Hrxn @900°C: +21.881,0 kJ/kg mol H2

3Fe2O3 + 2CO  2Fe° + 3CO2 G° @900°C: -8.149,4 kJ/kg mol CO; Hrxn @ 900°C: -11.401,1 kJ/kg mol CO

As observed, thermodynamically H2 reduces iron oxide easily than CO, as per change of Gibbs
free energy [2]. On the other hand, the exothermic or endothermic behavior is indicated by theenthalpy change (Hrxn) of the corresponding reactions.
Figure 2. Change of reduction degrees with time for CO:H2: 0:1; CO:H2: 1:0

Kinetically, the effect of temperature on the extent of iron ore reduction has been investigatedusing gases with different H2/CO ratios [3]. The changes of reduction degree at 1000°C for CO/H2
ratios of 1:0 and 0:1, are indicated in Figure 2. In general, the higher the temperature the fasterthe extent of the reduction process, whether the reducing agent is H2 or CO. However, thereduction of iron ore with H2 is more than 4 times faster as compared to CO; i.e. 98% reduction
in ~20 min vs. 83% reduction in 60 min at 1000°C. Reasons are:1) the equilibrium of H2 decreases with increasing temperature because it is an endothermal
reaction, leading to a higher reducing potential at high temperature, and as a result, thedriving force of the reduction reaction is enhanced;2) the high temperature contributes to a high mass transfer coefficient.
On the other hand, iron ore reduction with CO requires lower reducing gas temperature
because of the exothermal reaction behavior, and kinetically is much slower than the reduction
with H2.

11

The ENERGIRON ZR Process
The ENERGIRON ZR process, as shown in Figure 2, is a major step in reducing the size andimproving the efficiency of direct reduction plants [1]. The same ZR process scheme
configuration can be used for any application, regardless of whether using NG, H2, reformed gas
from external steam/NG reformer, syngas from coal gasifiers, or COG, depending on availability.
As indicated in Figure 2, the ENERGIRON ZR scheme can produce cold DRI (CDRI), hot DRI (HDRI)
which can be directly fed to: 1) Hytemp® System for transport and direct feeding to an adjacent
EAF, 2) to briquetting presses for production of HBI and 3) to a proprietary Tenova OSBF melter
for production of hot metal/pig iron. The latter is a breakthrough approach for production of
hot metal using NG as reducing agent, decreasing to <50% the carbon footprint as compared tothe conventional coal-based BF while keeping BOF downstream steelmaking unchanged.
Figure 2. ENERGIRON ZR Process schemeLong lasting experience with Hydrogen
Historically, the steelmaking route based on DR-EAF has always been characterized using H2. The
ENERGIRON technology using reformed gas as source of reducing gas, includes a conventional
steam/NG reformer. The off line reformer used for DR plants is based standard technology withhundreds of references in DR and hydrogen plants; there are more than 40 HYL/ENERGIRON

12

plants having used this type of NG reformers. For any reformer, H2 is produced in different
concentration, depending on the oxidants ratio being used; i.e.
CH4 + H2O = 3H2 + CO
CH4 + CO2 = 2H2 + 2CO
Typical operation characteristics for the ENERGIRON plants and for the DR competing
technology (Midrex) are shown in Table 1.
These industrial operating data reflect the long-lasting industrial experience of ENERGIRON
plants with intensive use of H2 for DRI production.
Table 1. Characteristics of reformed gas in DR technologies
ENERGIRON

Other DR
technology

H2O/C ratio in NG
Reformer

2.0 – 2.5

1.5

H2/CO ratio in
reducing gas

4–5

1.7

%H2 to reactor (%
vol.)

~70%

~55%

Parameter related to
H2

In addition to the vast industrial experience using H2, in the 1990’s, Tenova HYL carried out
extensive tests at pilot plant (Figure 3) with ≥ 90% (vol.) H2; producing H2 from reformed gas
from the industrial DR plant by water shifting and CO2 removal. The demonstration/pilot plantat Hylsa Monterrey had a production rate of 36-tonne DRI/day with all flexibilities to produce:
CDRI, HDRI for HBI production and HDRI for direct pneumatic transport to an adjacent pilot
plant EAF.
This plant also included all capabilities for synthesis of all type of reducing gases; from 100% H2
to 100% CO, including reformed gas, typical COG and gases from coal gasification. In fact, the ZR
scheme was developed and demonstrated in this facility during the 1980’s. The experimental
campaign included 15 different process conditions, depending on the DRI type and quality to beachieved.

