The MIDREX Process ®

The world’s most reliable and productive

Direct Reduction Technology

Solutions
for Steelmakers
 The MIDREX® Process
INTRODUCTION
CONTENTS
The growth and increasing sophistication of the world steel industry has created an escalating demand for higher quality iron
products. Over the past four decades Midrex Technologies, Inc. has risen to the occasion by supplying the industry with the
2 INTRODUCTION world’s most reliable and productive Direct Reduction Technology: The MIDREX® Process.

3 THE RISE OF DIRECT REDUCED IRON

“Midrex is a technology company founded on the pursuit of innovation and is dedicated to continuous
4 APPLICATIONS FOR MIDREX DRI PRODUCTS ®
improvement especially in the iron and steel industry.” - Don Beggs, inventor of the MIDREX® Process
5 MIDREX® DRI FOR ELECTRIC ARC FURNACES
The MIDREX® Process is the best industry example of this philosophy and its proven results. Plants using the MIDREX
6 MIDREX DRI FOR INTEGRATED MILLS
®
Process are the world’s largest, most flexible and longest running Direct Reduction (DR) plants. Product quality and flexibility
7 MIDREX® DIRECT REDUCTION PROCESS to produce various forms of iron together with some of the best production records industry-wide make MIDREX® Plants the
most profitable DR plants in the world to own and operate. Midrex builds DR plants that work day in and day out, year after
9 MIDREX® SHAFT FURNACE year to provide value for our clients. We provide dependable solutions so our clients can make the most of their investment and
11 FEED MATERIALS maximize their profits for years to come.

12 REDUCING GAS
17 HOT TRANSPORT OF DRI TO EAF
19 PLANT PERFORMANCE
20 VALUE OF MIDREX
21 MIDREX® PLANTS

ENVIRONMENTAL ASSURANCE
Midrex Technologies, Inc. along with its parent company Kobe Steel, Ltd., recognizes the importance of protecting the
environment and conserving natural resources. Through the years we have been proactive in increasing efficiency and
productivity while reducing the environmental impact of our processes.

MIDREX® Plants are designed to minimize water, noise and air pollution.

MIDREX® Plants meet applicable World Bank standards and more importantly, Midrex can and will provide DR Plants
designed to meet any local emissions or environmental standards regardless of location.

1 The MIDREX® Process CONTENTS INTRODUCTION The MIDREX® Process 2

 APPLICATIONS FOR MIDREX® DRI PRODUCTS
SINCE 1970, WORLD DRI CONSUMPTION HAS GROWN BY ALMOST 100-TO-1, A REMARKABLE RECORD
BY A RAPIDLY GROWING INDUSTRY. CONTINUED GROWTH IS EXPECTED AT A STEADY PACE.

DRI PRODUCTS CDRI CDRI HBI HDRI

THE RISE OF
DIRECT REDUCED IRON
RECENT YEARS HAVE SEEN AN EVER INCREASING NEED WORLDWIDE FOR METALLICS, SPECIFICALLY
Product Form Pellet & lump Briquettes* (density ≥ 5.0 Pellet & lump
DIRECT REDUCED IRON (DRI) IN ITS VARIOUS FORMS TO FEED THE STEEL INDUSTRY. grams per cubic centimeter
(g/cc)
DRI is premium iron that is made from oxide by removing A MIDREX® Plant can feed a single EAF or various combina-
Product Temperature Ambient Ambient 550° C or Higher
chemically bound oxygen from the iron without melting. It is a tions of EAFs and integrated complexes supplementing Blast
metallic low in residual metals and nitrogen. It has been used Furnace (BF) and Basic Oxygen Furnace (BOF) operation. Where used EAF & BOF EAF, BOF & BF EAF
for making almost every form of steel product from all types A single Super MEGAMOD® MIDREX® Plant is well-suited Charging Method Continuous & Batch Continuous & Batch Continuous & Batch
of sheets up to and including exposed auto body steels, extra to feed EAFs to replace a blast furnace/BOF complex. A
Description: CDRI (Cold DRI) is a high HBI (Hot Briquetted Iron) is a HDRI (Hot DRI) is discharged
deep drawing quality steels, wire and fine wire products, spe- MIDREX® Plant is also an excellent alternative to importing quality metallic ideal for use premium form of DRI and is hot from the shaft furnace and
cial bar quality, forging bar quality and seamless tube products. large quantities of scrap steel or to building a high cost blast in a nearby EAF. It can also be the industry and regulatory transported to an EAF for
transported via rail to another preferred method of preparing melting and provides the
furnace complex.
site when proper precautions DRI for long term storage and optimum way for DRI users
DRI products are a staple of the electric arc furnace (EAF) are made. It is not recommend- transport. HBI is commonly used to increase productivity and
industry and have found increasing usage in integrated mills MIDREX® DRI products are high quality metallic, low in re- ed for ocean transport. in EAFs and can also be added reduce cost.
to the Blast Furnace and BOF.
to improve their productivity and lower fuel consumption. sidual metals, that dilute undesirable elements contained in
other charge materials. High metallic iron content, adjustable
IMO Restrictions for Inerting (N2) or passivation No Special Precautions N/A
Its purity allows EAFs to produce steels that were historically carbon levels and consistent chemical and physical character- REQUIRED for cargo during
transport
considered to be solely within the domain of oxygen furnace istics provide steelmakers broad flexibility in selecting their the transport
steelmaking. Prior to the application of DRI, EAF’s had ex- furnace charges, along with the ability to produce higher Number of MIDREX® Plants 50 12 7
treme difficulty making these products because of the very quality steels than possible with scrap alone. currently in operation
limited supply of low residual, high grade scrap steel that
* The MIDREX® Process requires less oxide coatings than competing DR technologies, which allows for easier briquetting of DRI and stronger physical
could be sourced to feed to these EAF’s. HBI characteristics.

