Dr.

Lngen

Dr. Noldin

Trends in iron-making given the new reality of

iron ore and coal resources
Prof. Dr. Peter Schmle, ThyssenKrupp Steel Europe
Dr. Hans Bodo Lngen, Steel Institute VDEh
Dr. Jose Henrique Noldin, Lhoist Group

Dr. Schmle

Trends in iron-making

Introduction
Ironmaking in Europe
Dealing with new ores and wastes

Whats in the pipeline

Conclusion

New times, new realities! What exactly?

Huge supply / demand pressure

6%

Source: CRU, WSD (05.2014)

3%

World Coke and Pit Coal Production

World coke production by region

World Pit Coal Production

World production of beneficiated iron ore

Seaborne iron ore market

China buys any and all (>60% share)
Iron Ore sellers

Iron Ore buyers

Source: RMD database, April 2014 (2012 figures)

Qualities of raw materials

Very high moisture content in Brazilian fine ores

Source: HKM

Source: Tata Steel Europe

Qualities of raw materials

SiO2 and FeTOT content in Brazilian fine ores

Source: ThyssenKrupp Steel Europe

Trends in iron-making

Introduction
Ironmaking in Europe
Dealing with new ores and wastes

Whats in the pipeline

Conclusion

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 production Dream versus reality in Europe

Actual coke qualities at European blast

furnaces

Coke quality requirements by German blast furnace operators

Source: Steel Institute VDEh

Qualities of raw materials

3.0

Productivity [ t / 24 h & m IV ]

75

CSR [ % ]

70

65

60

55

BF 1
BF 2
BF 9
2.5

2.0

1.5
55

50
1995

2000

2005

Coke quality CSR

Source: ThyssenKrupp Steel Europe

2010

60

65

70

CSR [ % ]

Coke quality effects

75

Evolution of BF reductant rates in the EBFC member

countries

Source: Steel Institute VDEh, EBFC

Average slag volume of blast furnaces in Germany

Trends in iron-making

Introduction
Ironmaking in Europe
Dealing with new ores and wastes

Whats in the pipeline

Conclusion

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)
Source: J. M. Mourao (ABM, 2008)

Qualities of raw materials

Decreasing quality and availability of Brazilian lump ores
Screening of Brazilian lump ore
1. Screening 20% Fines
2. Screening 20% Fines
3. Screening ???

Source: HKM

Then what for BF operators?

What?

Lower Fe content in iron ore

Higher content of impurities
(P, Mn, etc)
Less availability of Lumps

Impacts

Higher slag rate

Higher reductant rate
Lower BF productivity
Changing HM quality

Measures

Improved process control

Strong cost control
Optimum PCI rates
Trend to increase pellets rate
Increased efficiency

Challenges to use ultra-fines in sinter plants

Challenge

Possible solutions

Reduced
permeability

Poor
agglomeration

Excessive
use of ultrafines in
sinter mix

HPS, IM, etc

Lower
productivity

Cold
agglomeration
improvement
(water!!)

Higher return
fines

Source: Authors

use of burnt
lime

Change lime
specs (size)

HPS = Hybrid Pelletized Sinter

IM = Intensive Mixer

Reasons for not or partly not recycling via the sinter plant

Source: Steel Institute VDEh

Trends in iron-making

Introduction
Ironmaking in Europe
Dealing with new ores and wastes

Whats in the pipeline

Conclusion

Blast furnace ironmaking

A modern technology
Blast furnace process 305 years old

First coke based blast furnace

in the world, Coalbrookdale, 1709
HM production 2 t / d

Highest hot metal production

in the world, Posco Pohang 4,
South Korea
HM production up to 17,000 t / d

Hot Metal production via Blast-Furnace and Corex/Finex

DRI production

Source: wsa, Midrex, Siemens VAI

New ironmaking technologies

Several efforts

Maturity of different ironmaking technologies

Source: Noldin Jr.; J. H.

28

Blast furnace ironmaking

Use of HBI in Europe Final solution?

Fe met. input from HBI = 10 % from total Fe in BF burden

Lit.

AK
Steel

Tata
IJmuiden

TKSE

Results from
Calc.

Test

Coke / Tot.
Red. Agents

-5.0 to -8.0

-8.6

-6.6

-6.0

-7.1

Productivity

4.0 to 10.0

12.4

7.6

5.1

7.3

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

Different strategies are possible but economics change

BF, coke plant, HBI produced in Germany: HM costs

Source: ThyssenKrupp Steel Europe

Trends in iron-making

Introduction
Ironmaking in Europe
Dealing with new ores and wastes

Whats in the pipeline

Conclusion

Conclusions
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.

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Trends in iron-making given the new reality of iron ore and coal resources
Prof. Dr. Peter Schmle, ThyssenKrupp Steel Europe
Dr. Hans Bodo Lngen, Steel Institute VDEh
Dr. Jose Henrique Noldin, Lhoist Group