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A demonstration plant (30 000 tpy of pig iron) was built to test a new ironmaking process based on two production steps: pre-reduction of iron-bearing materials in an RHF, and hot DRI smelting in an innovative oxy-coal reactor. The new technology was conceived to be cost-effective: no need of electric energy for smelting, high smelter productivity and optimisation of energy utilisation. During the development of RHF campaigns, plant reliability was increased, thanks to the operational experience acquired and to some modifications made to improve the stability of operation (especially the new green pellets dryer). Some factors regarding the process were investigated in different operating conditions (charge quality, temperature, residence time) and some important conclusions could be drawn. The results obtained during RHF operation as a stand-alone unit defined the reference configuration for the joint operation. Smelter campaigns can be divided into three phases: - checking the plant components, to verify correct design, proper working, flexibility and reliability; - checking the process characteristics and the operating practices (formation of the hot heel, reduction and melting of coal-based DRI, efficiency of coal injection, tapping); - defining plant performances during tests of long duration (stable operation), getting conclusive results regarding process consumptions (coal, oxygen, utilities), productivity, and quality of products. The new technology is not completely proven, but the good results already achieved are encouraging for the successful completion of the development stage.

Additional information

Authors: GUGLIELMINI A, Lucchini, Piombino (IT);DEGEL R, SMS Demag, Düsseldorf (DE)
Bibliographic Reference: EUR 22826 EN (2007), 132 pp. Euro: 25
Availability: (Catalogue Number: KI-NA-22826-EN-S)
ISBN: ISBN: 978-92-79-05447-1
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