New Ironmaking Processes

for CO2 Reduction

(FASTMET/ITmk3)

25.October.2007
Hidetoshi Tanaka
KOBE STEEL, LTD.

Asia-Pacific Partnership on Clean Development and Climate

4th Steel Workshop, Wollongong Australia

Contents

† FASTMET Process
† FASTMELT Process
† ITmk3 Process
† CO2 Reduction by using New Iron-making
processes
† Conclusion

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Necessity of New Ironmaking Processes

Background for Demanding New Ironmaking Process

† Coke is very expensive
† Steaming Coal is the cheapest energy
† Fine iron ore is abundantly available
† BF process consume a large amount of energy
and place a high burden on the environment.

Coal Based Direct reduction Processes

FASTMET®, FASTMELT® and ITmk3®,

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FASTMET Process Flow

Raw Material
Storage

Air Blower
Briquette
Mixer Machine

OR
ID Fan
Heat Bag Filter
Exchanger

Pellet Dryer RHF

Stack
Pelletizer

Fuel
Discharger
Burner
OR

DRI Container DRI Quench Tank

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 The image of Steel Dust recycling in
FASTMET Process

Secondary Dust (Zinc Oxide)

Zinc
Sale to
Alkali Zinc
Arsenic producer
Material Dust Lead

Zinc Product DRI

Alkali
Arsenic Iron
oxide FASTMET Recycling
Gangue Gangue Metallic
Iron in
PLANT
Sulfur steelmill
Copper
carbon Sulfur Copper

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FASTMET Commercial Plants

14,000t/y BF, BOF, EAF dust
Start-up : April 2001
Kobe Steel
KAKOGAWA

Nippon Steel
HIROHATA No1 & No2
190,000t/y Steelmaking dust
Start-up : March 2000 and Feb, 2005
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 Hot Metal Production
by FASTMELT® Process

† Direct combination of FASTMET and DRI melter

† Major functions of the DRI melter
„ Effective melting
„ Removal of gangue by melting
„ Reduction of residual FeO to Fe
„ Desulphurization
„ Adjustments of carbon contents in the molten
iron

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FASTMELT Process

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 Typical FASTMELT Molten Iron Chemistry

Temperature Fe C Si S P
1,450-1,550 deg.C 96-98% 2.0-4.0% 0.1-0.6% <0.05% <0.04%

FASTMELT process can produce very

similar molten iron as compare with BF

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What is ITmk3 ?
Iron-making Technology Mark Three
Mark
One:
BF-
BF-BOF
system

Mark Two:
Natural
Gas-
Gas-
based DR

ITmk3 is the third main breakthrough in iron-making

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 ITmk3 Process
High Grade Pure Iron Nuggets Metallic Iron 96-97%
Carbon 2.5-3.0%
¾ by using fine ore and coal Sulfur 0.05-0.07%
Size 5-25mm
¾ by separation of metal and slag
¾ with fast reduction and melting
rate (8 to 12 min.)
¾ at relatively lower temperature
(1350 to 1450℃)

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Product figure and Cross sectional view

of time sampled pellet

Metal
Slag
Dense metallic Molten slag separated
iron shell from metal

3min 5min 6min 9min

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 Asia-Pacific Partnership on Clean Development and Climate
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Separation of metal and slag

Metal (Iron Nugget)

Slag

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 ITmk3 process flow

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ITmk3 Pilot & Demonstration Plant

Kakogawa Mesabi
Bench Scale Plant Pilot Demonstration Plant
RHF outer dia. : 4.0m RHF outer dia.: 13.5m
Capacity: 0.4t-iron/h Capacity: 25,000t-iron/y

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Product Pile of Iron Nugget

More than 9,000mt of

iron nugget has been
melted in existing EAFs

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Potential Projects in Progress in the USA

New Mesabi Project

SDI/KSL

Potential Project out

Michigan Project
of the USA CCI/KSL
¾India
¾Ukrine
¾Australia

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 CO2 reduction by using FASTMET
Mine Location Consuming Location

Base Case CO2 Emission

Base
Coke Coke
Coal
Oven
BF

Iron Sinter
Ore Plant Sinter Hot Metal
TFe:56%
Mill Waste CO2 Redction
HBI Production ▲0.2 t-CO2/t-HBI I
from Mill Waste HBI
TFe:58% BF
MFe:50%
HBI Production FASTMET Hot Metal
in Mine Location

Coal CO2 Redction

HBI ▲1.02 t-CO2/t-HBI I
Iron TFe:85% BF
Ore MFe:78%
FASTMET
Hot Metal
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Energy Consumption of Different Processes

Electricity(to outside)
35.00
Other
Electricity
30.00 Fuel Gas
Coal
25.00
Energy Consumption (Gj/thm)

20.00

15.00

10.00

5.00

0.00
Large BF Mini BF FASTMELT ITmk3
(3Mt) (0.5Mt) (0.5M) (0.5M)
-5.00

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CO2 reduction by using FASTMELT/ITmk3

in Japan
3,000
CO2 Emission (kg-CO2/thm)

2,500
CO2 Reduction
2,000
▲1t-CO2/thm
1,500

1,000

500

0
Large BF Mini BF FASTMELT ITmk3
(3Mt) (0.5Mt) (0.5M) (0.5M)

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Conclusion
¾With growing concerns on the conservation of
resources and the environment, the new ironmaking
processes are receiving more and more attention.
¾Kobe/Midrex has jointly developed new ironmaking
processes such as FASTMET and ITmk3, which can
reduce CO2 emission as compared with the BF.
¾We will continue to develop and supply coal-based DR
processes and plants. In doing so, we aim to contribute
to both growing the ironmaking industry and improving
the global environment.

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