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Page 1: Innovative DR Technology for Innovative Steelmaking

Innovative DR Technology for Innovative DR Technology for Innovative SteelmakingInnovative Steelmaking

Thomas ScarnatiMB North African Steel Conference

June 2-5, 2008Cairo, Egypt

Page 2: Innovative DR Technology for Innovative Steelmaking

OverviewOverview

• The ENERGIRON Alliance

• Direct Reduction technologies and services

• Innovative solutions for energy and efficiency

• The importance of a strong technology partner

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Technology Sustains SurvivalTechnology Sustains Survival

• Becoming cost-efficient is key to sustaining market share.

Inefficient technologies are unsustainable

Environmental factors are critical

• Reducing raw materials costs, increasing product quality and providing higher returns on investment imply of necessity the use of the best technologies and practices

• For steel companies to improve and succeed, the importance of a strong technology partner cannot be overstated.

• ENERGIRON brings the combined support of two premier companies –Tenova and Danieli – to the world iron and steel industry.

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• ENERGIRON is the innovative HYL direct reduction technology jointly developed by Techint and Danieli, and whose name derives from the unique DRI product which distinguishes this technology from other available processes.

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ENERGENERGIRONIRON AllianceAlliance

• HYL Technologies, the pioneer of DRI Technology now known as Tenova HYL, has joined with Danieli to serve the direct reduction plant market.

• ENERGIRON is the innovative HYL direct reduction technology, jointly developed by Techint/Tenova and Danieli.

• This strategic alliance allows the companies to join their own know-how and technology for the design and construction of Gas Based Direct Reduction Plants, offered worldwide, under the new ENERGIRONtrademark.

• With this collaboration, HYL and Danieli can offer any project approach – from any size DR plant to a complete integrated minimill facility; from technology packages to EPC turn-key projects.

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ENERGENERGIRONIRON AllianceAlliance

• The combined resources and potentials of these partners in the field of DRI include:

A heritage of 47 direct reduction modules built or contracted for, including the first commercial plant worldwide, built in 1957.

A major steel maker, the Techint Group, with a production of over 7.5 Mtpy DRI and HBI, and over 15 Mtpy of annual steel production.

Patented DR technologies of HYL and Danieli as well as future developments.

Impressive plant making capabilities and powerful internationalnetworks of Danieli and Tenova.

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ENERGENERGIRONIRON DR TechnologyDR Technology

Reducing gases sourcesNatural GasReformed GasCoal GasificationCOGothers

Iron Ore Size: 3.2 - 18 mm

Wide range of raw material quality (Sulphur in Iron Ore is not a limitation)

Minimum iron ore losses in top gas: <1%

Reactor pressure: ≥6 bar (low gas

velocity)

NG

DRI

H2O

fuel

CO2(+H2S)

O2

Iron Ore

Highest yield: (Iron ore / DRI) <1.36 t oxide / t DRI

Flow feeders (1-row) adoption for large DR shafts/hot discharge: control of burden flow

Flexibility for using different sources of

Reducing gases with the SAME Basic

Scheme

Selective removal of oxidants from

the reduction process (H2O and

CO2): Optimisation of

energy consumption

--HighHigh--Carbon DRICarbon DRI--Hot DRI Hot DRI withwith HYTEMP HYTEMP SystemSystem--HBIHBI

Flexibility to process any Natural gas

qualityLow NOx emissions

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ENERGENERGIRONIRON ZR ZR ProcessProcessBasic Basic PrinciplesPrinciples• The ZR process allows the reduction of iron ores without the use of a

reformer by taking advantage of the fact that metallic Iron is a very good catalyst for natural gas reforming.

• The reduction zone of the DR shaft is used to perform simultaneously the Reduction of the Iron Ore and the reforming of natural gas.

• When Natural gas reforming takes place under a limited amount ofsteam, some carburization of the catalyst will occur.

• In the case of the ZR, since the catalyst is the DRI, carburization is intentional and controlled.

• The rate of Carburization can be controlled by adjusting the content of steam present in the gas stream.

• In the ZR process the carburization of the catalyst (DRI) takes place at high temperature resulting in the formation of Iron Carbide Fe3C.

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ENERGENERGIRONIRON ZR ZR ProcessProcessMainMain FeaturesFeatures• High-Carbon (controlled) in DRI: 2% – 5%.

• Due to the process configuration, the ZR plant:

is simple, very easy to operate and very stable,

has lower maintenance cost since no catalyst is ever replaced; the only high temperature equipment is a standard gas heater.

the compressors in the ENERGIRON ZR plant are standard centrifugal type.

Operates with any source of Natural gas quality without any treatment, such as hydrogenation, desulphurization, heavy hydrocarbons removal, etc.

can easily process high percentages of lump ores even with high sulfur content.

is the most environmentally friendly specially regarding NOx emissions since there is no preheating of the combustion air.

