1. Direct Reduction Ironmaking: Technologies, Trends and Outlook for North America
Henry P. Gaines, Jr PE
Christopher M. Ravenscroft Midrex Technologies, Inc.
Last year we talked about a “New Day” for DRI in North America, especially the USA.
Today I would like to revisit several Why this relative Revolution is with us, general changes in the demand for DRI Products, especially the benefits they bring to our business and a few of the nuances regarding the MIDREX Technology.
© 2014 Midrex Technologies, Inc. All rights reserved.

2. WHY Direct Reduced Iron? The versatile Ore-based metallic
Why so much interest?
The versatile Ore-based metallic
© 2014 Midrex Technologies, Inc. All rights reserved.

3. DRI Products Versatile Ore-based Metallics
CDRI: Cold Direct Reduced Iron
HDRI: Hot Direct Reduced Iron charged directly into a melter without cooling
HBI: Hot Briquetted Iron is direct reduced iron discharged from the shaft furnace at ≥650°C and compacted to a density ≥ 5 gm/cc
In discussions of today the use and benefit of DRI and DRI Products is often overshadowed with focus on “Nuance”, academic focus on development…………
So lets revisit the three different product forms and their benefits.
CDRI – In the beginning.
HBI – A new Commodity with huge benefits with respect to overall handling, shipping, storage and longevity.
No passivation
Unrestrained shipping on land and at sea
Significant improvement in integrity.
HDIR – Proven results and by far and away bring the most VALUE IN USE Possible.
© 2014 Midrex Technologies, Inc. All rights reserved.

4. Integrated Operational Value
Increasing need for Metallics
Low residuals
Uniform chemical composition
Lower emissions
EAF can produce steel grades unattainable with 100% scrap
Low NG energy costs particularly in USA
HDRI is a lower cost feed to the EAF than pig
HBI can be an economical means to increase BF productivity or to replace purchased scrap in the BOF …
EAF Steelmaking Operational Value
Integrated Operational Value
© 2014 Midrex Technologies, Inc. All rights reserved.

5. Typical levels of residual elements in scrap and HBI/DRI
Virgin Iron Source
Typical levels of residual elements in scrap and HBI/DRI
element content (%) in scrap and HBI/DRI
%Cu
%Sn
%Ni
%Cr
%Mo
%Mn %S %P
%Si
No. 1 Bundles
0.07
0.008
0.03
0.04
0.02
0.01
0.005
Shredded
0.22
0.11
0.18
0.4
0.025
No.1 HMS
0.25
0.09
0.1
0.3
No. 2 Bundles
0.5
No. 2 HMS
0.55
0.2
DRI/HBI
0.002
trace
0.009
0.003 * *
Both Phosphorus and Silica are contained in the oxide form; they are not in the elemental form.
© 2014 Midrex Technologies, Inc. All rights reserved.

6. HBI will play a future roll in the integrated steel industry
Benefits of charging HBI to a blast furnace (BF) are:
Greater productivity
Lower blast furnace fuel consumption
Lower coke consumption, and therefore greatly decreased CO2 emissions for ironmaking
HBI has been used as part of the regular, routine operation of a commercial blast furnace in North America for more than 25 years as well as other blast furnaces around the world.
Apologize
I’ve began using this graph at the 2012 SEAISI Conference……BUT it tells a story that is just beginning to be understood by more than just a few and put into use on a growing scale……..voestalpine Stahl.
Charging of 30% HBI yields approximately a 24% increase in production.
© 2014 Midrex Technologies, Inc. All rights reserved.

7. More DR Capacity is On the Way
Midrex expects USA production of DRI to surpass ten million tons per year sometime near the end of this decade. This means additional plants need to be permitted and contracted within the next 2 to 4 years.
© 2013 Midrex Technologies, Inc. All rights reserved.

8. More DR Capacity is On the Way
Midrex expects USA production of DRI to surpass ten million tons per year sometime near the end of this decade. This means additional plants need to be permitted and contracted within the next 2 to 4 years.
© 2013 Midrex Technologies, Inc. All rights reserved.

9. More DR Capacity is On the Way
Midrex expects USA production of DRI to surpass ten million tons per year sometime near the end of this decade. This means additional plants need to be permitted and contracted within the next 2 to 4 years.
© 2013 Midrex Technologies, Inc. All rights reserved.

10. Module size: are mega modules the way forward for US DRI?
Meeting Market Demands:
Not simply larger capacities but also operational flexibility:
Fuels
Feed Material
Product
© 2014 Midrex Technologies, Inc. All rights reserved.

11. Production and Flexibility
Flexibility Means
The ability to use varying feed mixes. MIDREX DRI Plants have run on
100% Pellets
100% Lump, albeit on a limited scale.
Many varying mixes in between.
But usually at a max of 30% Lump
The ability to run on different fuels
Of course NG
+15 years on syn-gas produced by the COREX Process
Until two months ago, the only commercial process to do so.
Syn-gas from commercial gassifier now in commissioning by JSPL and certainly meeting expectations.
But equally important, and really more important, the ability to produce varying product forms both individually and simultaneously.
Will discuss more in a few minutes.
© 2014 Midrex Technologies, Inc. All rights reserved.