CDRI HBI HDRI

With the advent of the thin slab caster (TSC) in the early
1990’s, a renewed appreciation arose for the purity of DRI TYPICAL CHARACTERISTICS Fe Total (%) 90 – 94 90 – 94 90 – 94

and its usefulness in making sheet steels. This caused DR OF MIDREX IRON Fe Metallic (%) 83 – 90 83 – 90 83 – 90
Metallization (%) 92 – 97 92 – 96 92 – 96
plants to be built to supply iron for the EAF/TSC mills.
Carbon (%) 1.0 – 3.0 0.5 – 1.5 1.0 – 3.0
MIDREX® Plants commonly produce DRI products
P* (%) 0.005 – 0.09 0.005 – 0.09 0.005 – 0.09
with metallization levels up to 97%, and metal-
S* (%) 0.001 – 0.03 0.001 – 0.03 0.001 – 0.03
lization is controllable independent of other Gangue* (%) 2.8 – 6.0 2.8 – 6.0 2.8 – 6.0
major product parameters. Mn, Cu, Ni, Cr, Mo,
trace trace trace
Sn, Pb, and Zn (%)

Bulk Density (kg/m3) 1,600 – 1,900 2,400 – 1,900 1,600 – 1,900

Degree of Metallization, % = (lbs/ft3) 100 – 120 150 – 175 100 – 120

[( % Metallic Fe)/( % Total Fe)] x 100 Apparent Density (g/cm ) 3

3.4 – 3.6 5.0 –5.5 3.4 – 3.6
Product Temperature (° C) 40 80 600 – 700
Typical Size (mm) 4 - 20 30 x 50 x 110 4 - 20
*Depends on iron ore source

3 The MIDREX® Process THE RISE OF DIRECT REDUCED IRON APPLICATIONS FOR MIDREX® DRI PRODUCTS The MIDREX® Process 4
MIDREX® DRI FOR ELECTRIC ARC FURNACES
THE GREATEST USER OF DRI PRODUCTS IS THE EAF STEELMAKING INDUSTRY.
Even though DRI use is often associated with the production
of high grade, low residual metal, low nitrogen products,
most of the product is actually used to make common grades
of long products, reinforcing bar and light structural prod-
ucts. This is simply because in many locations there is not
enough scrap steel available and local demand for these light
construction steels is sufficient to justify building of an EAF
mini-mill. In such a location, a MIDREX® Plant is an excellent
alternative to importing large quantities of scrap steel or to
building a high cost blast furnace complex.
The benefits of DRI products are not limited to their chemical
characteristics. In an EAF, DRI products can be either batch
or continuously charged.
In batch charging, the use of high bulk density DRI/HBI can
eliminate the need for a second or third scrap charge. This
results in lower energy losses, more power on-time and
improved productivity. Midrex DRI or HBI is mixed with scrap
in the bucket. Generally, DRI or HBI can be added at up to 30
percent of the charge.
5 The MIDREX® Process MIDREX® DRI FOR ELECTRIC ARC FURNACES MIDREX® DRI FOR INTEGRATED MILLS The MIDREX® Process 6
Continuous charging systems can be used to feed up to
100 percent of the required metallics. More commonly, one
bucket of scrap is charged and the remainder is continuously
fed CDRI, HBI or HDRI. This can reduce the number of batch
charges and allows the furnace roof to stay on, retaining
valuable heat. Maintaining a consistent temperature leads
to improved bath heat transfer and faster metallurgical
reactions. HDRI can be charged directly using the MIDREX
HOTLINK® System, the hot conveyor-based Hot Transport
System developed by Midrex and Siemens VAI or by hot
transport vessels. HDRI usage reduces operating cost and
increases productivity.
Melting Benefits of HDRI in EAF
• Increases EAF productivity by 15-20% or higher
• Decreases EAF electricity requirements by at least
120-140 kWh/t liquid steel
• Decreases EAF electrode consumption by at least
0.5-0.6 kg/t liquid steel
• Decreases EAF refractory consumption by at least
1.8-2 kg/t liquid steel
MIDREX® DRI FOR INTEGRATED MILLS
MORE THAN TEN PERCENT OF THE HBI SHIPPED OVERSEAS IS BOUND FOR USE IN BLAST FURNACES, MOSTLY
IN NORTH AMERICA AND IN WESTERN EUROPE. HBI CAN HELP REDUCE BLAST FURNACE EMISSIONS WHILE
INCREASING PRODUCTIVITY. HBI IS ALSO OFTEN USED IN BASIC OXYGEN FURNACES AS A COOLANT.
BLAST FURNACE
EFFECT OF CHARGING METALLIC IRON INTO
Integrated works employ HBI in their blast furnaces to remarkably A BLAST FURNACE - PRODUCTIVITY INCREASE
increase hot metal production and lower coke consumption. HBI
may be used for up to 30% of the blast furnace charge with no
Percent increase in productivity
requirement for additional capital expenditure. 40
30
Its use is cost effective when the steelworks is hot metal short,
20
or if a blast furnace is down for a reline or idled until hot metal
demand increases. Use of HBI also decreases CO2 generation. 10
Practiced mostly in North America and in Western Europe, it is
0
used for two main reasons. One is to routinely increase the pro- 0 10 20 30 40 50
duction from a specific blast furnace, to either increase the steel Percent of iron charged as metallic iron
output from a works or to allow for the closure of a smaller, older,
less efficient blast furnace. The other is to raise the output of
a blast furnace while another blast furnace is taken down for
maintenance.
BASIC OXYGEN FURNACE
A common practice is to use HBI as a cold charge in the BOF
to supplement scrap. It can be loaded in the charging box and
charged and melted like scrap. In cases where scrap has high
levels of residual metals, HBI is a preferred charge material. This
practice is most common in areas where supplies of prime grades
of scrap steel, relative to demand, are readily available.
MIDREX® DIRECT REDUCTION PROCESS
OVERCOMING TECHNICAL, COMMERCIAL AND GEOGRAPHICAL CHALLENGES IS MIDREX’S SPECIALTY,
AND IS A MAJOR FACTOR AS TO WHY THE MIDREX® PROCESS IS THE WORLD’S LEADING TECHNOLOGY
FOR PRODUCING DIRECT REDUCED IRON.
MIDREX® Plants are designed to meet the specific
requirements of each client and can do so because the
MIDREX Process allows for the broadest selection
of proven process options.
3.0
MIDREX Plant capacities range from 0.5 million tons
2.5
per year to more than 2.5 million tons per year and
For more than 40 years, Midrex has produced reliable
ironmaking technologies. Our shaft furnace-based
MIDREX® Process provides an efficient way to reduce
iron oxide with the greatest operational flexibility.
MIDREX® Plants are the industry’s largest, most efficient
and most profitable producers of CDRI, HBI and HDRI.
GROWTH OF MIDREX CAPACITY
Prototype
Series 400
Series 600
MIDREX® DIRECT REDUCTION PROCESS FLEXIBILTY