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ENERGENERGIRONIRON ZR ZR ProcessProcessEnergyEnergy OptimizationOptimization

The overall energy efficiency of the ZR process is optimized by the integration of high reduction temperature (above 1050°C), “in-situ” reforming inside the shaft furnace, as well as by a lower utilization of thermal equipment in the plant. Therefore, the product takes most of the energy supplied to the process, with minimum energy losses to the environment.

DR ProcessDR Process

DRI characteristics at shaft furnace discharge:Metallization: 94%Carbon: 3.5%Temperature: 700°C

NG to Process1.70

Total NG2.30

Fuel NG to Gas Heater

0.48

Fuel NG to others

0.12

Evaporation0.30

Flue gases0.05

DRI Sensible Heat

0.12

DRI Energy1.83DR ProcessDR Process

DRI characteristics at shaft furnace discharge:Metallization: 94%Carbon: 3.5%Temperature: 700°C

NG to Process1.70

Total NG2.30

Fuel NG to Gas Heater

0.48

Fuel NG to others

0.12

Evaporation0.30

Flue gases0.05

DRI Sensible Heat

0.12

DRI Energy1.83

It is important to note the efficient use of energy while producing a high-energy content DRI with 3.5% C and 700°C.

ZR Overall EfficiencyHot DRI: 87%Cold DRI: 83%Others: < 70%

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ENERGENERGIRONIRON DR Technology DR Technology N. Gas ReformerN. Gas Reformer

Nat. gas H2O

fuel

CO2

Iron Ore

Reformer

water fuel

DR Shaft

DRI

Reduction Section

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ENERGENERGIRONIRON DR Technology DR Technology N. Gas ReformerN. Gas Reformer• Main Features:

Flexibility for carbon control in DRI: 1% – 3%.

Minimum power consumption: ≤ 35 kWh/t.

The scheme has the flexibility to process any natural gas quality.

No restrictions related to sulfur content in the iron ores, which is foreseen an important issue in the next future.

Possibility for power co-generation -to even attain “zero”power consumption- taking advantage of the steam produced in the reformer convective section.

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EnvironmentalEnvironmental AspectsAspects ––COCO22 EmissionsEmissions

• As compared to other DR schemes, the ENERGIRON ZR-based configuration reduces overall CO2 emissions by 6% to 10% for cold and hot DRI, respectively, for liquid steel production.

• Additionally, about 55% of total CO2 emissions from the ENERGIRON ZR plant is selectively removed and can be specially disposed, sequestrated or used for other applications.

ScenarioLocation:

other Cold DRI ZR Cold High-C DRI other Hot DRI ZR Hot High-C DRI94% Mtz.; 2% C 94% Mtz.; 3.7% C 94% Mtz.; 1.5% C 94% Mtz.; 3.7% C

Item/unit kg CO2/t LS kg CO2/t LS kg CO2/t LS kg CO2/t LSIron ore (production) 132 129 132 129

CO2 in flue gases + removal system 447 455 455 461Electricity & O2 to DR plant 90 80 98 86

Subtotal DR Plant 669 664 684 676Power & O2 requirements 443 415 339 305

Carbon addition 35 3 59 3Subtotal EAF 478 419 399 308

Total DR-EAF route 1147 1082 1082 984As % -6%

CO2 Emissions / tonne of Liquid SteelDR-EAF: ZR High Carbon DRI vs. other DRI

Power generation: 0,74 kg CO2/kWh

Scheme

-10%

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HYL HYTEMP HYL HYTEMP PneumaticPneumatic TransportTransport SystemSystem

• Deliver hot DRI to:

EAF charging bins system.

External cooler

• External cooler for cold DRI production, whenever the EAF cannot receive hot DRI.

• Capacity for 100% cold DRI or 100% hot DRI production or any combination.

Transp. Gas

Make up

HYTEMPHYTEMP®® SystemSystem

Hot DRI Hot DRI from 0 from 0 –– 100%100%

HYTEMPHYTEMP®® SystemSystem ExternalCooler

Cold DRI Cold DRI from 0 from 0 –– 100%100%

H2O

fuel

CO2

O2

Reducing gases -Possible sources

Natural GasNatural GasReformed GasReformed GasSyngas (coal)Syngas (coal)othersothers

Reactor

Iron OreIron Ore

NG

EAF

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HYTEMP HYTEMP SystemSystem ––DesignedDesigned forfor OptimizedOptimized SteelmakingSteelmaking• Delivers energy to the EAF via

highly carburized DRI

• Totally enclosed system

Increases yield, as there are no fines or dust losses – allgo to the furnace.

