BHUBANESWAR INSTITUTE OF INDUSTRIAL

TECHNOLOGY

Seminar on
HYL Process

Presented by Ghanesh Kumar Mahanta
Branch-Metallurgical and Materials Engineering
Registration no-1001365015

Introduction

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.

Generally all process are used the coal for reduction of iron ore.Why HYL There are many process are there for production of DRI like MIDREX Process. 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. . Rotary Klin Process etc.

Depending upon the Reductant Process are differents.What is DRI DRI is the Direct reduction of Iron Ore by some reductant. . The Reductant may be the Solid or Gas.

Krupp Rein 2. Circored Reductant Non-Coking Coal DRI Technology Kiln Process 1. HYL-III 3. Iron carbide 5.Gassified Coal DRI/HBI/HDRI Gas Based Process Technology Shaft Furnace (Moving Bed) 1. Midrex 2.Different Process Reductant Natural Gas. NSC 4. SL/RN (Outocompu) 4. Krupp CODIR 3. ACCAR 5. Ghaem 6. DRC .

HBI Two different forms of the same product: •DRI is the traditional form.DRI vs. usually by sea  . 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.

the reduction of iron oxide is carried out by a mixture of CO & H2 at a temperature of about 750-950°C. normally a catalyst is used. . To enhance the reformation process.  The reducing gas is produced by reformation of natural gas. The reformation is partial oxidation of hydro-carbons.Gas Based Processes  In the gas based processes.

Major Facility in Gas Based Process  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 .

product storage & handling system q) Repair shop and laboratory .j) Natural gas system k)Major Inert Facility gas/sealingas Gassystem Based Process l) Compressed air system m) Steam facilities (for HYL-III plant only) n) Electrical equipment o) Instrumentation p) Raw material.

017% 0.57% 66.66% 4 P 0.011% 0.10% _______ 7 MgO 0. NO ITEM PELLET IRON ORE LUMP 1 Fe 66.08% _______ .005% 6 CaO 2.Raw Materials SL.25% 0.71% 3 Al2O3 0.28% 1.50% 2 SiO2 2.015% 5 S 0.

0 5 Bulk density. % 90-91 90-91 2 Degree of metallisation.0 3.5-2.8 2. % 3. cm3 _______ 30X60X100 or. t/m3 1.0 4 Gangue.Quality of Products SL.5-4.5 1.NO ITEM DRI HBI 1 Fe total. % 92-94 92-94 3 Carbon. % 1. 30X60X90 .5-4.7 6 Nominal volume.

HYL Process .

Reactions in HYL 3Fe2O3 +H2 = 2Fe3O4+ H2O 3Fe2O3 + CO = 2Fe3O4 + CO2 Fe3O4 + H2 = 3FeO +H2O Fe3O4 + CO = 3FeO + CO2 FeO + H2 = Fe + H2O FeO + CO = Fe + CO2 .

Pre-heating of the charge along with partial (secondary) reduction by hot gases coming out of the primary reduction step. This step completes reduction and allows controlled carbon deposition (1. 2.HYL Process Cont. Primary reduction. Cooling of the reduced charge by fresh gas which itself gets pre-heated and is available for primary reduction. 3. 1. Discharging the sponge and re-charging the reactor with fresh charge to start the process all over again. . 4.5-2.25%). where the partially (secondary) reduced charge is further reduced by the strong reducing gas coming from the cooling stage.

. In the HYL II process reducing gas (rich in carbon monoxide and hydrogen) is generated. and (2) reduced the number of heating furnace for the original four units to two units. which permits heating the gas to the higher temperature. typically by nickel based catalytic reforming.HYL II HYL II is the Development process of HYL where (1) use high temperature alloy tube in the reducing gas reheating furnace.

a single shaft furnace with a moving bed is used in place of the four original fixed bed reactors.HYL III HYL III process. . a gas reformer. The principles of operation of the furnace are similar to the midrex shaft furnace. and a gas reheated. The main equipment of HYL-III comprises a DR shaft furnace.

HYL III Process .

000 tpa module iii) 750.Available Module Size Typically HYL offers the following module sizes : i) 250.000 tpa module ii) 500.000.000 tpa module iv) 1.000 tpa module .

ADVANTAGES Product flexibility: High-C. HBI 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 . Higher product quality High-Carbon Cold and/or Hot DRI.

Conclusion The HYL Micro-Module is a low cost. while maintaining quality and reliability. High Carbide Iron. . The independent operation of the HYL Process has enable this dramatic reduction in DR plant size. high quality option for small steel producers or merchant suppliers to produce high quality.