Million Tons/Year
provide a wide range of product combinations that 2.0 MEGAMOD
include CDRI, HBI and multiple ways to charge HDRI. 1.5 SUPER MEGAMOD
This allows users to create the plant best suited
for their project and site-specific requirements,
1.0 FEED MATERIALS Pellets Lump Ore
providing greater flexibility for the needs of captive 0.5
use or merchant sale.
0
Plant Size ENERGY SOURCES REDUCING GAS
MIDREX Plants may be sized to support the Client’s
needs whether that need is to provide a partial or
total charge for EAF(s), for Blast Furnace(s), for Basic MIDREX®
Oxygen Furnace(s) or for merchant purposes (sales SynRG™ Reformer
to other steel works). Only MIDREX Plants have Flexibility of MIDREX® Plants ®
Natural Gas
proven performance in this regard.
NG Plant
• Combination plants allow for simultaneous discharge of Steam Reformer
Midrex is proud to be the leader in this field with HDRI and CDRI or HBI
as determined by EAF operation
plants making more than 60% of total worldwide and market conditions.
DRI production. In addition more than 80% of all DRI
• The MIDREX® Plant can continue operation when EAF is Coal
products made with natural gas as the fuel are made
offline. Pet Coke Gasifier MIDREX®
by MIDREX Plants. The steel industry will need more
Refinery Bottoms Shaft Furnace
and more clean sources of iron and Midrex will be at • Use of proprietary SIMPAX® Software for process
the forefront, always developing new and ever more automation and HDRI quality prediction enables plant
Coke Oven Thermal Reactor Plant
efficient and profitable technologies. operators to optimize plant availability, efficiency
Gas (COG) System™
and productivity.

Coal COREX® COREX® / ®

Pet Coke Plant

PRODUCT CDRI HDRI HDRI

CDRI HBI
OPTIONS & HBI & CDRI & HBI

7 The MIDREX® Process MIDREX® DIRECT REDUCTION PROCESS MIDREX® DIRECT REDUCTION PROCESS The MIDREX® Process 8
MIDREX® SHAFT FURNACE
Hot, high quality reducing gas is introduced into the burden
THE MIDREX PROCESS USING THE MIDREX SHAFT FURNACE CONVERTS IRON OXIDE IN PELLET OR LUMP
® ® where the metallization is highest and then passes through the THE OVERALL REDUCTION REACTIONS ARE:
FORM INTO HIGHLY METALLIZED DIRECT REDUCED IRON THAT CAN BE DISCHARGED EITHER HOT OR burden in counter-flow to the descending solids (iron oxide Fe2O3 + 3H2 2Fe + 3H2O
being converted into metallic iron). This maximizes both the
COLD WITH UNIFORM PRODUCT QUALITY. COMBINATIONS OF CDRI, HDRI OR HBI CAN BE PRODUCED Fe2O3 + 3CO 2Fe + 3CO2
chemical efficiency and thermal efficiency of the gas.
SIMULTANEOUSLY WITHOUT DISRUPTION TO PRODUCT DISCHARGE.
Midrex pioneered the application of this design for direct re-
Most naturally occurring iron ore exists as hematite (Fe2O3), and contains about 30% oxygen by weight. In the MIDREX®
duction. Our long and extensive experience, that has produced
Process, the chemically bonded oxygen in the iron ore is removed using a high temperature reducing gas composed of
650 million tons of DRI to date, has been used to steadily
hydrogen (H2) and carbon monoxide (CO) to produce metallic iron (Fe).
improve the technology and continues to inspire innovation.

The direct reduction of the iron oxide occurs inside the MIDREX® Shaft Furnace, a cylindrical refractory lined vessel. Iron oxide
The H2 and CO reducing gas can be produced one of several
is fed from the top and DRI is discharged at the bottom allowing for consistent even flow assuring uniform reduction.
ways depending on the fuel source available (more details on
this follows in the Reducing Gas section starting on page 12).

Carbon dioxide (CO2) and water vapor (H2O) are byproducts

MIDREX® SHAFT FURNACE of the iron oxide reduction reactions.

H2 CO2
• Iron Oxide pellets and/or lump are fed to top
of furnace and flow downward. Iron Oxide Charging
FeO Fe
• Iron Oxide is heated and converted to DRI
by a high temperature reducing gas.
CO H2O
• Products can be discharged hot or cold in
combinations that include CDRI, HBI or HDRI

CARBON IN DRI PRODUCTS

REACTIONS WITHIN THE MIDREX SHAFT FURNACE ® Carbon content of DRI Products can be critical when used in the EAF. One reason is that DRI by its very nature is less than
Pre Heat 100% metallized, and carbon is necessary to complete the metallization of the iron in the EAF. Carbon is also a supplemental
way to provide energy to the EAF and for the formation of foamy slag. Too little carbon requires that additional carbon be
REACTION HEAT DESCRIPTION
added to the EAF for these purposes; however, too much carbon requires additional oxygen be added to burn off the surplus.
3Fe2O3 + CO 2Fe3O4 + CO2 Exothermic Reduction by CO Reduction This means longer power on times and longer tap-to-tap times for the EAF and loss of Fe, resulting in lower productivity.
3Fe2O3 + H2 2Fe3O4 + H2O Exothermic Reduction by H2

Fe3O4 + CO 3FeO + CO2 Endothermic Reduction by CO
Fe3O4 + H2 3FeO + H2O Endothermic Reduction by H2
FeO + CO Fe + CO2 Exothermic Reduction by CO
FeO + H2 Fe + H2O Endothermic Reduction by H2
3Fe + CH4 Fe3C + 2H2 Endothermic Carburizing Reaction
3Fe + 2CO Fe3C + CO2 Exothermic Carburizing Reaction
3Fe + CO + H2 Fe3C + H2O Exothermic Carburizing Reaction
The range of carbon needed is directly related to the metallization and amount of DRI charged in relation to the amount and
quality of the scrap also in the charge. Based on comprehensive and exhaustive modeling and testing, the world’s leading EAF
Transition Technology Suppliers have determined that the optimum content should range from 2.0% to 2.7% when the EAF is charged
with 100% HDRI. Slightly higher carbon levels in the DRI may be preferable when CDRI is used as all, or part of the DRI Product
charge to the EAF.
Flexibility to produce variable amounts of carbon can be instrumental to optimum operation. MIDREX® Plants are unique in
Product Discharge their ability to control DRI Product carbon levels from 0.5% to 3.0% independent of other parameters unlike other competing
processes.