No environmentalrepercussions.

Virtually maintenance free operation. No mechanicalparts.

• In 10 years of operation, therehas been no downtime from theHYTEMP System.

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A A HistoryHistory ofof InnovationInnovation

• Beginning with the first successful industrial scale DR plant in 1957, virtually all majoradvances in the field of direct reduction are traceable to HYL technology developmentsand patents. Some of which are:

1958 – Batch charging of DRI to the EAF at 600°C.1965 – Use of more than 30% DRI in an EAF charge, eventually increasing in stages up to 100% by 1972.1968 – Continuous feeding of DRI to the EAF.1972 – Production of extra-deep drawing steels in EAF using DRI.1984 – First pilot operation of a DR plant without external gas reformer.1993 – HYTEMP pneumatic transportation system and hot DRI feeding to the EAF.1993 – First Zero kWh direct reduction plant begins operation at Vikram Ispat plant, India.1994 – HYL begins producing high carbon DRI with 3.0 to 5% carbon content.2000 – First plant to successfully use 100% lump ore charge on a routine basis (Usiba HYL plant, Brazil). Vikram Ispat becomes second in 2006.2003 – Successful design of HYL ZR plants based on coal gasification and COG.

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SolidSolid PlantPlant OperationOperation ResultsResults

88%968,18189%974,2011.10Saudi ArabiaHadeed D

115%775,763127%857,0470.68MexicoTernium 4M

136%832,424121%737,0610.61MexicoTernium 2P5

118%2,364,839112%2,231,3182.00MexicoArcelorMittal LC

138%688,538135%676,2620.50MexicoTernium 3M5

89%1,070,08379%953,9291.20MalaysiaPerwaja Steel

105%1,417,28296%1,289,9861.35IndonesiaPTKS

99%595,19062%466,5960.75/0.50IndiaVikram Ispat

118%364,529121%376,1000.31BrazilUsiba

114%1,029,440114%1,027,5000.90RussiaLebGOK

Cap. Util.Prod. 2007Cap. Util.Prod. 2006CapacityLocationPlant

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IronmakingIronmaking & & SteelmakingSteelmaking ServicesServices

• Tenova HYL has its roots in steelmaking

Ironmaking technology is designed to optimize steelmaking

• We provide training, technical assistance and maintenance/operationservices for all aspects of the industry – from mines to DR to meltshopand finished products.

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Solid Technology Partners Solid Technology Partners –– TenovaTenova

• Tenova is a network of technologies and companies.

• Each company preserves its specific competences and distinctive skills.

• Each company preserves its name under a single global brand.

• Materials handling, plantequipment manufacture, steelmaking equipment andoptimization technologies.

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Solid Technology PartnersSolid Technology Partners –– DanieliDanieli

• EPC Contractor for iron and steel projects worldwide

• Design, manufacturing, assembly, project management and R&D

• Partner with Tenova HYL in direct reduction process, equipment and plant development

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ENERGENERGIRON IRON –– HYL III/ZR modulesHYL III/ZR modules

Notes:d) 100% lump ore feed New Projects since end of 2005 (under execution)e) Syngas based plant New Projects signed in 2008 (under execution)

201094.0 (3.5)3.55HYTEMP/DRIENERGIRON2Egypt2 Plants

201094.0 (3.5)1.20HYTEMP/DRI

ENERGIRON ZR1AzerbaijanDETAL

201094.0 (3.0)1.60 HYTEMP/DRI

ENERGIRON III1Abu DhabiGHC-2

200994.0 (2.0)1.70 HYTEMP/DRI

ENERGIRON ZR1IndiaJindal (e)

200994.0 (3.0)1.60 HYTEMP/DRI

ENERGIRON III1Abu DhabiGHC-1

2006 / 200894.0 (3.0)0.50 DRIHYL III/ZR1IndiaVikram Ispat

(d)

200894.0 (2.8)0.80 DRIHYL III1VenezuelaSidor

200893.0 (3.5)0.20DRIHYL-ZR1UAEAl Nasser

Start Up

Product Quality

% Met. (Carbon)

Capacity

(Million ton/yr)

Design

ProductTechnologyModulesCountryPlant

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Final RemarksFinal Remarks

• The most cost-efficient producers will be those that adopt the best technologies and practices

• The ENERGIRON alliance brings together two strong companies as technology partners for iron and steel makers worldwide.

• Based on the ENERGIRON process and the HYL HYTEMP System, this technology leads the way in innovation, productivity, cost-effectiveness and environmental compliance.

• Hot, high carbon DRI fed directly to an EAF is today’s most efficient and cost-effective way to quality steel.

• Training support and technical services in iron and steelmaking assure that client companies maintain their operations at the forefront of industry competitiveness.

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