Prof. Dr. Peter Schmle, ThyssenKrupp Steel Europe
Dr. Hans Bodo Lngen, Steel Institute VDEh
Dr. Jose Henrique Noldin, Lhoist Group
Trends in iron-making given the new reality of
iron ore and coal resources
Dr. Lngen Dr. Noldin Dr. Schmle
Introduction
Ironmaking in Europe
Dealing with new ores and wastes
Conclusion
Trends in iron-making
Whats in the pipeline
New times, new realities! What exactly?
Huge supply / demand pressure
Source: CRU, WSD (05.2014)
6 % 3 %
World Coke and Pit Coal Production
World coke production by region World Pit Coal Production
World production of beneficiated iron ore
Source: RMD database, April 2014 (2012 figures)
Iron Ore sellers
Iron Ore buyers
Seaborne iron ore market
China buys any and all (>60% share)
Source: HKM
Qualities of raw materials
Very high moisture content in Brazilian fine ores
Source: Tata Steel Europe
Qualities of raw materials
SiO2 and FeTOT content in Brazilian fine ores
Source: ThyssenKrupp Steel Europe
Introduction
Ironmaking in Europe
Dealing with new ores and wastes
Conclusion
Trends in iron-making
Whats in the pipeline
Evolution of Hot Metal Production in the EBFC member
countries
Source: Steel Institute VDEh
Qualities of raw materials
Source: ThyssenKrupp Steel Europe
Qualities of raw materials
Severe raw material deterioration is impacting operational strategy and economics of steel production in Europe
Source: ThyssenKrupp Steel Europe
Ferrous burden composition 1990 and 2013 in the EBFC
member countries
Source: Steel Institute VDEh, EBFC (European Blast Furnace Committee)
Sinter production and sinter/hot metal ratio in EBFC
member countries
Average chemical composition of sinter in Germany
Source: Steel Institute VDEh
Coke quality requirements by German blast furnace operators
Actual coke qualities at European blast
furnaces
Coke production Dream versus reality in Europe
Source: Steel Institute VDEh
50
55
60
65
70
75
1995 2000 2005 2010
CS
R
[ %
]Qualities of raw materials
Source: ThyssenKrupp Steel Europe
1.5
2.0
2.5
3.0
55 60 65 70 75
CSR [ % ]
Pro
du
cti
vit
y
[ t
/ 2
4 h
& m
IV
] BF 1
BF 2
BF 9
Coke quality effects
Coke quality CSR
Evolution of BF reductant rates in the EBFC member
countries
Source: Steel Institute VDEh, EBFC
Average slag volume of blast furnaces in Germany
Introduction
Ironmaking in Europe
Dealing with new ores and wastes
Conclusion
Trends in iron-making
Whats in the pipeline
Source: J. M. Mourao (ABM, 2008)
Availability of ore fines
Iron ore profile changing over the decades
Finer iron ore Lower sinter productivity New tools (Intensive Mixer, Hybrid Pelletized Sinter) and new lime practices (type, kg)
Screening of Brazilian lump ore
1. Screening 20% Fines
2. Screening 20% Fines
3. Screening ???
Source: HKM
Qualities of raw materials
Decreasing quality and availability of Brazilian lump ores
Lower Fe content in iron ore
Higher content of impurities (P, Mn, etc)
Less availability of Lumps
Higher slag rate
Higher reductant rate
Lower BF productivity
Changing HM quality
Improved process control
Strong cost control
Optimum PCI rates
Trend to increase pellets rate
Increased efficiency
What? Impacts Measures
Then what for BF operators?
Challenges to use ultra-fines in sinter plants
Excessive use of ultra-
fines in sinter mix
Reduced permeability
Lower productivity
Higher return fines
Poor agglomeration
HPS, IM, etc
use of burnt lime
Cold agglomeration improvement
(water!!)
Change lime specs (size)
Challenge Possible solutions
Source: Authors HPS = Hybrid Pelletized Sinter
IM = Intensive Mixer
Reasons for not or partly not recycling via the sinter plant
Source: Steel Institute VDEh
Introduction
Ironmaking in Europe
Dealing with new ores and wastes
Conclusion
Trends in iron-making
Whats in the pipeline
Blast furnace process 305 years old
Highest hot metal production
in the world, Posco Pohang 4,
South Korea
HM production up to 17,000 t / d
First coke based blast furnace
in the world, Coalbrookdale, 1709
HM production 2 t / d
Blast furnace ironmaking
A modern technology
Hot Metal production via Blast-Furnace and Corex/Finex
DRI production
Source: wsa, Midrex, Siemens VAI
28
Maturity of different ironmaking technologies
New ironmaking technologies
Several efforts
Source: Noldin Jr.; J. H.
Calc. Test
-6.6 -6.0
7.6 5.1
Tata
IJmuiden
Results from
-8.6
12.4
AK
Steel
Coke / Tot.
Red. Agents %
Productivity %
-5.0 to -8.0
4.0 to 10.0
Lit.
-7.1
7.3
TKSE
Fe met. input from HBI = 10 % from total Fe in BF burden
Sources: - AISI Technical Committee on Ironmaking, New Orleans, Louisiana, 1999
- Direct Reduced Iron, Technology and Economics of Production and Use, The Iron and Steel Society, Warrendale, PA, 1999
- Calculations by Prof. Schmoele (ThyssenKrupp Steel Europe)
Blast furnace ironmaking
Use of HBI in Europe Final solution?
BF, coke plant, HBI produced in Germany: HM costs
Blast furnace ironmaking
Different strategies are possible but economics change
Source: ThyssenKrupp Steel Europe
Introduction
Ironmaking in Europe
Dealing with new ores and wastes
Conclusion
Trends in iron-making
Whats in the pipeline
HM and Iron Ore production increased at a rate of 6% p.a. over the last 10 years
Iron ore deterioration chemistry and size has been observed since many years but with severe acceleration in the last 10 years
Ironmakers have reacted to raw materials change with creativity and technology understanding ! But profitability remains a challenge
There could be a trend to increase use of pellets in blast furnaces
At the same time, sinter plants are likely to increase the use of ultra-fines which shall enable a vast adoption of new practices and new equipment (Intensive
Mixer, HPS)
Despite the challenges, blast furnace ironmaking shall continue as the main source of high quality hot metal in the foreseeable future.
Conclusions
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Prof. Dr. Peter Schmle, ThyssenKrupp Steel Europe
Dr. Hans Bodo Lngen, Steel Institute VDEh
Dr. Jose Henrique Noldin, Lhoist Group
Trends in iron-making given the new reality of iron ore and coal resources