9 The MIDREX® Process MIDREX® SHAFT FURNACE MIDREX® SHAFT FURNACE The MIDREX® Process 10
FEED MATERIALS REDUCING GAS
THE MIDREX® PROCESS IS DESIGNED TO OPERATE WITH VIRTUALLY ANY BLEND OF PELLETS AND LUMP VARIOUS FUEL SOURCES INCLUDING NATURAL GAS, COAL, COKE OVEN GAS AND PROCESS SYNGAS
ORES. MIDREX® PLANTS HAVE PROCESSED IRON OXIDE PELLETS AND LUMP ORES OF VARYING QUALITY CAN BE USED TO CREATE A SUITABLE REDUCING GAS FOR THE MIDREX® PROCESS.
FROM MORE THAN 50 SOURCES AROUND THE WORLD.
MIDREX® Process Energy Source Flexibility
The process handles a diverse array of feed Energy Source MIDREX® Plant Reference Reducing Gas Train Reducing Gas H2:CO Start-up
materials including low grade high sulfur ores
in both pellet and lump forms. The typical Natural Gas More than 60 modules MIDREX® Reformer 1.5 to 1.7 Since 1969
in operation
characteristics for widely traded DR-Grade
pellets and lump ores are often dictated by Natural Gas FMO (formerly OPCO) Steam Reformer, Heater + 3.2 to 3.9 1990
MIDREX® Reformer
the requirements of the steel plant to maximize
productivity. COREX® Offgas Arcelor Mittal South Africa CO2 Removal + Heater 0.3 to 0.4 1999

MIDREX Plants often use lower quality iron ore, COREX® Offgas JSW Projects Limited CO2 Removal + Heater 0.5 to 0.6 Construction
even Blast Furnace grade pellets depending on TYPICAL CHARACTERISTICS OF DR-GRADE PELLETS
the cost of raw materials and the economics of AND LUMP USED IN EAF STEELMAKING Coal Gasifier JSPL Angul I CO2 Removal + Heater 2.0 Construction
the Steel Mill. CHEMICAL CHARACTERISTICS

Pellets Lump Reducing gas can be produced using natural gas through a traditional steam reformer or the unparalleled stoichiometric
Midrex has a comprehensive testing program
Fe (%) 67.0 67.0 MIDREX® Reformer. When the source is coal including high sulfur coals or Coke Oven Gas (COG), Midrex uses the MXCOL®
that evaluates existing raw material sources and
SiO2 + Al2O3 (%) 3.0 3.0 flowsheet by means of either a gasifier or Thermal Reactor System™ (more on page 15). Reducing gas can also be produced from
investigates new ones. The Midrex Research and
S (%) 0.008 0.008 the off gas generated by COREX® or FINEX® Plants. An important property of the reducing gas is the reductant / oxidant ratio,
Technology Development Center is fully equipped
P (%) 0.03 0.03 or “gas quality.” The gas quality is a measure of the potential for the gas to reduce iron oxide. The higher the gas quality the
to assess the suitability of pellets and lump ores
TiO2 (%) 0.15 0.15 lower the volume of gas required to react with the iron; pushing less gas means the process is more efficient.
for direct reduction use. Midrex works with iron
oxide suppliers to develop new and improved
PHYSICAL CHARACTERISTICS

sources of raw materials and with plant operators Pellets Lump Gas Quality = (% H2 + % CO) / ( % H2O + % CO2)
to evaluate sources for their needs.
Nominal Size 6 x 16 mm 10 x 35 mm
10 x 35 mm (%) — 85 min.
9 x 16 mm (%) 95 min. —
FEEDSTOCK OPTIONS
Minus 5 mm (%) 3 max. 5 max.
Compression Strength (kg) 250 min. —
Less than 50 kg (%) 2 max. —

REDUCTION CHARACTERISTICS
PELLETS
Pellets Lump

Midrex Linder Test (760° C)

Metallization (%) 93 min. 93 min.
Minus 3.36 mm (%) 2 max. 5 max. Hadeed Module E MIDREX® Plant, Saudi Arabia Comsigua MIDREX® Plant, Venezuela

Hot Load Test (815° C)
LUMP Tumble Strength (% plus 6.73 mm) 90 min. 85 min.
Compression Strength (kg) 100 min. —
Clustering (% plus 25 mm after 10 rev.) 0 0

Lower quality iron ores are often used in MIDREX® Plants depending on the cost of the raw materials and the
impact of down stream steelmaking operations. The Midrex Materials Testing Lab can evaluate all types of iron
oxide pellets and lump ore to determine suitability for Direct Reduction. ArcelorMittal South Africa Plant FMO Planta de Briquetas (formerly OPCO) JSPL Angul I, India - Under Construction
COREX®/MIDREX® Venezuela, Using Steam Reformers MXCOL® Coal Gasifier

11 The MIDREX® Process FEED MATERIALS REDUCING GAS The MIDREX® Process 12
REDUCING GAS
The SynRG® Reformer features lower NOx burners, new catalyst composition and configuration, revolutionary new tube
NATURAL GAS IS THE CLEANEST, GREENEST FUEL FOR PRODUCTION OF DRI. metallurgy and a new footprint.

To date Midrex has supplied more than 70 MIDREX® Reformers for projects around the world. The largest MIDREX®
USING NATURAL GAS
Reformers produce nearly 400,000 Nm3/hr of reducing gas, enabling the production of more than 2.0 million tons per year
To create reducing gas from natural gas, the natural gas must first be reformed into hydrogen (H2) and carbon monoxide (CO).
of DRI. Even larger units are available.
The MIDREX® Process typically uses natural gas as the reductant and fuel by means of the unique MIDREX® Reformer.

