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Use of DRI/HBI in ironmaking and steelmaking furnaces

Article · April 2016

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 Riduzione diretta

Use of DRI/HBI in ironmaking

and steelmaking furnaces
C. Di Cecca, S. Barella, C. Mapelli, A. F. Ciuffini, A. Gruttadauria, D. Mombelli, E. Bondi

The iron and steel production processes are characterized by a considerable environmental impact. The reduction of this
impact, in particular emissions, is the target of modern society; this goal can be achieved through process optimization.
The two main production processes, the blast furnace one and the one from electric arc furnace, are of different
specificities and therefore different levers are present in order to decrease the amount of pollutants in the atmosphere.
The adoption of pre reduced iron charge for these processes seems to be a good operating practice. A further reduction
of pollutants linked to the coke oven batteries can be carried out thanks to the reduction of loaded cast iron within the
converter. The decrease of the hot charge means that a lower amount of coal is consequently required. The electrical
cycle, due to its structure, has a lower environmental impact, but the maximization of the process yield is a desirable
objective for the purpose of a reduction of the environmental impact and economic optimization of such a steel cycle.
The direct-reduced iron (DRI), due to its operative flexibility, is a suitable element to achieve this target.

Keywords: Direct Reduced Iron - Hot Briquetted Iron - Blast Furnace - Basic Oxygen Furnace -
Electric Arc Furnace

Introduction monoxide (reducing gas) in a vertical furnace which constitutes

The steel production is one of the most important industrial
processes. Steel has accompanied the technological development
of civilization because of its properties of high strength and
ductility. (1) Actually, different production routes are used: the
Blast Furnace Route, the Direct Reduction route and the Electric
Arc Furnace route. The BF plants are created for the production
of huge amounts of steel. (2)The beginning of each igneous
metallurgical process consists in the reduction of iron ore. In the
blast furnace, cast iron is produced then it is converted into steel
by blowing oxygen in the converter (BOF). The electric arc furnace
cycle is based on the melting of metal scrap. The manufacturing
process of HBI involves the use of a reformer where there is
the transformation from natural gas to hydrogen and carbon
Cosmo Di Cecca, Silvia Barella, Carlo Mapelli,
Andrea Francesco Ciuffini, Andrea Gruttadauria,
Davide Mombelli
Dipartimento di Meccanica, Politecnico di Milano
Via La Masa 1, 20156, Milano
E-mail: cosmo.dicecca@polimi.it
Enrico Bondi
Italian manager collaborating
with the Politecnico di Milano
the reduction reactor and a “heat recovery unit” (2) (3). The
manufacturing process is energetically less expensive, if compared
to the production of cast iron, as it is not necessary to bring the
iron ores to the melting temperature, unlike in the blast furnaces.
Besides, installation costs are significantly lower than the full cycle
of steel production. The Direct Reduced Iron (DRI) is often used in
briquetted form (Hot Briquetted Iron HBI) and it can be charged in
the blast furnace, inside the converters and in the EAF. (4) (5)
The environmental impact reduction is the ultimate goal of modern
society, particularly for the iron and steel making industries.
Fruehan defines sustainable steelmaking goals as: (i) conservation
of natural resources, (ii) reduction of greenhouse gas emissions, (iii)
reduction of volatile emissions, (iv) reduction of landfill waste and
(v) reduction of hazardous waste. (6)
Table 1 compares the selected parameters for each iron and
steelmaking technology, based on a metric t of produced steel
for BF/BOF and EAF and iron for DRI. Table 1 shows, if compared
to EAF and DRI technologies, BF/BOF route has two to four
times higher consumption of equipment and emissions and this
requires more energy, water and land consumption. Moreover,
the greenhouse gases, main pollutants, and metal emissions are
higher than in the other cases. The most considerable difference
between the technologies was in the level of emissions of main
pollutants (SO2, NOx and CO), mercury and cadmium in the BF/
BOF route, which are several orders of magnitude above the other
two technologies.
Only in the case of PM10 the BF/BOF emissions are of similar to
EAF and DRI ones. (7)

La Metallurgia Italiana - n. 4 2016 37

Direct reduction

Tab. 1 - Comparison of sustainability parameters for the major steelmaking technologies

BF/BOF EAF DRI

Energy consumption (GJ/t) 22 5.8 10
CO2eq emissions (t CO2eq/t) 2.1 0.7 0.4
Water consumption (m3/t) 2.6 0.6 0.8
Land use (m2/t) 1.7 0.5 0.4

Emissions to air (kg/t)

NOx 1 0.04 0.2
SO2 1 7.4*10-4
CO 56 9.8
PM10 0.15 0.14 0.13
PM2.5 1.4*10-2 0.3*10-2 7.7*10-2
Pb 2.6*10-4 1.4*10-4
Hg 9.8*10-6 0.1*10-6
As 6.2*10-6 6.6*10-6
Cr6+ 4.5*10-6
Ni 3.5*10-6 1.6*10-5
Cd 8.1*10-6 0.5*10-6

