Presented by Ghanesh Kumar Mahanta
Branch-Metallurgical and Materials Engineering
HYL process was developed by Hojalata y Lamina S.A.
(HYLSA) of Monterrey, Mexico in the HYL process, lump ore
and fired plates are produced in the fix bed retorts by
performed natural gas.
first commercial HYL plant was installed at Monterrey
and started production late in 1957.
There are many process are there for production of DRI like
MIDREX Process, Rotary Klin Process etc.
Generally all process are used the coal for reduction of iron
In substitution of coal we can use the natural gas and some
fuel gas for reduction of iron ore and production of DRI
commercially in HYL.
DRI is the Direct reduction of Iron Ore by some reductant.
The Reductant may be the Solid or Gas.
Depending upon the Reductant Process are differents.
Natural Gas,Gassified Coal
Gas Based Process
Shaft Furnace (Moving Bed)
4. Iron carbide
1. Krupp Rein
2. Krupp CODIR
3. SL/RN (Outocompu)
Two different forms of the
•DRI is the traditional form, in
either pellet or lumpore form
•HBI is compressed DRI
Two different uses
•DRI is for onsite production and
use in EAF melt shops
•HBI is for commercial shipment
to customers worldwide,
usually by sea
In the gas based processes, the reduction of
iron oxide is carried out by a mixture of CO &
H2 at a temperature of about 750-950 C.
reducing gas is produced by reformation
of natural gas. The reformation is partial
oxidation of hydro-carbons. To enhance the
reformation process, normally a catalyst is
a) Direct reduction furnace
b) Hot briquetting system (OPTIONAL)
c) Process dust collection system
e) Recuperator and flue gas system
f) Gas scrubber and cooler
g) Process gas compressors and blowers
h) Water system
i) Effluent treatment system
j) Natural gas system
k) Inert gas/seal gas system
l) Compressed air system
m) Steam facilities (for HYL-III plant only)
n) Electrical equipment
p) Raw material, product storage & handling system
q) Repair shop and laboratory
r) Ventilation and dedusting system
IRON ORE LUMP
3Fe2O3 +H2 = 2Fe3O4+ H2O
3Fe2O3 + CO = 2Fe3O4 + CO2
Fe3O4 + H2 = 3FeO +H2O
Fe3O4 + CO = 3FeO + CO2
FeO + H2 = Fe + H2O
FeO + CO = Fe + CO2
1. Pre-heating of the charge along with partial (secondary)
reduction by hot gases coming out of the primary reduction
2. Primary reduction, where the partially (secondary) reduced
charge is further reduced by the strong reducing gas coming
from the cooling stage.
3. Cooling of the reduced charge by fresh gas which itself gets
pre-heated and is available for primary reduction. This step
completes reduction and allows controlled carbon deposition
4. Discharging the sponge and re-charging the reactor with
charge to start the process all over again.
HYL II is the Development process of HYL where
(1) use high temperature alloy tube in the reducing gas
reheating furnace, which permits heating the gas to the higher
temperature, and (2) reduced the number of heating furnace for
the original four units to two units.
In the HYL II process reducing gas (rich in carbon monoxide
and hydrogen) is generated, typically by nickel based catalytic
HYL III process, a single shaft furnace with a moving bed is
used in place of the four original fixed bed reactors.
The main equipment of HYL-III comprises a DR shaft
furnace, a gas reformer, and a gas reheated. The principles of
operation of the furnace are similar to the midrex shaft
Typically HYL offers the following module sizes :
i) 250,000 tpa module
ii) 500,000 tpa module
iii) 750,000 tpa module
iv) 1,000,000 tpa module
Product flexibility: High-C, Cold and/or Hot DRI,
Higher product quality
High-Carbon content DRI
Direct use of hot DRI in the EAF
Flexibility to process a wide range of iron ores
HYL R & D and steelmaking support
Minimum reducing gas requirements
Higher metallic yield
Lower production cost
Use of alternative reducing gases
Low environmental impact
HYL Micro-Module is a low cost, high
quality option for small steel producers or
merchant suppliers to produce high quality, High
The independent operation of the HYL Process
has enable this dramatic reduction in DR plant
size, while maintaining quality and reliability.