MIDREX® REFORMER
Midrex designed and built the world’s first commercial high temperature, stoichiometric CO2 reformer. This concept is unique THE MIDREX® REFORMER
to the MIDREX Process and enables the production of a high quality reformed gas that can be fed directly to the direct
reduction shaft furnace. • Refractory lined furnace with catalyst tubes through which gas flows upward

• Combined CO2 removal and heater in one step

The MIDREX Reformer converts recycled offgas MIDREX® PROCESS FUELED BY NATURAL GAS
from the MIDREX® Shaft Furnace plus fresh natural • Natural gas plus recycled top gas (feed gas) is catalytically reformed
MIDREX REFORMER®
gas into hydrogen (H2) and carbon monoxide (CO). • Reducing gas is approximately 90% (H2 + CO), at temperatures of
900-950° C , and used without quenching and without reheating
Iron Ore
Natural gas plus recycled top gas is heated in a
refractory lined furnace and catalytically reformed. Reformer Tubes with Catalyst
Reducing Gas
The use of recycled gas and the ability to feed hot
reformed gas to the shaft furnace without quenching
and reheating provide for a very efficient process. TYPICAL COMPOSITION
Flue Gas
INLET OUTLET
Top Gas Fuel H2 35 55
Unique to the MIDREX Process specifically due to the Top Gas
CO 19 35
MIDREX Reformer is the recycle of waste CO2 from CO2 15 2
the reduction furnace creating an additional reaction Scrubber H2O 13 6
Natural MIDREX®
of CH4 + CO2 to produce 2H2 and 2CO. Gas MIDREX® Shaft Feed Gas CH4 17 1
Reformer Reducing Gas Furnace N2 1 1
Fuel Gas and
Combustion Air Temp. (°C) 580 980

CH4 + H2O CO + 3H2 (H2O reforming)

CH4 + CO2 2CO +2H2 (CO2 reforming) STEAM REFORMER

Product
The optimum way to use natural gas to produce reducing gas is to use a MIDREX® Reformer; however, MIDREX has
produced reducing gas with a conven­tional steam reformer such as used in the petro-chemical industry.
The MIDREX Reformer eliminates the need for a
separate CO2 removal system as it reforms the CO2 One such example is the FMO Planta de Briquetas (formerly OPCO) in Puerto Ordaz,
to CO and it also completely eliminates the need for Venezuela. This MIDREX® Plant started up in 1990 using an existing steam reformer
a process gas re-heater. originally supplied for another process technology.

SynRG® REFORMER
The FMO Plant decided to increase capacity in the 1990s. A number of options were
Through continuous innovation and commercial
studied and eventually it was decided that best solution was to augment the steam
application, Midrex has introduced its next genera-
reformer by adding a small MIDREX® Reformer. The MIDREX Reformer began
tion MIDREX® SynRG® Reformer that provides even
operation in 1996 with the steam reformer and increased the capacity of the plant
greater efficiency of operation and lower capital
to more than one million tons of HBI per year.
expenditure.

FMO Planta de Briquetas (formerly OPCO)

Puerto Ordaz, Venezuela

13 The MIDREX® Process REDUCING GAS REDUCING GAS The MIDREX® Process 14
REDUCING GAS MXCOL® GASIFIER SYNGAS SOLUTION
Gasification refers to the reaction of coal or other solid or liquid carbonaceous feedstock with oxygen to produce a synthesis
gas (syngas). As opposed to combustion, in which air or oxygen produces CO2 and water, gasification uses lesser amounts of
MXCOL® (PRONOUNCED “M-X-COAL”) IS THE NAME AND TRADEMARK FOR THE COMMERCIALLY PROVEN air or oxygen to produce H2 and CO.
MIDREX® SHAFT FURNACE TECHNOLOGY THAT USES SYNGAS DERIVED FROM COAL.
Commercially available gasification technology can be paired with a MIDREX® Shaft Furnace through MXCOL® to produce DRI.
USING COAL The designs include gas-cleaning and conditioning systems to provide a reducing gas suitable for direct reduction. After cleaning
MXCOL® can receive syngas from many sources including commercial gasifiers (using high or low quality coals or other alter- and conditioning, the gas is reheated to the proper temperature and introduced to the furnace. After scrubbing and CO2
native fuels) and the new Thermal Reactor System™ (technology using an innovative partial oxidation system). The MIDREX® removal, the offgas is recycled with fresh syngas.
Shaft Furnace can also use the off gas of the coal-based COREX® Hot Metal Process from Siemens VAI Metals Technologies.
The benefit is that it produces very
MXCOL COKE OVEN GAS (COG) SOLUTION
® MXCOL® GASIFIER OPTION high quality syngas regardless of the
Coke ovens produce coke for use in blast furnaces and generate an offgas containing H2 and CO. This gas is used typically for quality of the fuel.
Iron Oxide
feedstock to chemical plants, heating applications and production of electricity, but chemically can have more economic value
to the steelmaker to create additional iron units. Possible feedstocks include coal,
Coal
Pet Coke lignite, pet coke and other petroleum
The MXCOL® option for using coke Refinery Bottoms refinery bottoms. As energy costs
oven gas (COG) incorporates a MXCOL® COG OPTION Recycle Gas rise, gasification enables the use of
new Thermal Reactor System ™ lower quality coals or waste prod-
Iron Oxide Gas
from Midrex Technologies, Inc. and Gasifier Cleaning & ucts to produce energy.
CO2 MIDREX®
Conditioning Shaft Furnace
Praxair, Inc. This unique technology Clean Removal
O2
Coke Oven Gas Scrubber
utilizes partial oxidation to reform
(COG)
the COG gas for use in the MIDREX® COG Air
Pre-Heater Separation Syngas
Recycle Gas Gas
Process to produce DRI, HBI or Plant Heater
HDRI. When the coke ovens are
located on the site of an inte- MIDREX® Turbo Expander
Shaft Furnace
grated blast furnace steel works, CO2
DRI / HBI / HDRI
Thermal Removal Scrubber
HBI produced by the MIDREX Reactor Gasification Plant MIDREX® Plant
Process can be used onsite to in- O2
Gas
crease the capacity of the blast fur- Air Heater
nace. HBI is used on an increasing Separation
Plant Syngas Reducing Gas
basis to provide alternate feed ma- DRI / HBI / HDRI COREX® OFFGAS
COREX®/ MIDREX® OPTION
terial for blast furnace operations. The world’s first application of
Thermal Reactor System ™ MIDREX Plant ®

Some operators feed up to 30% coal gasification to produce DRI Iron Oxide
HBI to their blast furnace on a con- in a MIDREX® Plant started up in
Additives/
sistent basis to improve its perfor- 1999 at ArcelorMittal Steel South
Ore/Pellets
mance and reduce environmental Iron Oxide
HBI Africa (formerly Saldanha Steel). COREX®
COG
This is known as the COREX®/ Export
emissions. DRI / HBI / HDRI Reduction Top Gas Syngas Recycle Gas
Coke Hot Metal MIDREX® Process. Shaft