13 For CDRI conditions, some minimum required amount of NG was injected to theconical/cooling zone of the reactor. The following results were achieved: Metallization of
94%-96%, %C content of ~1,0%. H2 has been controlled in a range of ~90% vol.
 For the HDRI, HBI was produced to prevent fast re-oxidation due to low %C. Metallizationof 94%-96% and %C obtained between 0,2% – 0,8% being the latter for the condition ofsome NG injection to the reduction circuit. H2 was also controlled in ~90% vol.
These tests provided all necessary information to define: Process and design parameters mainly related to optimized flow-temperature correlation.
 DRI quality in terms of metallization and carbon content.
 Optimization of operating pressure, reactor L/D ratio, solids residence time (), toconsistently achieve the DRI quality, determination of fluidization factor (ƒ) to ensuring
proper gas velocities and distribution through the solids bed, among others for the propergas distribution and design of the scheme for H2 utilization.
These campaigns at demonstration/pilot plant tests with highest H2 volumes providing the factthat the ENERGIRON process is already fit for the use of 100% H2, when needed. All required
data for design and operation under this condition is available and can be directly applicable toany existing and/or new DR plant installation.
Figure 3. HYL Pilot Plant tests campaigns with ≥90% (vol.) H2
A

14

Scheme with high H2 use and energy consumption figures
For the case of H2, the same ZR scheme applies. The only difference is that, for H2 utilization
higher than ~73% (energy) or ~90% vol. at reactor inlet, the scheme is simplified by-passing theselective CO2 removal system. For higher H2 concentrations, any carbon input to the system, viaNG, along with other components like N2, are eliminated through the tail gas purge from thesystem, which is used as fuel in the gas heater (Figure 4).
Figure 4. ENERGIRON ZR Scheme with H2 use
H2O

CO2

H2O

CO2

NG

H2

Scheme with partial use of H2

H2

Scheme with ≥90% vol. H2

In terms of energy consumption, the impact of H2 (figures as % of total energy input), as
compared to NG is indicated in Figure 7, showing the potential energy credit of the %C in the
DRI, when being melted in a EAF.
Figure 7. Energy consumption figures as function of NG/H2 ratios (% energy input)

15

Unique advantage for the use of H2 with high operating pressure
Unique benefits of the ENERGIRON ZR technology for the direct use of H2 is related to the highoperating pressure (6-8 bar a), which is reflected in: Gas sealing
Tight sealing is required to prevent any leak of the most diffusible gas in nature. In the
ENERGIRON DR plants, the high operating pressure is managed using mechanical sealing
for pressurization/depressurization from atmosphere. Mechanical sealing allows higher
pressure drop (P) due to friable ores and/or additional fines and is preventing any gas
leak/air intake. By this, any additional P is simply handled by the compressor instead oflower gas flow and/or decreasing production rate.
 Fluidization and gas distribution
Regarding the reduction reactor design, there are two fundamental parameters which
define the size and geometry of the shaft: 1) the fluidization factor (ƒ) and the solids
residence time (). The gas velocity of the gas inside any moving bed reduction shaft has
the following functionality:(1) VG = Vmf * ƒ = k * [FG(act) * FS * (M * T )1/2] / [ Di2 * P1/2]
where:VG is the actual gas velocity inside the shaft
ƒis the fluidization factor (<1)
Vmf is the velocity of minimum fluidization; i.e., the gas velocity
at which the solids flow is suspended
k is a function of solids and gas properties, the bed’s void
fraction and particle size distributionFG(act) = Specific reducing gas flowrate (actual cond.)
Fs= Production rateM
= Gas molecular weightT= Reducing gas TemperatureP= Operating pressureDi= Reactor internal diameter16

On the other hand, the residence time is defined as:(1)  = VR / [FS/S] = L * AR / [FS/S]
where:

is the residence time

VR, AR = volume, area of the cylindrical (reduction) areaL= the height of the reactor cylindrical (reduction) section

S= solids density

The fluidization factor (ƒ) cannot exceed a maximum value and the residence time () is
determined from experimental data, leading to the required volume (VR). Thus once M (MH2 =2),
solids properties, required reducing gas (FG) and H2 temperature (T) are fixed, the only variables
to optimize the reactor design are: diameter (Di) and height (L).
From above equation (1), It can be easily noted that a high operating pressure allows better
flexibility in terms of diameter (Di), height (L), and residence time () for a better gas distribution.
 Effect of high operating pressure on overall power consumption for H2 scheme
Regarding the recycle gas compressor for, the power requirements is a function of thecompression ratio; i.e.
Compression  (P2/P1)k
For the same P, higher suction pressure at compressor leads to lower power consumption, as
observed in Table 2 below.
Table 2. Effect of high operating pressure for High-H2 scheme (~96% vol.) on power consumption
Parameter @ PG
compressor

