Moscow Institute of Steel & Alloys (MISIS), Russia has developed and mastered a new Smelting Reduction process

for making liquid hot metal. The process is tested and mastered at the pilot plant operated at the Novolipetsky Steel Works, Russia. The process is being marketed under the name Romelt.

ROMELT process is a single-stage method for production of hot metal from various iron-containing materials by their smelting reduction with the use of power-generating coals. The process was developed by National Technological Research University Moscow Institute of Steel & Alloys MISIS

ROMELT process ensures treatment of: of: Poor grade Iron ores containing from 35-40% Fe Wastes of ferrous and non-ferrous metallurgy ( incl. muds, slags and dusts)

ROMELT process does not require: require:

Enrichment and agglomeration of iron-containing materials Use of coke

That allows to fully reject from sintering and coke chemical processes, deep enrichment of iron ore

ROMELT technology ensures production of the following: following:

Pig iron Granulated slag Zinc-containing dust Electric power

The main element of the process is a ROMELT furnace, where reduction of iron-containing materials by coal carbon is taking place in boiling slag bath. In this case slag bath is intensively blown through with air blast enriched with oxygen.

Romelt furnace

1 - agitated slag, 2 - sump for slag, 3 - sump for hot metal, 4 - hearth with refractory lining, 5 - channels for slag and hot metal, 6 - feed tunnel, 7 - gas-escape branch pipe, 8 - lower tuyeres, 9 - upper tuyeres, 10 - calm slag, 11 - water-cooled panels

Zones of the Romelt furnace

Waste-heat boiler zone

Post combustion zone Agitated slag zone Calm slag zone Metal zone

ROMELT technology pilot test: test:

Pilot production unit was constructed in 1985 at Novolipetsk Steel Plant (NLSP) 41 pilot tests were run using various iron-containing materials and coals More than 40 thousand tons of hot metal were produced, and then hot metal was used in converter for steel making There were received 16 foreign patents on ROMELT technology and furnace construction, 3 licenses for realization of the technology were sold to : ISF Kaiser Engineering (USA), Nippon Steel (Japan), ROMELT- Sail (India)

Romelt furnace at Novolipetsky Steel Works

Flow sheet diagram of Romelt furnace at Novolipetsky Steel Works

Charge preparation plant and gas cleaning system of Romelt furnace

Coal discharge from the dumper in discharge charge preparation plant

Lower tuyeres

Upper tuyeres

Inside of Romelt furnace

Slag lining on water-cooled panels water-

Iron bearing materials composition (wt.%)

Component Fe total SiO2 Al2O3 CaO MgO MnO TiO2 K2O Na2O ZnO PbO Cu2O Cr2O3 V2O5 S P2O5 As2O3 C Ag (g/t) Iron Ore 58 - 59 4.5 - 4.7 2.5 - 2.7 2.0 - 2.1 0.3 - 0.35 0.06 - 0.07 0.14 - 0.15 0.07 - 0.08 0.03 - 0.04 0.1 0.06 - 0.1 0.11 - 0.12 Blast and BOF BOF Dust Dust Mixture 51 56 45 1 1.5 8 10 1.2 2.2 0.1 0.4 0.07 0.1 0.1 0.3 1.6 2.5 0.4 0.04 0.1 0.4 0.2 0.003 Up to 2 Up to 10 60 64 1.4 1.5 0.1 0.3 8.5 9 0.7 0.9 0.6 0.03 0.16 0.15 0.2 0.9 2.5 0.2 0.4 0.02 0.1 0.1 1.2 1.6 Mill Scale 71.2 1.5 0.2 0.2 0.69 0.01 0.01 0.05 0.01 Scale from the Billet Continuous Casting 81 2.4 0.7 2.2 0.47 0.04 0.02 0.03 0.25 Lead-and-Zinc Works Slag 24.0 32.9 11.45 5.31 3.69 0.41 1.08 2.73 7.63 0.85 0.82 1.0 0.28 0.09 18 Vanadium Sludge 25 30 16 20 2.5 3.5 79 1.5 2.5 57 69 25 2 4.5 46

Proximate and ultimate composition of coals (wt.%)

Coal with Low Coal with High Content of Content of Volatile Matter Volatile Matter Moisture Content fixed Ash S V.M. C H O N 12.2 67.6 10.67 0.38 19.28 10.93 4.12 2.84 1.39 10.3 51.7 10.37 0.77 34.55 21.0 4.94 6.36 2.25

Smelting products
Chemical analysis of slag (wt.%) Chemical analysis of metal (wt.%)
C Si Mn P S 4.4 - 4.6 0.06 0.11 0.05 -0.11 0.05 0.12 0.02 0.05 SiO2 MnO S P2O5 FeO CaO MgO Al2O3 TiO2 Na2O K 2O Pb Zn 35 38 1 1.15 0.05 0.1 0.1 0.13 1.5 3.5 35 38 8 10 9 11 0.2 0.4 0.4 0.8 0.25 0.4 Up to 0.02 Up to 0.02