This facility includes a COREX® MIDREX®

Coke Oven Shaft Furnace
Plant, supplied by Siemens VAI, Coal CO2
Scrubber Removal Scrubber
which uses a melter/gasifier to
Gasifier
simultaneously produce hot metal Melter
Integrated Mill Blast Furnace Basic Oxygen Furnace
and a by-product synthesis gas Gas
O2 Heater
that feeds a MIDREX MEGAMOD®
Shaft Furnace. Slag
DRI / HBI / HDRI
Hot Metal
COREX Plant
®
MIDREX Plant
®

15 The MIDREX® Process REDUCING GAS REDUCING GAS The MIDREX® Process 16
HOT TRANSPORT OF DRI TO EAF
MIDREX®
HOT TRANSPORT CONVEYOR Shaft Furnace
MIDREX OFFERS MULTIPLE METHODS FOR HOT TRANSPORT: HOTLINK®, HOT TRANSPORT
CONVEYORS AND
HOT TRANSPORT CONVEYOR
HOT TRANSPORT VESSELS THAT ALLOW IMPLEMENTATION AT A WIDE VARIETY OF EXISTING MILLS AS WELL In cases where the meltshop is not immedi- HDRI
AS NEW GREENFIELD SITES. ALL THREE METHODS HAVE BEEN COMMERCIALIZED. ately adjacent to the MIDREX® Shaft Furnace, Optional Distance to EAF
less than 200 m
an option is to use an insulated mechanical
Midrex pioneered the Shaft Furnace design for HDRI that has been part of all MIDREX® Hot Discharge plants since 1984. For conveyor to transport HDRI to the meltshop at
any of the hot transport options, the MIDREX® Plant can be designed to produce CDRI or HBI as a secondary product stream a temperatures of 550° C or higher. DRI Cooler
when the meltshop cannot accept HDRI. Plants are designed to produce the two products simultaneously and to switch from
Briquette
one product to another quickly without disrupting product flow. In this case, DRI is discharged hot from the Machine
Hot Transport EAF
furnace onto a fully enclosed and insulated DRI Storage Conveyor
conveyor, which is designed to minimize Electric Arc Furnace
temperature loss and prevent re-oxidation. The
MIDREX HOT CHARGING METHODS conveyors are specially designed for Midrex by HBI Storage
Aumund Fördertechnik GmbH.
HOTLINK® HOT TRANSPORT CONVEYOR HOT TRANSPORT VESSELS
(Distances < 40m) (Distances < 200m) (Distances > 100m)
The HDRI is fed to storage bins located above the EAF. As one bin is being filled, the other one is discharging HDRI to the EAF.
It is critical that the transport method from the shaft furnace to the EAF be capable of delivering HDRI without adversely affect-
ing product quality, while providing maximum operational flexibility. Module E at Hadeed in Saudi Arabia is the first MIDREX
Plant to incorporate this option. This patented hot transport system was pioneered by Midrex Technologies, Inc., Siemens VAI
Metals Technologies and Aumund Fördertechnik.

HOT TRANSPORT VESSELS

Another means for transporting HDRI to the
MIDREX®
meltshop is with the use of vessels, normally HOT TRANSPORT VESSELS Shaft Furnace
with a capacity of 45-90 tons. The vessels are
first filled with inert gas or nitrogen, and con-
Reference: Jindal Shadeed (Oman) Reference: Hadeed Mod E (Saudi Arabia) Reference: Lion HBI (Malaysia) HDRI
nected to a sealed and purged feed leg. The
Optional Distance to EAF
vessel is then filled and transported by truck or greater than 100 m
rail to the meltshop.
HOTLINK® DRI Cooler
HOTLINK® is based on proven technology and
MIDREX® The use of vessels is ideal for situations in
HOTLINK® Shaft Furnace Briquette
the design using primarily gravity transport which there is an existing meltshop and it is Machine
EAF

minimizes HDRI metallization and temperature not possible to locate the shaft furnace close
DRI Storage Hot Transport Electric Arc Furnace
losses. HDRI enough to utilize HOTLINK® or a hot transport
Distance to EAF Vessel
Optional conveyor.
less than 40 m
HOTLINK® delivers HDRI to the EAF at tempera- HBI Storage
tures up to 700° C by positioning the MIDREX® MIDREX® Plants pioneered the use of hot
Hot Discharge Furnace just outside and above transport vessels in the 1990s and other
DRI Cooler
the exterior wall of the meltshop. This allows hot plants including LION HBI use similar vessels.
Briquette Hot Transport
DRI to be discharged from the shaft furnace to a Machine Conveyor More than 40 million tons of HDRI have been
surge bin and then directly to the EAF. EAF charged to the EAFs by this method.
DRI Storage

The primary goal is to supply hot DRI to the EAF Electric Arc Furnace
as demand requires. HOTLINK® Plants have been HBI Storage
built in Egypt and Oman.

