The HYL process uses natural gas to directly reduce iron ore into DRI through a gas-based reduction process. It was developed in the 1950s in Mexico. The HYL process uses fixed bed reactors that are heated to reduce iron ore pellets or lumps into sponge iron using a mixture of carbon monoxide and hydrogen produced from the reforming of natural gas. Later developments included moving to a single rotating shaft furnace (HYL III) and allowing production of DRI, HBI, or hot briquetted iron.

1. Seminar on
HYL Process
Presented by Ghanesh Kumar Mahanta
Branch-Metallurgical and Materials Engineering
Registration no-1001365015

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. 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. 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. 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. 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. 
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. 








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. 








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. 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. 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

13. 3Fe2O3 +H2 = 2Fe3O4+ H2O
3Fe2O3 + CO = 2Fe3O4 + CO2
Fe3O4 + H2 = 3FeO +H2O
Fe3O4 + CO = 3FeO + CO2
FeO + H2 = Fe + H2O
FeO + CO = Fe + CO2

14. 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.

15. 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.

16. 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.

18. 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

19. 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

20. 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.