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INDUSTRIAL TECHNOLOGIES PROGRAM Next Generation Metallic Iron Nodule Technology in Electric Furnace Steelmaking Lowering Production Costs of High-quality Iron Benefits for Our Industry and Our Nodules Will Enable More Efficient Steelmaking Nation
Metallic iron nodule technology produces A current trend in the steel industry is a furnaces and electric arc furnaces. Furnace a high quality scrap substitute, reduces gradual decline in blast furnace/ coke oven steel atmospheric control methods are being production costs, increases steel quality production and an increase in electric furnace explored to counteract the oxidizing effect produced by electric arc furnaces, and enables steel production. To ease this transition, this of carbon dioxide and the high turbulence of more effective use of sub-bituminous coal. project will explore an alternative ironmaking combustion gas. In addition, researchers are technology that can process available raw investigating how to overcome the operational materials into a value-added iron product and difficulties of using sub-bituminous coal as the is compatible with existing transportation reductant in the production process. Medium- Applications in Our Nation’s infrastructure. volatile bituminous coal is currently the most Industry desirable and commonly used reductant in this This proj ect investigates ways to lower the Successful development of this new ironmaking process, but sub-bituminous coal is a more production costs of high-quality metallized process will produce potentially lower cost steel economically attractive alternative. iron nodules as feedstock for both basic oxygen scrap substitutes. Also, greater availability of high-quality iron nodules will increase the quality of steel and the competitiveness of mini-mills and other steel producers.
High quality iron nodules produced from North American iron ore concentrate using the experimental linear hearth pilot furnace (>97% Fe in nodules). Nodules and exuded slag are shown.
Boosting the productivity and competitiveness of U.S. industry through improvements and environmental performance INDUSTRIAL TECHNOLOGIES PROGRAM
Project Description Progress and Milestones Project Partners
The objective of this project is to investigate This project involves modifying linear hearth University of Minnesota-Duluth reducing processing temperature, controlling furnace conditions and conducting a series Natural Resources Research Institute
the gas temperature and gas atmosphere of reduction and smelting tests to verify the Duluth, MN Principal Investigator: over metallized iron nodules, and effectively efficacy of processing conditions required for Donald Fosnacht ([email protected]) using sub-bituminous coal as a reductant for high-quality iron nugget production. producing high quality metallized iron nodules Phase I Nu-Iron Technologies, LLC at low cost. Charlotte, NC • Investigate burner and oxygen supply Barriers options (Complete)
Major barriers to be overcome include: • Explore chemistry of iron nuggets (Complete) • Simulation of the Linear Hearth Furnace operating conditions. • Characterize char and carbonization of the coal (Complete) • Lack of specific knowledge about furnace atmosphere parameters such as size • Perform tests in box furnace (Complete) constraints, proximate analyses of the coal/ Phase II char, and time at temperature. • Reduce turbulence with current air fuel • Chemical make up of iron nuggets burners in pilot-scale linear hearth furnace (LHF) Pathways • Optimize new furnace configuration and The objectives of this project will be achieved establish parameters for routine production through (1) modifying the linear hearth furnace, of high quality iron (2) a series of reduction and smelting tests to verify the utility of the processing conditions, and • Evaluate sub-bituminous coal as a fuel and (3) quantifying overall economics predictions reductant. for full scale implementation. • Develop energy and mass balances of the process and establish process economics
Commercialization A Strong Energy Portfolio for a The testing phase involves quantifying overall Strong America energy use characteristics, types of material that can be processed, fuels needed for successful Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner operation, and the overall economics predicted environment, and greater energy independence for full-scale implementation. Upon successful for America. Working with a wide array of state, demonstration, the project team will begin plans community, industry, and university partners, the to transition the technology for industrial use. U.S. Department of Energy’s Office of Energy Iron nodule technology could potentially use up Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies. to 30% less energy than rotary hearth furnace technology.
September 2007
For more information, visit www.eere.energy.gov/industry or call 1-877-337-3463