Smelting products

Averaged dry gas composition at various combustion degrees, (vol.%)

Post combustion degree, % 39.0 64.3 CO 30.6 19.5 CO2 19.6 35.1 H2 12.5 5.9 N2 35.6 38.6

Chemical analysis of metal when melting blast and BOF dust mixture (wt.%)
C 4.4 4.5 Mn Si P S 0.09 0.13 0.08 0.1 0.08 0.1 0.04 0.06

Chemical analysis of slag and dust when melting blast and BOF dust mixture (wt.%)
Fetot CaO SiO2 MgO Al2O3 MnO Slag Total dust Fine dust 3.2 39.4 36.4 6.9 10.5 Zn Pb Na2O K2O P2O5 S C 3.3 0.008 Traces 0.25 0.22 0.92 0.04 0.4 12.46 0.6 28.7 3.18 6.6

36.3 4.95 5.07 0.84 3.08 22.7 3.8 4.4 0.75 0.76

0.55 0.76 0.20 1.20 11.6 0.35 0.44 0.37 4.94 4.0

Chemical analysis of metal when melting lead-zinc works slag (wt.%) leadC 4.3 Mn 0.08 Si 0.05 Cu 1.14 Zn <0.02 Ag <0.001 P 0.19 S 0.2

Chemical analysis of slag when melting lead-zinc works slag (wt.%) leadFetot CaO SiO2 MgO Al2O3 MnO ZnO PbO Na2O K2O P2O5 S C

2.0 34.54 40.0 4.95 11.2 0.55 0.04

2.26 0.51 0.092 0.04

Chemical analysis of dust when melting lead-zinc works slag (wt.%) leadFetot CaO SiO2 MnO Cu Zn Pb Na2O K2O P2O5 Total 4.8 0.32 0.39 0.02 0.47 37.6 8.41 0.53 0.08 0.27 Fine 3.9 0.32 0.47 0.02 0.37 >75 7.32 0.61 0.08 0.21 S 1.6 1.4 C Cl Ag (g/t) 0.57 ~0.06 170 0.46 ~0.09 170

Slag tapping

Hot metal tapping

Basic technological parameters achieved on pilot Romelt furnace

0.95 (BOF dust) 0.81 (iron ore) 1.60 (scale) 720 924 84.0

Specific productivity, t/m2/hour

Oxygen specific rate, nm3/t Coal specific consumption, kg/t Post combustion degree, %

Essence of Romelt furnace

Turns non-sintered, completely oxidized iron containing material into liquid iron and slag with a single unit; Utilizes a post-combustion zone to generate a sufficient amount of heat; Uses water-cooled panels instead of lining on the walls of the reaction chamber; Combines the furnace and waste-heat boiler for conversion of physical and chemical heat of gases into electricity; Uses various sorts of coal as a fuel and reducing agent.

Priority direction of applying ROMELT technology is waste utilization and supply of pig iron to mini plants that require growing demand in scrap.

Romelt plant at:

mini-mils

integrated steel works

Main units of ROMELT complex

Receiving and storage facilities Mixture bins building Main building with installation of ROMELT unit including : ROMELT furnace proper Ladle high temperature heating unit Slag granulation unit Waste heat boiler cooler of furnace gases Gas cleaning plant Circulating system of chemically treated water Heat utilization power station with water preparation Oxygen Station

Comprehensive tests at pilot-plant permitted to start commercial realization of the project. According to the technological assignment of MISISat present Iron Making plant on the basis of ROMELT technology is under construction in the Union of Myanmar.

Union of Myanmar: building of Romelt Works

Design parameters of ROMELT plant in the Union of Myanmar.

Plant capacity 200 thousand tons of pig iron per year.

Production of auxiliary products: Granulated slag Electric power 125 thousand tons per year 150 mln. kW-h

General Contractor VO TYAZHPROMEXPORT General Designer JSC GIPROMEZ

View on the green field of future Romelt plant

October 2005

April 2005

Romelt plant construction site in the Union of Myanmar (January 2011)

Main shops on Romelt Works

1. coal preparation unit;

1 6 5 4 2 7 3

11 10 9 8

2. ore preparation unit; 3. Romelt shop; 4. stock bins of raw materials; 5. pig casting machine; 6. pig iron storage; 7. storage of granulated slag; 8. oxygen plant; 9. waste-heat recovery electric power station; 10.main step-down substation; 11.water treatment plant.