12. Growing DRI plant Capacity to meet sizes of BF facilities
Don’t get me wrong
Capacity IS important.
We prefer to reference CAPACITY vs SIZE…………
Through the years, MIDREX has increased our capacity through responsible engineering based on sound and proven performance.
© 2014 Midrex Technologies, Inc. All rights reserved.

13. MIDREX® Plants Meet Demands 2.0 mtpy production is now a reality
Not a rare occurrence,
Virtually every MIDREX Plant commissioned has at one time exceeded it rated “SIZE” if you prefer to call it that.
A number of MIDREX Plants now consistently produce 500,000 tonnes per year more than their “SIZE” would indicate.
World Record Production for Single DRI Module
Design capacity 1,760,000 tpy
© 2014 Midrex Technologies, Inc. All rights reserved.

14. voestalpine Texas, LLC MIDREX® 2.0 MTPY HBI Plant
Customer: voestalpine Texas Llc., USA Plant Type: 2 mtpy MIDREX® Direct Reduction HBI Plant Plant Start-up: December 2015 Feed material: 100% pellets (Brazil, Canada) DR plant erection: carried out by a consortium of MIDREX and Siemens Product: 100% HBI - half to merchant market, half to use in voestalpine BFs in Austria
© 2014 Midrex Technologies, Inc. All rights reserved.

15. DRI products will play a future roll in the integrated steel industry
Will utilize the low-cost natural gas based on the shale gas production in the USA
Increase blast furnace productivity in the Linz and Donawitz / Austria
Decrease specific CO2 emissions
Provide additional HBI for merchant market Altos Hornos de Mexico (AHMSA), has signed MOU to purchase HBI from voestalpine Texas
© 2014 Midrex Technologies, Inc. All rights reserved.

16. How easily are plants retrofitted for hot DRI?
Any hot Discharge MIDREX® Plant can easily be configured to transport HDRI
© 2014 Midrex Technologies, Inc. All rights reserved.

17. Options for Hot transport Combo Plant design allow for maximum flexibility
Temperature dominates.
HDRI → Higher Productivity + Lower Power Consumption
© 2014 Midrex Technologies, Inc. All rights reserved.

18. Increasing Productivity & Efficiency
Lion Case Study
Increasing Productivity & Efficiency
© 2014 Midrex Technologies, Inc. All rights reserved.

19. Alternative DRI technology:
how are alternative technologies developing?
What kind of capacities are feasible?
Technology is being developed and implemented to address market needs such as in areas of the world without NG…
Innovation continues that benefits both new and older MIDREX® Plants
And on the note of technology development……
The MIDREX Process consistently performs as the standard of the industry and WE, MTI have seen nothing to indicate it is not still THE State of the ART!
Deviating from the fundamentals would be like INTEL ditching the primary fundaments on which they based their early processors……Did they do this? No………………They continue to innovate and evolve to perform better, faster, more reliably and more economically than ever before.
There have been theoretical or academic argument made to suggest that the MIDREX Process produces more fines…….I think we all know now quite the opposite is true.
There have been argument that the MIDREX Process is less efficient…………….If so, why do owners who own multiple technologies ALWAYS keep their MIDREX Plant running idling other capacity when demand is down and times are tough? The reason is actual consumption, all consumption, based on tonnes produced.
© 2014 Midrex Technologies, Inc. All rights reserved.

20. New Technologies Coal gasification COREX® Off Gas Coke Oven Gas (COG)
Innovation that meets industry needs in areas such as India
Commercial pairing of MIDREX® Process with a coal sources for direct reduction ironmaking
Same capacities as NG-based Plants
Coal gasification
COREX® Off Gas
Coke Oven Gas (COG)
© 2014 Midrex Technologies, Inc. All rights reserved.

21. World’s First MXCOL® Facility DR Plant + Coal Gasifier
Jindal Steel & Power
World’s First MXCOL® Facility
DR Plant + Coal Gasifier
Capacity: 1.80 million tpy HDRI
Furnace Type: MIDREX MEGAMOD®
Hot Discharge Furnace (7.15 m ID)
Reducing Gas: Coal Gasification
Location: Angul, Odisha,India
JSW STEEL (COREX®/MIDREX®)
Capacity: 1.20 million tpy HDRI/CDRI
Furnace Type: MIDREX MEGAMOD®
Hot Discharge Furnace (7.15 m ID)
Reducing Gas: COREX export gas
Products:Hot DRI (0-100%) and/or Cold DRI (0-100%)
Location: Toranagallu Karnataka State, India
© 2014 Midrex Technologies, Inc. All rights reserved.

22. New Technologies – The TRS®
Technology ready for industrial application..
Results continue to exceed expectations.
© 2014 Midrex Technologies, Inc. All rights reserved.

23. THANK YOU Designed for Today, Engineered for Tomorrow™
Visit for more technical presentations and the 2013 World Direct Reduction Statistics Booklet
© 2014 Midrex Technologies, Inc. All rights reserved.