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Seminar on HYL Process


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This Presentation is based on the HYL Process for production of DRI.

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Seminar on HYL Process

  1. 1. Seminar on HYL Process Presented by Ghanesh Kumar Mahanta Branch-Metallurgical and Materials Engineering Registration no-1001365015
  2. 2. The 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. The first commercial HYL plant was installed at Monterrey and started production late in 1957.
  3. 3. 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 ore. 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.
  4. 4. 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.
  5. 5. Reductant Natural Gas,Gassified Coal DRI/HBI/HDRI Gas Based Process Technology Shaft Furnace (Moving Bed) 1. Midrex 2. HYL-III 3. NSC 4. Iron carbide 5. Ghaem 6. Circored Reductant Non-Coking Coal DRI Technology Kiln Process 1. Krupp Rein 2. Krupp CODIR 3. SL/RN (Outocompu) 4. ACCAR 5. DRC
  6. 6. Two different forms of the same product: •DRI is the traditional form, in either pellet or lumpore form •HBI is compressed DRI  Two different uses (theoretically) : •DRI is for onsite production and use in EAF melt shops •HBI is for commercial shipment to customers worldwide, usually by sea 
  7. 7.  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.  The 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 used.
  8. 8.          a) Direct reduction furnace b) Hot briquetting system (OPTIONAL) c) Process dust collection system d) Reformer e) Recuperator and flue gas system f) Gas scrubber and cooler g) Process gas compressors and blowers h) Water system i) Effluent treatment system
  9. 9.          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 o) Instrumentation p) Raw material, product storage & handling system q) Repair shop and laboratory r) Ventilation and dedusting system
  10. 10. SL. NO ITEM PELLET IRON ORE LUMP 1 Fe 66.57% 66.50% 2 SiO2 2.25% 0.71% 3 Al2O3 0.28% 1.66% 4 P 0.017% 0.015% 5 S 0.011% 0.005% 6 CaO 2.10% _______ 7 MgO 0.08% _______
  11. 11. SL.NO ITEM DRI HBI 1 Fe total, % 90-91 90-91 2 Degree of metallisation, % 92-94 92-94 3 Carbon, % 1.5-2.5 1.0 4 Gangue, % 3.5-4.0 3.5-4.0 5 Bulk density, t/m3 1.8 2.7 6 Nominal volume, cm3 _______ 30X60X100 or, 30X60X90
  12. 12. 3Fe2O3 +H2 = 2Fe3O4+ H2O 3Fe2O3 + CO = 2Fe3O4 + CO2 Fe3O4 + H2 = 3FeO +H2O Fe3O4 + CO = 3FeO + CO2 FeO + H2 = Fe + H2O FeO + CO = Fe + CO2
  13. 13. 1. Pre-heating of the charge along with partial (secondary) reduction by hot gases coming out of the primary reduction step. 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 (1.5-2.25%). 4. Discharging the sponge and re-charging the reactor with fresh charge to start the process all over again.
  14. 14. 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 reforming.
  15. 15. 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 furnace.
  16. 16. 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
  17. 17. 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 HBI
  18. 18. The HYL Micro-Module is a low cost, high quality option for small steel producers or merchant suppliers to produce high quality, High Carbide Iron. The independent operation of the HYL Process has enable this dramatic reduction in DR plant size, while maintaining quality and reliability.