ENERGIRON

Other DR
technology

Suction pressure (bar
a)

5,4

1,1

Discharge pressure(bar a)7,5

3,2

Gas flow (Nm3/t DRI)

1440

1440

Power (kWh/t DRI)

20

82

17

The impact on power consumption for PG compressor with H2 for lower pressure operation is 4
times higher, reflecting the higher overall energy efficiency of the higher operating pressure of
ENERGIRON process.
RemarksThe ENERGIRON ZR process is a proven DR technology for H2 use:
Same process scheme for NG and H2 in any proportion
All ENERGIRON DR plants with external reformer are already using ~70% H2 (%vol.).
Extensive campaigns were carried out in a demonstration plant in the 1990’s with >90% H2.
ENERGIRON has been the DR technology of choice for projects based on up to 100% Green H2 from renewable energy, like HYBRIT in Sweden and SALCOS in Germany.

References[1]Pablo Duarte, Markus Dorndorf. METEC & 4th ESTAD 24-28 June 2019. Düsseldorf, Germany.
Technological achievements and experience on H2 use for DRI production in Energiron Plants.
[2]Amit Chaterjee; Second edition 2012; Sponge iron production by direct reduction of iron oxide.
[3]International Journal of Minerals, Metallurgy and Materials. Volume 22, Number 7, July 2015,
Page 1.
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You may Contact : Jorge MARTINEZ Tenova HYL; Monterrey, Mexico; Email;jorge.martinez@tenova.com
Praveen CHATURVEDI; Tenova Technologies Pvt Ltd, India; tel +91 9167725604;
Email; hylindia@tenova.com

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PROCESS INTEGRATION OF COAL BASED SPONGE IRON PLANT
Shabina Khanam, Associate Professor Deptt. of Chemical Engineering, IIT Roorkee
Back GroundSponge iron, also known as Direct Reduced Iron (DRI), is widely used in the steel making
process. By contributing 25% of the world’s DRI production, today, India is the largest producerof sponge iron in the world. Although most of these plants have acquired the desired level ofoperational efficiency, energy utilization is found to be below the desired limit. Hence, a large
scope exists to make the sponge iron industry more competitive by cutting down its internalenergy losses using modern technology. The present process consumes around 42 times moreenergy than that is required theoretically as shown in Fig. 1.

Fig. 1 Theoretical and actual energy consumption in sponge iron process
The energy consumption gap in Fig. 1 can be reduced by the use of Process Integration (PI)techniques up to a maximum of 50% as can be seen from Fig. 2 (https://www.slideshare.net/arvindbjo/pinch-analysis-a-tool-for-efficient-use-of-energy):

Fig.2 Potential savings in energy that can be achieved using PI techniques in different industries

19Further, cost components to produce one tonne of sponge iron is shown in Fig. 3, which showsthat coal consumption alone contributes 31.8% to the total cost. For the Sponge Iron industry,
the major source of energy is coal. This energy is produced by the combustion of coal in thepresence of air. If the energy consumption is reduced through proper heat integration amongst
different components of the process then the consumption of coal can also be reduced, which
subsequently reduces the production cost and will increase profit margins.

Fig. 3. Cost components (source: our research work)
Heat Recovery Options in Sponge Iron Plant
In India, different coal based sponge iron production processes are used such as SL/RN, Codir,
ACCAR, DRC, TDR, SIIL, and Jindal. All these processes use some common equipment such as
feed pipe, rotary kiln, transfer chute, rotary cooler, product processing and handling system,
dust settling chamber (DSC), after burning chamber (ABC), gas cleaning system and chimney.
SL/RN process was developed jointly by the Steel Company of Canada, Lurgi Chemie, Republic
Steel Company, and National Lead Corporation in 1964. This process is the oldest and probably
most widely used coal-based sponge iron process in India.
It appears from the literature that in SL/RN process around 30-40% of heat is lost with waste
gas. This heat can be recovered using Pinch analysis, which works based on PI principles. The
prime objective of Pinch analysis is to achieve financial savings by better process heat
integration (maximizing process-to-process heat recovery and reducing the external utility loads
i.e. coal). There are five key steps of pinch analysis in the design of heat recovery systems forboth new and existing processes:
Step-1: Data Extraction, which involves collecting data for the process and the utility system
Step-2: Targeting, this establishes figures for best performance in various respects
Step-3: Design, where an initial heat exchanger network is established20

Step-4: Optimization, where the initial design achieved in Step-3 is simplified and improved
economically
Step-5: Try to change the operational strategy of the process to maximize heat integration

Following options can be proposed to recover heat in SL/RN process:







Preheating of kiln feed, coal and total air using waste gas exiting ESPPreheating of kiln feed, coal and total air using waste gas exiting ABC
Power generation using the heat of waste gas exiting ABC
Cooling of hot sponge iron through waste gas
Hot sponge iron is used to preheat kiln air
Hot sponge iron can be cooled by supplying its heat to water, which is further used topreheat air or can be used for some other purpose.