17 The MIDREX® Process HOT TRANSPORT OF DRI TO EAF HOT TRANSPORT OF DRI TO EAF The MIDREX® Process 18
PLANT PERFORMANCE VALUE OF MIDREX
MIDREX® DIRECT REDUCTION PLANTS, THROUGH YEARS OF EXPERIENCE AND CONTINUOUS INNOVATION, VALUE IS INSTRUMENTAL TO SUCCESS.
ARE THE STANDARD BY WHICH THE DIRECT REDUCTION INDUSTRY IS MEASURED.
THE VALUE OF A DRI TECHNOLOGY SUPPLIER CAN
MIDREX® Plants are designed to help owners and operators best deal with real world market changes. There are several
BE MEASURED BY THE ENTIRE TECHNOLOGY
factors that can affect the profitable operation of a direct reduction plant such as ore costs, energy costs, labor and the
PACKAGE, PROJECT EXECUTION AND OVERALL
unpredictability of the steel market. Out of all the variable factors, the choice of process technology is the only one that the
owner can truly control and more importantly, it is the one that can affect profitability in both good and bad economic times.
PLANT PERFORMANCE.
MIDREX® Plants demonstrate by far the greatest availability (hours of continuous operations) of any direct reduction MIDREX® Plants are the most price effective DRI Plants to
technology. Every MIDREX Plant ever commissioned has exceeded its annual rated capacity on a real annual basis. Numerous build, own and operate. They have this reputation due to the
MIDREX Plants have produced up to 500,000 or more tons of DRI in a calendar year than their original design capacity. In years of technology innovation, operation and longevity of
terms of both total tons produced and percentage of rated capacity, MIDREX® is the industry leader. each plant built.
Every single MIDREX Plant ever commissioned has exceed-
Hours of Operation x Capacity = Production = Profits ed its design capacity and has done so consistently on an
annual basis. At least 20 MIDREX Plants have operated an
impressive 8,300 continuous hours (or even higher) within
MIDREX® Plant Performance is defined by how well the flexibility and proven reliability of the MIDREX Plant operation allows a given year. That means these plants were in operation for
a client to take advantage of boom markets as well as weather the storm of bad times. more 95% of the year. The simple fact is if a DR Plant is not
running it cannot make product. If it can only run at a fraction
In good market conditions MIDREX Plants overwhelmingly produce more DRI than any other technology. When the market of its total design capability then it is a waste of a large capital
is down, MIDREX Plants can be efficiently operated at lower capacities to provide the best economics for overall operation. investment, so we design and construct our plants to
DR plant owners that have both MIDREX and competing technologies routinely idle the DR plant utilizing the competing produce consistently with as little disruption as possible.
technology and run only their MIDREX Plant during the tough economic period.
At Midrex we define value as the total worth of what we
Further, MIDREX Plants stay in production for many years. Even plants built in the early-1970 continue in operation, exceeding can bring to our clients and customers. This goes far beyond
their original planned product quality and productivity. MIDREX Plants are so reliable that if local economic conditions cause
profitability to decline, they are typically moved to another location.
providing the most innovative and top producing technology
solutions. It also includes providing the best methods of
building plants, from design and ore testing to transferring
technology through onsite training and on-going MIDREX®
Licensee support. Midrex can also assist with ECA financing
if needed for the project. In addition, progressive installation
and construction methods and plans mean most MIDREX
Plants can be erected and ready to run in 24 months.
We have experienced erection, operations and maintenance
personnel from around the world. Our engineering staff has
pioneered some of the Direct Reduction industry’s most
impressive innovations. Midrex’s technical services team
provides ongoing support through periodic technical services
bulletins and annual MIDREX® Operations conferences. In
addition, our dedicated Midrex Global Solutions aftermarket
group helps keep operations running smoothly by sourcing
spare parts and engineered solutions because value to us
means passing value on to our clients.
MIDREX’S FOCUS IS TO BRING OUR CLIENTS NOT
ONLY THE BEST TECHNOLOGY SOLUTION, BUT TO
BRING THEM THE BEST FINANCIAL PAYBACK FOR
THEIR INVESTMENT.

Hours of Operation x Capacity = Production = Profits

Profits x Years = VALUE

INNOVATION THAT WORKS

2.0
Million tons per year

1.5
pm ent
g y D evelo
o l o
1.0 Techn

0.5

0.0
35 or more 30 to 35 25 to 30 20 to 25 15 to 20 10 to 15 10 or less
Prior to 1977 1977 to 1982 1982 to 1987 1987 to 1992 1992 to 1997 1997 to 2002 2002 to present

Average Rated Capacity Age of Plants (years) & Date of Start Up

Best Annual Production of Period

19 The MIDREX® Process PLANT PERFORMANCE VALUE OF MIDREX The MIDREX® Process 20
MIDREX® PLANTS
Design Shaft Furnace
Plant Location Capacity (Mt/y) Modules Product Start-up Status**
SINCE 1969, THERE HAVE BEEN MORE THAN 70 MIDREX SHAFT FURNACE DIRECT REDUCTION MODULES
®

BUILT IN 21 COUNTRIES WORLDWIDE.

