the kobe midrex process

1Asia-Pacific Partnership on Clean Development and Climate4th Steel Workshop, Wollongong Australia

New Ironmaking Processes for CO2 Reduction

25.October.2007Hidetoshi Tanaka

KOBE STEEL, LTD.

(FASTMET/ITmk3)

Asia-Pacific Partnership on Clean Development and Climate4th Steel Workshop, Wollongong Australia

Contents

FASTMET Process FASTMELT Process ITmk3 Process CO2 Reduction by using New Iron-making

processes Conclusion


Necessity of New Ironmaking Processes

Coal Based Direct reduction ProcessesFASTMET, FASTMELT and ITmk3,

Background for Demanding New Ironmaking Process Coke is very expensive Steaming Coal is the cheapest energy Fine iron ore is abundantly available BF process consume a large amount of energy

and place a high burden on the environment.


FASTMET Process Flow

RHF

DischargerBurner

Mixer

Raw MaterialStorage

Air Blower

HeatExchanger

Bag Filter

DRI Container

Stack

ID Fan

DRI Quench Tank

Pellet Dryer

Pelletizer

BriquetteMachine

OR

OR

Fuel


Secondary Dust (Zinc Oxide)

Lead

Product DRI

Ironoxide Gangue

Alkali

Sulfur

Material Dust

Copper

Zinc

FASTMET

PLANT

Zinc

CopperSulfur

Recyclinginsteelmill

Sale toZincproducer

Zinc

MetallicIronGangue

Alkali

Arsenic

Arsenic

The image of Steel Dust recycling in FASTMET Process

carbon


Nippon SteelHIROHATA No1 & No2

190,000t/y Steelmaking dust

Start-up : March 2000 and Feb, 2005

FASTMET Commercial Plants

Kobe SteelKAKOGAWA

14,000t/y BF, BOF, EAF dust

Start-up : April 2001


Hot Metal Production by FASTMELT Process

Direct combination of FASTMET and DRI melter Major functions of the DRI melter Effective melting Removal of gangue by melting Reduction of residual FeO to Fe Desulphurization Adjustments of carbon contents in the molten

iron


FASTMELT Process


Typical FASTMELT Molten Iron Chemistry


ITmk3 ProcessHigh Grade Pure Iron Nuggets

by using fine ore and coal by separation of metal and slag with fast reduction and melting

rate (8 to 12 min.) at relatively lower temperature

(1350 to 1450)

Metallic Iron 96-97% Carbon 2.5-3.0%Sulfur 0.05-0.07%Size 5-25mm


Product figure and Cross sectional view of time sampled pellet

Slag

Metal

Dense metallic iron shell

Molten slag separated from metal

Dense metallic iron shell

Molten slag separated from metal

3min 5min 6min 9min



Separation of metal and slag

Slag

Metal (Iron Nugget)


ITmk3 process flow


ITmk3 Pilot & Demonstration Plant

Kakogawa

Bench Scale Plant

RHF outer dia. : 4.0m

Capacity: 0.4t-iron/h

Mesabi

Pilot Demonstration Plant

RHF outer dia.: 13.5m

Capacity: 25,000t-iron/y


Product Pile of Iron Nugget

More than 9,000mt of iron nugget has been melted in existing EAFs


Potential Projects in Progress in the USA

New Mesabi ProjectSDI/KSL

Michigan ProjectCCI/KSL

Potential Project out of the USA

IndiaUkrineAustralia

10


CO2 reduction by using FASTMET

SinterPlant

IronOre

Consuming Location

Coal

SinterTFe:56%

Coke

Mine Location

CokeOven

Base Case

Hot Metal

BF

CO2 EmissionBase

CO2 Redction0.2 t-CO2/t-HBI IHBI Production

from Mill Waste

FASTMET

HBITFe:58%

Mill Waste

Hot Metal

BF

MFe:50%

CO2 Redction1.02 t-CO2/t-HBI I

HBI Productionin Mine Location

Coal

IronOre

FASTMETHot Metal

BFHBITFe:85%

MFe:78%


Energy Consumption of Different Processes

-5.00

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

Large BF(3Mt)

Mini BF(0.5Mt)

FASTMELT(0.5M)

ITmk3(0.5M)

Energy Consumption (Gj/thm)

Electricity(to outside)OtherElectricityFuel GasCoal

11


CO2 reduction by using FASTMELT/ITmk3

0

500

1,000

1,500

2,000

2,500

3,000

Large BF(3Mt)

Mini BF(0.5Mt)

FASTMELT(0.5M)

ITmk3(0.5M)

CO2 Emission (kg-CO2/thm)

CO2 Reduction

1t-CO2/thm

in Japan


ConclusionWith growing concerns on the conservation of resources and the environment, the new ironmaking processes are receiving more and more attention.

Kobe/Midrex has jointly developed new ironmaking processes such as FASTMET and ITmk3, which can reduce CO2 emission as compared with the BF.

We will continue to develop and supply coal-based DR processes and plants. In doing so, we aim to contribute to both growing the ironmaking industry and improving the global environment.

the kobe midrex process

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