romelt technology

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 atThe 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 ensuresROMELT process ensures

treatment oftreatment 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 requireROMELT process does not 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 ROMELT technology ensures

production of the followingproduction of the following::

Pig iron

Granulated slag

Zinc-containing dustZinc-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 slag bath. In this case slag bath is

intensively blown through with air

blast enriched with oxygen.

Romelt furnaceRomelt 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 Zones of the Romelt furnacefurnace

Waste-heat boiler zone

Post combustion zone

Agitated slag zone

Calm slag zone

Metal zone

ROMELT technology pilot testROMELT technology pilot test::

Pilot production unit was constructed in 1985 atNovolipetsk Steel Plant (NLSP)

41 pilot tests were run using various iron-containingmaterials and coals

More than 40 thousand tons of hot metal wereproduced, and then hot metal was used inproduced, and then hot metal was used inconverter for steel making

There were received 16 foreign patents on ROMELTtechnology and furnace construction, 3 licenses forrealization of the technology were sold to : «ISFKaiser Engineering» (USA), «Nippon Steel»(Japan), «ROMELT- Sail» (India)

Romelt furnace atRomelt furnace at

Novolipetsky Steel WorksNovolipetsky Steel Works

Flow sheet diagram of Romelt furnaceFlow sheet diagram of Romelt furnace

at Novolipetsky Steel Worksat Novolipetsky Steel Works

Charge preparation plant and gasCharge preparation plant and gas

cleaning system of Romelt furnacecleaning system of Romelt furnace

Coal dCoal dischargeischarge from the dumper in from the dumper in

charge preparation plantcharge preparation plant

Lower tuyeresLower tuyeres

Upper tuyeresUpper tuyeres

Inside of Romelt furnaceInside of Romelt furnace

Slag lining on waterSlag lining on water--cooled panelscooled panels

Component Iron Ore Blast and BOF

Dust Mixture BOF Dust

Mill

Scale

Scale from the Bil-

let Continuous

Casting

Lead-and-Zinc

Works Slag

Vanadium

Sludge

Fe total 58 - 59 51 – 56 60 – 64 71.2 81 24.0 25 – 30

SiO2 4.5 - 4.7 4 – 5 1.4 – 1.5 1.5 2.4 32.9 16 – 20

Al2O3 2.5 - 2.7 1 – 1.5 0.1 – 0.3 0.2 0.7 11.45 2.5 – 3.5

CaO 2.0 - 2.1 8 – 10 8.5 – 9 0.2 2.2 5.31 7 – 9

MgO 0.3 - 0.35 1.2 – 2.2 0.7 – 0.9 0.69 0.47 3.69 1.5 – 2.5

MnO 0.06 - 0.07 0.1 – 0.4 0.6 – – – 5 – 7

TiO 0.14 - 0.15 0.07 0.03 – 0.04 0.41 6 – 9

Iron bearing materials composition (wt.%)Iron bearing materials composition (wt.%)

TiO2 0.14 - 0.15 0.07 0.03 – 0.04 0.41 6 – 9

K2O 0.07 - 0.08 0.1 0.16 – – 1.08 –

Na2O 0.03 - 0.04 0.1 – 0.3 0.15 – 0.2 – – 2.73 –

ZnO 0.1 1.6 – 2.5 0.9 – 2.5 0.01 – 7.63 –

PbO - 0.4 0.2 – 0.4 0.01 – 0.85 –

Cu2O - 0.04 – – – 0.82 –

Cr2O3 - – – – – – 2 – 5

V2O5 - – – – – – 2 – 4.5

S 0.06 - 0.1 0.1 – 0.4 0.02 – 0.1 0.05 0.02 1.0 4 – 6

P2O5 0.11 - 0.12 0.2 0.1 0.01 0.03 0.28 –

As2O3 - 0.003 – – – 0.09 –

C - Up to 2 1.2 – 1.6 – 0.25 – –

Ag (g/t) - Up to 10 – – – 18 –

Coal with Low

Content of Volatile Matter

Coal with High Content of

Volatile Matter

Moisture Content

12.2 10.3

С 67.6 51.7

Proximate and ultimateProximate and ultimate

composition of coals (wt.%)composition of coals (wt.%)

Сfixed 67.6 51.7 Ash 10.67 10.37 S 0.38 0.77

V.M. 19.28 34.55

♦ C 10.93 21.0

♦ H 4.12 4.94 ♦ O 2.84 6.36

♦ N 1.39 2.25

C 4.4 - 4.6

Si 0.06 – 0.11

SiO2 35 – 38

MnO 1 – 1.15

S 0.05 – 0.1

P2O5 0.1 – 0.13

FeO 1.5 – 3.5

Chemical analysis of

metal (wt.%)

Chemical analysis of

slag (wt.%)