The BF/BOF route requires the largest energy for steel production,
this is due to the coke-making and sintering processes needed
to treat the raw materials. As a consequence, CO2 equivalent
emissions are also the largest for this route. EAF has slightly
larger greenhouse gas emissions per t of produced metal, if
compared to DRI, mainly due to the use of electricity, while in
case of the DRI process only natural gas is used to reduce the
iron ore. SO2, CO emission and main metals are negligible in DRI
technology.
The innovative nature is to use the DRI as replacement of cast
iron, to increase the cold charge in BOF. The lower use of cast
iron reduces the coke consumption and, as a consequence,
environmental impact is reduced.
• a decrease of the coke consumption, because a fraction of
the charged raw material has been already reduced under
the form of direct reduced iron (DRI/HBI) (Figure 1);
• a decrease of CO2 released in the atmosphere, due to a
lower intensive use of coke;
• a decrease of the sulphur concentration in the pig iron, due
to a lower amount of the introduced coke;
• a possible increase of the pig iron productivity that can be
expected at a maximum level of 10%.

The HBI’s advantages are:

- high bulk density, which results in saving space;
- chemical composition is well known and certified by the
manufacturer;
- minimum amount of armful elements, such as Cu, Ni, Cr, Mo,
Sn, Pb and V;
- high thermal and electrical conductivity;
- low reactivity with fresh and salt water. (8)

Use of DRI/HBI in Blast Furnace (BF)

DRI/HBI can be used in blast furnace for the production of pig
iron. The introduction of such a raw material is consistent with
the production process of the blast furnace, because even during
a traditional process, performed by the introduction of coke and
iron ores, the metal direct reduction takes place in the lowest
part of the divergent section. Just before the melting period,
the blast furnace is interested by the presence of direct reduced Fig.1 - Expected values of the decrease of the coke
iron and thus, the charging of DRI/HBI aims at avoiding the consumption and the expected increase of the productivity
reduction processes needed to reduce a fraction of the charged on the basis of the data published by several steelmaking
raw material. This implies: companies during the last decades.

38 La Metallurgia Italiana - n. 4 2016


Recent data revealed by AK Steel (9) are used to charge an
average amount of about 200kg/t-HM (HM-Hot Metal/Pig Iron)
of the metallic charge and nowadays it is the highest ascertained
value. The collection of the data revealed by Voest Alpine and Ilva
(10) allow determining the equivalent coke (Cokeeq) needed to
complete a fulfill a reduction process as function of the charged
fraction (f) of HBI per 1t if the produced hot metal:
On the other hand, this decrease of the charged coke involves
Fig. 2 - Red Points represent the productivity increase and the coke savings obtained by the introduction of DRI/HBI enriched
by carbon, while Blue points are associated to the reference experiments performed by traditional DRI/HBI confirming
the well consolidated trend.
Several issues will be clarified in the future:
• what is the contribution of DRI/HBI in the structural
stabilization of the raw materials descent within the blast
furnace. It points out an intermediate behavior between the
iron ores and the coke but it has not been clearly quantified;
• what is the variation of the gas permeability in the blast
furnace after the HBI addition and its thermal softening.
Use of DRI/HBI in Basic Oxygen Furnace (BOF)
The process of steelmaking performed by the BOF consists in
three main steps:
- charge of the converter;
- oxygen blowing;
- tapping into the ladle.
The overall metallic charge, composed by cast iron and scrap, is
influenced by the local availability of scrap and liquid iron. The
metallic charge in the BOF converter, is mainly composed by cast
iron (85%) and the remaining part by steel scrap. (12)
La Metallurgia Italiana - n. 4 2016
Riduzione diretta
the amount equivalent coke (including PCI-Powdered Carbon
Injection) and not the large coke. At the moment the minimum
value of this last parameter has been stated at 274kg/t-HM (11).
Lowest values have not been tested and they can be detrimental
for the gas permeability and for the structural stability of the
material during its descent.
A promising further decrease of the coke consumption and an
increase of the blast furnace productivity can be reached by the
introduction of DRI/HBI enriched by carbon to form Fe3C that
represents a well established product in the Energiron technology
developed by HyL (Figure 2).
The cold charge is a mix of different scrap typologies:
1. heavy demolition scrap
2. light demolition scrap
3. busheling
4. turning chips
5. discarded section of slabs and billets
6. granulated cast iron
7. DRI/HBI
The amount of light and heavy scrap fraction is always maintained
constant for each heat. In the scrap box, the light scrap is located
on the bottom to promote the material sliding during the charging
step. At Ilva Taranto an experimental campaign has been realized
in order to increase the cold charge inside 365t BOF up to 90t
through the use of metal scrap and HBI. For the experimental
trials the metal scrap has been set at 45t, while the HBI has been
added by a step of 5t up to an overall amount of 45t. Thus, for the
forty observed heats, seven groups of conversion trials have been
characterized by the same cold charge, that is sum of 25t scrap
and of the added HBI. The cast iron and the HBI average chemical
composition were measured (Table 2, Table 3).
39
Direct reduction