MIDREX® PROCESS (Continued)
Khouzestan Steel V Ahwaz, Iran 0.80 1 CDRI ‘08 O
Overcoming technical, commercial and geographical challenges, MIDREX® Plants are able to perform reliably at or above rated Lion DRI Banting, Malaysia 1.54 1 HDRI/HBI ‘08 O
capacity in climates that range from the dry, sandy heat of Saudi Arabia to the frigid cold of Canada and Russia. To-date only three HOSCO I & II Bandar Abbas, Iran 1.65 2 CDRI ‘09/‘10 O
MIDREX® Modules have ever been decommissioned, the two small demonstration plants built in Portland, Oregon in 1967-69 and Essar Steel VI Hazira, India 1.50 1 CDRI ‘10 O
the first full sized commercial scale plant built in Georgetown, South Carolina, USA in 1969-71. Much of the equipment from the Khorasan Steel I Khorasan (Mashad), Iran 0.80 1 CDRI ‘10 O
IMPADCO Khorasan (Mashad), Iran 0.80 1 CDRI ‘11 O
Georgetown facility remains in operation at sister plants operated by the same owner.
Jindal Shadeed Sohar, Oman 1.50 1 HDRI/HBI ‘11 O
IGISCO Ardakan (Yazd), Iran 0.80 1 CDRI ‘12 * C
Arfa Steel Ardakan (Yazd), Iran 0.80 1 CDRI ‘12 * C
Design Shaft Furnace
Khorasan Steel II Khorasan (Mashad), Iran 0.80 1 CDRI ‘12 * C
Plant Location Capacity (Mt/y) Modules Product Start-up Status**
Jindal Steel & Power9 Angul, India 1.80 1 HDRI/CDRI ‘12 * C
Tuwairqi Steel Mills Karachi, Pakistan 1.28 1 HDRI/CDRI ‘12 * C
MIDREX® PROCESS ESISCO Sadat City, Egypt 1.76 1 HDRI/CDRI ‘13 * C
Oregon Steel Mills 1 Pilot Plant1 Portland, Oregon, USA 0.08 1 CDRI ‘69 D Saba Bandar Abbas, Iran 1.50 1 CDRI ‘13 * C
Oregon Steel Mills 2 Pilot Plant1 Portland, Oregon, USA 0.08 1 CDRI ‘69 D SULB Hidd, Bahrain 1.50 1 HDRI/CDRI ‘13 * C
ArcelorMittal Georgetown2 South Carolina, USA 0.40 1 CDRI ‘71 D JSW Projects Ltd. Toranagallu, Karnataka, India 1.20 1 HDRI/CDRI ’13 * C
ArcelorMittal Hamburg Hamburg, Germany 0.40 1 CDRI ‘71 O LGOK 3 Gubkin, Russia 1.80 1 HBI TBA C
ArcelorMittal Canada 1 Contrecoeur, Quebec, Canada 0.40 1 CDRI ‘73 O
TenarisSiderca Campana, Argentina 0.40 1 CDRI ‘76 O
ArcelorMittal Canada 2 Contrecoeur, Quebec, Canada 0.60 1 CDRI ‘77 O
SIDOR I Matanzas, Venezuela 0.35 1 CDRI ‘77 O FOOTNOTES PRODUCTION OF DIRECT REDUCED IRON 2011 Total Production
Acindar3 Villa Constitucion, Argentina 0.60 1 CDRI ‘78 O BY SHAFT FURNACE PROCESSES 55.5 Mt
1. Original demonstration plants built for Oregon Steel Mills used to
Qatar Steel I Mesaieed, Qatar 0.40 1 CDRI ‘78 O develop the MIDREX® Process. Ceased operating after the cost of
SIDOR II Matanzas, Venezuela 1.29 3 CDRI ‘79 O natural gas to the plants rose to more than ten times the original cost.
ArcelorMittal Point Lisas I & II Point Lisas, Trinidad & Tobago 0.84 2 CDRI ‘80/’82 O Total of all other shaft furnace
2. Facility idled after its natural gas supply rose to eight times
Delta Steel Warri, Nigeria 1.02 2 CDRI ‘82 I
original cost. Parent company sold facility as it was about to restart;
processes
Hadeed A & B Al-Jubail, Saudi Arabia 0.80 2 CDRI ‘82/’83 O new owners relocated main process equipment to support their
OEMK I - IV Stary Oskol, Russia 1.67 4 CDRI ‘83/’85/’85/’87 O more strategically located MIDREX® Plants.
MIDREX® Process
Antara Steel Mills Labuan Island, Malaysia 0.65 1 HBI ‘84 O
3. Record holder for most cumulative production from a single
Khouzestan Steel Co. I - IV Ahwaz, Iran 1.84 4 CDRI ‘89/’90/’92/’01 O (1970 through 2011)
Direct Reduction module, producing more than 25 million tons
EZDK I El Dikheila, Egypt 0.72 1 CDRI ‘86 O to date.
LISCO 1 & 2 Misurata, Libya 1.10 2 CDRI ‘89/’90 O
Essar Steel I & II Hazira, India 0.88 2 HBI/HDRI ‘90 O 4. 1st commercial COREX®/MIDREX® Plant
FMO Puerto Ordaz, Venezuela 1.00 1 HBI ‘90 O 5. Original module first built in 1990s in the USA as the 1.2 mtpy AIR
VENPRECAR Matanzas, Venezuela 0.82 1 HBI ‘90 O plant idled due to low industry demand and record high natural gas
Essar Steel III Hazira, India 0.44 1 HBI/HDRI ‘92 O prices in North America; moved to Trinidad & Tobago in 2005, and
Hadeed C Al-Jubail, Saudi Arabia 0.65 1 CDRI ‘92 O the plant was expanded by Midrex Technologies Inc. to new a new
design capacity of 1.6 mtpy.
Mobarakeh Steel A - E Mobarakeh, Iran 3.20 5 CDRI ‘92/’93/’94 O
JSW Ispat, Ltd. Raigad, India 1.00 1 CDRI ‘94 O 6. Original modules first built in the 1970s in the UK and moved to
EZDK II El Dikheila, Egypt 0.80 1 CDRI ‘97 O USA in the late 1990s, then dismantle and moved again to Saudi
LISCO 3 Misurata, Libya 0.65 1 HBI ‘97 O Arabia in 2005-2006.
ArcelorMittal Lázaro Cárdenas Lázaro Cárdenas, Mexico 1.20 1 CDRI ‘97 O 7. Largest Producing DRI module currently in operation - nearly 2 Mt
COMSIGUA Matanzas, Venezuela 1.00 1 HBI ‘98 O in 2011.
ArcelorMittal Point Lisas III Point Lisas, Trinidad & Tobago 1.36 1 CDRI ‘99 O
8. Largest HBI Shaft Furnace Module in Production
ArcelorMittal South Africa4 Saldanha Bay, South Africa 0.80 1 CDRI ‘99 O
EZDK III El Dikheila, Egypt 0.80 1 CDRI ’00 O 9. 1st commercial MXCOL® Plant using coal gasifier
Essar Steel IV Hazira, India 1.00 1 HBI/HDRI ‘04 O * Client’s projected date of start up as of 3Q 2012
Nu-Iron5 Point Lisas, Trinidad & Tobago 1.60 1 CDRI ‘06 O
Essar Steel V Hazira, India 1.50 1 HBI/HDRI ‘06 O ** Status Codes:
Mobarakeh Steel F Mobarakeh, Iran 0.80 1 CDRI ‘06 O
O – Operating
DRIC I & II6 Dammam, Saudi Arabia 1.00 2 CDRI ‘07 O I – Idle
Hadeed E7 Al-Jubail, Saudi Arabia 1.76 1 HDRI/CDRI ‘07 O C – Under Contract or Construction
LGOK II8 Gubkin, Russia 1.40 1 HBI ‘07 O D – Decommissioned
Qatar Steel II Mesaieed, Qatar 1.50 1 CDRI/HBI ‘07 O

21 The MIDREX® Process MIDREX® PLANTS MIDREX® PLANTS The MIDREX® Process 22
www.midrex.com

USA / CORPORATE HEADQUARTERS:

Midrex Technologies, Inc.
2725 Water Ridge Parkway
Suite 100
Charlotte, NC 28217 USA
Tel: +1 (704) 373 1600
Email: sales@midrex.com

UK:
Midrex UK Ltd.
Two London Bridge
London, SE1 9RA
United Kingdom
Tel: +44(0)207 0891520
Email: info@midrex.com

CHINA:
Midrex Metallurgy Technology Services
(Shanghai) Ltd.
1505 Park Place
1601 Nan Jing West Road
Shanghai 200040 PRC
Tel: +86 21 61573700
Email: sales@midrex.cn

INDIA:
Midrex Technologies India Private, Ltd.
Global Foyer, Golf Course Road
Gurgaon-122002, Haryana | India
Tel: 0124-4908712
Email: sales@midrex.in

November 2012