In a recent research work of ours, we have analysed the above options using 4 steps (Step-1 toStep-4) of pinch analysis. The salient outcomes of heat recovery options are:1) Sponge iron plant consumes 14.2% - 37.4% less coal in the heat integrated process incomparison to an existing process.
2) This integration amounts to saving of 7.26 Cr/yr – 18.97 Cr/yr (depending on heat recovery
option considered)3) The payback period is found from 6 months – 2.5 years (depending on the heat recovery
option selected)
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You May Contact:
Ms. Shabina Khanam, Associate Professor
Deptt. of Chemical Engineering, IIT Roorkee ,Indian Institute ofTechnology Roorkee, Roorkee – 247 667, Uttarakhand
Email: shabina.khanam@ch.iitr.ac.in, shabinahai@gmail.com

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News Release

Midrex and AMI to offer DRI-based steelmakers
complete process optimization solutions
Charlotte, North Carolina, USA and Monterrey, Nuevo León, Mexico, September 10, 2020 – Midrex
Technologies, Inc. and AMI Automation have entered into a strategic agreement to provide steelmakers
worldwide with a new approach to process optimization for DRI-based integrated EAF steel mills.
The alliance offers steelmakers a comprehensive way to use Midrex’s and AMI’s latest digital tools and extensive
process know-how together to optimize the complete DRI/EAF process. Combining each companies’ respective
strengths will streamline the entire process remotely – from reduction of iron ore through production of liquid
steel in the EAF to achieve the optimum
performance for combined DRI/steelmaking plants.
Midrex continues to bring innovation to the direct reduction industry with the introduction of Remote
Professional Services (RPS) as part of MidrexConnect®. RPS digitally transforms data into actions. Midrex
engineers in Charlotte can evaluate all areas of a MIDREX® Plant anywhere in the world in real-time to optimize
product quality and process performance, enhance equipment protection, and increase plant availability.
AMI will provide its comprehensive suite of SmartFurnaceTM products and services to optimize the EAF’s. The
new approach provides the equipment, the technical know-how, the continuous remote monitoring andsupport, OPTaaSTM (Optimization-as-a-Service), to ensure the highest efficiency EAF performance using an
INDUSTRY 4.0 digital business approach. The AMITech Center (ATC Remote Monitoring Center) is a criticalcornerstone of this initiative and provides the latest technologies available to allow AMI´s specialists tocontinuously monitor and optimize the EAF operation using Analytics, Machine Learning and AI tools. This new
approach ensures that customers will be using the best and most modern technology and optimization practices
to melt DRI in their EAF’s.
Fernando Martinez, Vice President and co-founder of AMI Automation commented, “We are thrilled to have thisstrategic relationship with Midrex. AMI has a long history of helping our customers use our technology tooperate the most efficient EAF’s in the world. Working with Midrex will allow, for the first time, the entire
steelmaking process to be coordinated.
It also reinforces AMI’s commitment to innovation and finding ways to help our customers achieve and maintainnew performance levels using digital tools and new digital business models combining the best process knowhow in the industry.”22