Tab. 2 - Average chemical composition computed for the cast iron

Fe C Mn Si P S
% wt. 92.5 4.5 0.55 0.7 0.075 0.0035
St. Dev. + 2.5 + 0.2 + 0.15 + 0,3 + 0,025 + 0,0015

Tab. 3 - Average chemical composition computed for HBI

Metallic Fe C P2O5 S Gangue

%wt. 85 1.25 0.065 0.0165 3.525
St. Dev. +2 + 0.45 + 0.045 + 0.0135 + 1.575

The yield of each type of charged material has been computed on The HBI yield is comparable with the scrap yield, but this last is
the basis of the tapped steel (Table 4). featured by a higher standard deviation because of the organic
and inorganic contaminants on the scrap surface or charged
Tab. 4 - Mean and standard deviation with it.
of the different elements of metallic charge
Use of DRI/HBI in Electric Arc Furnace (EAF)
Mean St. Dev. The physical properties of DRI/HBI and its correct allocation
inside the EAF buckets affect the quality and the metallurgical
Cast Iron Yield 90% 1% yield. In North America and Europe DRI/HBI is used to lower the
HBI Yield 89% 1% concentration of the metallic residuals (i.e. copper and tin) (13).
The allocation of the charged material in the scrap bucket is
Scrap Yield 89% 2% realized according to a precise scheme (5) (Figure 3)

Fig. 3 - Scheme of EAF bucket charge

DRI/HBI melts fast when it is plunged in molten metal because of
the excellent conductive heat transfer, so it has to be charged in
the second bucket. A proper charging of DRI/HBI can help the arc
stability and the protection of the furnace lining.
The most important factors affecting electricity consumption,
when DRI is charged, are:
• DRI/HBI quality, including metallic iron, carbon, gangue
(SiO2/Al2O3), sulfur, and phosphorus contents;
• DRI/HBI temperature;
• EAF power and thermal efficiency.
The experimental trials have pointed out that the best charging
condition can be achieved when the DRI/HBI is charged in the
second bucket and in a carburized bath. This behavior has been
explained through an experimental investigation in a laboratory
furnace to evaluate the interaction between the pig iron and the
HBI. Different thermal conditions have been imposed in order
to point out the interaction between liquid pig iron and HBI.
The melting experiments have been performed for 10 minutes
at 1200° C, 1300° C, 1400° C, 1500° C and for 20 minutes at
1500° C and they have involved 100g of pig iron and 100g of

40 La Metallurgia Italiana - n. 4 2016

 Riduzione diretta

HBI featured by the same chemical composition used in the BOF
experiments (Table 2, Table 3). At the end of the experiments the
samples were water quenched.
The specimens have been etched using Nital 2%, as recommended
by the standard ASTM E407-07. In the specimen treated at
1200° C (Figure 4) neither pig iron nor HBI melted: they are
completely detached, without any junction promoted by melting
phenomenon. Moreover, no diffusion process takes place because
of the low process temperature. In the other samples, the pig iron
and portions of HBI melt partially, creating a mixed zone.

Fig. 4 - Microstructures displayed by the thermally treated for 10 minutes

at 1200° C (A), 1300° C (B), 1400° C (C), 1500° C (D) and for 20 minutes at 1500° C (E) samples.

La Metallurgia Italiana - n. 4 2016 41

 Direct reduction
The HBI solved in the carbon-enriched bath formed by the pig
iron melting. This process is promoted by the carbon diffusion
into HBI. Actually, the increasing carbon concentration in HBI
ensures the lowering of its melting temperature.
This behavior is confirmed by the changes in the microstructure
at the interface and nearby. The diffusive character of these
phenomena is pointed out by the strong interaction shown in
diffusional short circuits, such as grain boundaries. The performed
experiments indicate that the carbon diffusion can induce two
phenomena:
• the promotion of the melting process;
• the reduction of the oxide contained in HBI and so the
increase of the metallurgical yield associated to the HBI use.
Conclusions
A study on the use of direct reduce iron along the main
steelmaking processes has been performed. These considerations
can be stressed:
• the use of DRI/HBI in blast furnace allows a decrease of the
equivalent charged coke, of the CO2 emission and of sulfur
concentration in the tapped cast iron;
• in the basic oxygen furnace and in the electric arc furnace
a properly carburized metal bath allows the recovery of the
iron oxides in the DRI/HBI;
• the interaction between carburizing materials in the metal
bath, such as pig iron, and the DRI/HBI has to be achieved in
order to maximize the metallurgical yield of the conversion
and of the melting process;
• in EAF route DRI/HBI has not to be charged by first bucket
because such a raw material has to be added into a molten
bath enriched by carbon.
42
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