Power transmission line 132 kV

The project construction

Iron ore preparation unit

Blending storage

Crusher

Unloading of the equipment on the Romelt Works

Oxygen plant

Utilities

Lift pump house No 1

Equipment of waste-heat boiler waste-

Separation tank

WasteWasteheat boiler

Main constraction

General view of Romelt furnace

Romelt furmace chimney stack

Roof of Romelt furnace

Wall cooling panels of 2nd & 3nd rows

End cooling panels of 1nd & 2nd rows

Technical staff training

Myanmar trainees

Lecture on Romelt process being delivered to Myanmar trainees

Using Romelt technology

Romelt shop arrangement and process traffic

Iron containing wastes generated at Bhilai Steel Plant

Annual generation, dry (2012) thou. tonne Chemical composition, (wt.%) % from all wastes

Name of wastes

Fetot. FeO Fe2O3 SiO2 Al2O3 CaO MgO Na2O K2O ZnO

1. B. Flue Dust 2. BF Sludge 3. BF Ventilation Dust 4. THF Sludge 5. LD Sludge 6. Mill Scale TOTAL: Average composition

98.0 44.7 10.0 17.8 59.5 10.0 240.0

40.8 34.4 1.63 32.77 9.1 18.6 36.4 7.42 28.98 4.2 25.13 2.8 10

3.4

3.8

1.1

0.2 0.1 0.1 0 0.2 0

0.2 0.1 0.1 0 0.2 0

0.1 1 0 0 2.5 0

25 25 20 0 2 0

5.36 5.18 2.1 2.6 0 24.9 6.1 14.2 6.7 1.4 0 1.5 0

22.33 8.4

7.4 67.1 0.26 66.84 1.68 24.8 82.9 50.0 4.2 70 0

30.0 3.04 0.26 100 0 0

36.75 14.58 36.26 6.81 2.56 4.95 1.96 0.15 0.15 0.85 16.2

Proximate and ultimate composition of coal* (wt.%)

Cfix Ash Stot. Volatile Matter, incl.: C H O N 54.3 19.0 0.96 25.7 12.0 3.46 8.96 1.29

Ash composition of coal (wt.%)

Fe2O3 SiO2 5.2 57.8 Al2O3 29.6 CaO 2.3 MgO 2.0 MnO 0.08 Na2O 0.53 K2O 0.71 TiO2 1.56 P2O5 0.21

* Mixture of local and RSA coals, 50:50

Calculated composition of products of the Romelt furnace

Metal composition, wt.% C Si Mn P S 4.5 <0,1 <0.1 0.002 0.028
Slag composition, wt.%

Gas composition, vol.%

CO2 H2 CO N2 H 2O

43.8 2.6 22,6 10.5 20.5

SiO2 MnO S P2O5 FeO CaO MgO Al2O3 TiO2 Na2O K 2O CaO/SiO2

39.1 0.01 0.06 0.014 3.0 33.3 8.5 15.1 0.26 0.34 0.36 0.85

Main technological indices

Indices Hot metal productivity Granulated slag productivity Electric power generation Value 90 thou. tonne per annum 60 thou. tonne per annum 80 mln. kWt-hour per annum

Specific consumptions per 1 tonne of hot metal Iron containing waste 2886 kg Coal 637 kg Lime 113 kg Oxygen 984 nm3 Compressed air 220 nm3 Mazut 28 kg Electric power 100 kWt-hour Technical water 84 m3 Chemically treatment water 6 m3

Main units of Romelt complex

Romelt shop; heat recovery power station (at the request of the customer); oxygen plant; air compressor unit; water treatment unit;

Capital cost of Romelt plant, ths.USD

part 1 part 2 part 3 part 4 Construction site development Main objects, including
Romelt shop

452 20 779
20 779

Auxiliary and service objects Power-producing objects, including

Oxygen plant Heat-recovery power station (HRPS) Air compressor unit

0 22 135
12 000 9 500 635

part 5 part 6 part 7 part 8 part 9 part 10 part 11 part 12

Transport and communication equipment Power supply, water-supply engineering, water carriage, heat supply and others Land improvement Temporary construction Other works and costs Technical supervision Personnel training Design work, field supervision, know-how TOTAL parts 1-12 Contingencies reserve(3%) TOTAL including contingencies reserve Taxes-and-duties (10%) TOTAL

226 1 355 226 678 2 259 678 903 4 517 54206 1 626 55 832 5 583 61 416

TOTAL
Capital cost of Romelt plant

61.4 mln. USD

Estimate cost value of Romelt hot metal, USD/tonne

Including co-products: granulated slag and electric power Without co-products
126 163

Efficiency of Romelt complex

Economic indices NPV for 15 year, mln. USD 75 29.2 5.1

IRR, % Pay-back period, year

including construction time (2 years)

Discounting pay-back period, year

including construction time (2 years)

6.2

realization price of hot metal 400 USD/t discounting rate 12 %

Dynamics of internal rate of return (IRR)

40% 35% 30% 25% 20% 15% 70% 80%
Capital cost

IRR, %

90%

100%

110%

120%

130%

Marketable products

Process costs

Dynamics of pay-back period pay7.5 7

Pay-back period, year

6.5 6 5.5 5 4.5 4 70% 80%

Capital cost

90%

100%

110%

120%
Process costs

130%

Marketable products

Dynamics of discounting pay-back period discounting pay11

Discounting pay-back period, year

10 9 8 7 6 5 4 70% 80% 90% 100% 110% 120% 130%

Capital cost Marketable products Process costs

MISA and Tyazhpromexport together with other Russian and foreign partners are ready to work out process and design of Romelt units of various production rates as well as perform construction, commissioning and personnel training activities