“The power of digitalization is allowing us to better focus our process expertise on optimizing the performanceof MIDREX Plants,” KC Woody, COO of Midrex Technologies, said. “By teaming up with AMI, we can offer ourcustomers practical and sustainable solutions from the DRI plant through the EAF melt shop.”
Midrex Technologies, Inc.
Midrex is the world leader for direct reduction ironmaking technology and aftermarket solutions for the steel
industry. As the technology provider of the MIDREXP® PProcess for 50-plus years, Midrex designs, builds andservices Direct Reduced Iron (DRI) plants.
The MIDREX Process fits the need of steelmakers seeking a dependable and clean source of iron. Each year,
MIDREX Plants produce more than 60% of the world's DRI in its three forms: cold DRI (CDRI), hot DRI (HDRI), andhot briquetted iron (HBI). The MIDREX Process is unsurpassed in the industry in terms of production and process
flexibility.
The company’s headquarters and research and technology development center are located in Charlotte, NC,
USA. Midrex Technologies also has offices in the United Kingdom, China, Russia, India, and Dubai.
For more information, please visit www.midrex.com.
About AMI Automation
AMI Automation is a premier international automation and control solutions company. Its Meltshop Solutions
division is a recognized innovator and world leader with over 30 years dedicated to EAF Optimization using thelatest automation and control technologies to make EAF’s run better and more efficiently. AMI Automation´steam of experienced, specialized engineers is one of the largest technical groups fully dedicated to EAF
Optimization.
With this new partnership AMI continues its focus on designing, manufacturing and implementing innovativetechnology solutions to provide process improvements that help run companies more efficiently.
For more information, please visit www.amiautomation.com
Media Contacts:
Lauren Lorraine
Manager – Marketing and Communications
Midrex Technologies, Inc.
Phone: (704) 378-3308
Email: llorraine@midrex.com
Jamie Hansen
Director of Sales and Marketing – Meltshops
AMI Automation
Phone: (216) 533-3288
Email: jamie.hansen@amiautomation.com
Midrex Technologies, Inc., 3735 Glen Lake Drive, Suite 400, Charlotte, North Carolina, 28208 USA Phone: 704-373-1600, www.midrex.com AMI Automation Blvd. Díaz
Ordaz 402, Rincón de Santa María, 64650 Monterrey, N.L., Mexico Phone: +52 (81) 1001.4050, www.amiautomation.com

23

Statistics
Item

Performance of Indian Steel Industry
April-Sept.
2020-21*(mt)April-Sept.
2019-20(mt)%Changes*

Crude Steel Production

43.36355.000-21.2

Hot Metal Production

30.17836.602-17.6

Pig Iron Production

2.020

2.960

-31.8

14.53718.351Sponge Iron Production
Total Finished Steel (alloy/stainless + non-alloy)
Production
38.58651.621

-20.8
-25.3

Import

1.985

4.018

-50.6

Export

6.544

3.935

66.3

Consumption

35.86450.989-29.7

Source: JPC; *provisional; mt=million tones

XXXXXXXXXX-----XXXXXXXXXXRESULTS OF E-AUCTION FOR COAL MINES UNDER 11TH TRANCH(11TH tranche of auction under the coal mines (Special Provisions) Act, 2015)

S.No.

Coal Mine

Auction Closing
Date

Closing Bid Submitted by

Closing Bid %age
shareof
Revenue

1

Takli-JenaBellora NorthSouth

02.11.2020

Aurobindo Reality andInfrastructure Pvt. Ltd.

30.75

02.11.2020

JMS Minng Pvt.Ltd.

10.5

2

Urtan

and

24

S.No.

Coal Mine

Auction Closing
Date

Closing Bid Submitted by

ClosingBid%age share of
Revenue

3

MarkiMangali-II

02.11.2020

Yazdani International Pvt Ltd.

30.75

4

Radhikapur West02.11.2020

Vedanta Limited

21

5

Chakla02.11.2020

Hindalco Inds.Ltd

14.25

6

Bandha03.11.2020

EMIL Mines & Mineral
Resources Limited

21

7

Brahmadiha

03.11.2020

The
AndhraPradeshMineralDevelopment
Corp. Ltd.

41.75

8

Dhirauli

03.11.2020

Stratatech
MineralResources Pvt Ltd.

12.5

9

Sahapur West03.11.2020

Sarda Energy and Minerals
Ltd.

26

10-11

Gotitoria (East)
Gotitoria (West)04.11.2020

Boulder Stone Mart Pvt.
Ltd.

54

12

Urtan North

04.11.2020

JMS Mining Pvt. Ltd.

9.5

13

Gare Palma IV 1

04.11.2020

Jindal Power Ltd.

25

14

RajharaNorth
Central & Eastern

05.11.2020

Fairmine Carbons Pvt. Ltd

23

15

Sahapur East

05.11.2020

Chowgule and Company
Pvt. Ltd

41

16

Radhikapur East

06.11.2020

EMIL Mines and Mineral
Resources Ltd.

16.75

17

Urma Paharitola

06.11.2020

Aurobindo Reality andInfrastructure Pvt. Ltd

26.5

18

Gondulpara

07.11.2020

Adani Enterprises Ltd.

20.75

19

Gare Palma IV/7

09.11.2020

Sarda Energy and Minerals
Ltd.

66.75

&

Source: Ministry of CoalXXXXXXXXXX-----XXXXXXXXXX

Sponge Iron Manufacturers Association
1501, Hemkunt Tower, Nehru Place ,New Delhi-110019,INDIA
Tel: +91 26294492, 41619204, Email: dkedsima@gmail.com

25