Smelting productsSmelting products

Si 0.06 – 0.11

Mn 0.05 -0.11

P 0.05 – 0.12

S 0.02 – 0.05

CaO 35 – 38

MgO 8 – 10

Al2O3 9 – 11

TiO2 0.2 – 0.4

Na2O 0.4 – 0.8

K2O 0.25 – 0.4

Pb Up to 0.02

Zn Up to 0.02

Post combustion degree,

%CO CO2 H2 N2

Averaged dry gas composition

at various combustion degrees, (vol.%)

Smelting productsSmelting products

%CO CO2 H2 N2

39.0 30.6 19.6 12.5 35.6

64.3 19.5 35.1 5.9 38.6

C Mn Si P S

4.4 – 4.5 0.09 – 0.13 0.08 – 0.1 0.08 – 0.1 0.04 – 0.06

Chemical analysis of metal when melting Chemical analysis of metal when melting

blast and BOF dust mixture (wt.%)blast and BOF dust mixture (wt.%)

Chemical analysis of slag and dust when Chemical analysis of slag and dust when

Fetot CaO SiO2 MgO Al2O3 MnO Zn Pb Na2O K2O P2O5 S C

Slag 3.2 39.4 36.4 6.9 10.5 3.3 0.008 Traces 0.25 0.22 0.92 0.04 -

Total dust 36.3 4.95 5.07 0.84 3.08 0.4 12.46 3.18 0.55 0.76 0.20 1.20 11.6

Fine dust 22.7 3.8 4.4 0.75 0.76 0.6 28.7 6.6 0.35 0.44 0.37 4.94 4.0

Chemical analysis of slag and dust when Chemical analysis of slag and dust when

melting blast and BOF dust mixture (wt.%)melting blast and BOF dust mixture (wt.%)

Fetot CaO SiO2 MgO Al2O3 MnO ZnO PbO Na2O K2O P2O5 S C

C Mn Si Cu Zn Ag P S

4.3 0.08 0.05 1.14 <0.02 <0.001 0.19 0.2

Chemical analysis of metal when Chemical analysis of metal when

melting leadmelting lead--zinc works slag (wt.%)zinc works slag (wt.%)

Chemical analysis of slag when Chemical analysis of slag when


Fetot 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 0 2.26 0.51 0.092 0.04 -

Chemical analysis of dust when Chemical analysis of dust when


Fetot CaO SiO2 MnO Cu Zn Pb Na2O K2O P2O5 S C Cl Ag (g/t)

Total 4.8 0.32 0.39 0.02 0.47 37.6 8.41 0.53 0.08 0.27 1.6 0.57 ~0.06 170

Fine 3.9 0.32 0.47 0.02 0.37 >75 7.32 0.61 0.08 0.21 1.4 0.46 ~0.09 170

Slag tappingSlag tapping

Hot metal tappingHot metal tapping

Basic technological parameters Basic technological parameters

achieved on pilot Romelt furnaceachieved on pilot Romelt furnace

Specific productivity, t/m2/hour {

0.95 (BOF dust)

0.81 (iron ore)

1.60 (scale)

Oxygen specific rate, nm3/t 720

Coal specific consumption, kg/t 924

Post combustion degree, % 84.0

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

Essence of Romelt furnaceEssence of Romelt furnace

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 to mini plants that require

growing demand in scrap.

Romelt plant at:Romelt plant at:

mini-mils

integrated steel works

Main units of ROMELT complexMain 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 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 “MISIS”at present assignment of “MISIS”at present

Iron Making plant on the basis of

ROMELT technology is under

construction in the Union of

Myanmar.

Union of Myanmar: Union of Myanmar:

building of Romelt Worksbuilding of Romelt Worksbuilding of Romelt Worksbuilding of Romelt Works

Design parameters of ROMELT plant Design parameters of ROMELT plant

in the Union of Myanmar.in the Union of Myanmar.

Plant capacity 200 thousand tons of pig iron

per year.

Production of auxiliary products:

General Contractor VO TYAZHPROMEXPORT

General Designer JSC GIPROMEZ

Granulated slag 125 thousand tons per year

Electric power 150 mln. kW-h

OctoberOctober 20052005

View on the green field of future Romelt plantView on the green field of future Romelt plant

AprilApril20052005

RomeltRomelt plant construction site in the plant construction site in the

Union of Myanmar (January 2011)Union of Myanmar (January 2011)

1. coal preparation unit;

2. ore preparation unit;

3. Romelt shop;

4. stock bins of raw materials;

5. pig casting machine;

6. pig iron storage;

11

55

66

1010

1111

Main shops on Romelt WorksMain shops on Romelt Works

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.

22

3344

77

99

55 1010

88

Power transmission line Power transmission line 132 132 kVkV

The project constructionThe project construction

Blending storageBlending storage

Iron ore preparation unitIron ore preparation unit

Blending storageBlending storage

CrusherCrusher

Unloading of the equipment on the Romelt WorksUnloading of the equipment on the Romelt Works

Oxygen plantOxygen plant

UtilitiesUtilities

Lift pump Lift pump house No 1house No 1

Separation Separation tanktank

Equipment of wasteEquipment of waste--heat boilerheat boiler

WasteWaste--heat boilerheat boiler

Main Main constractionconstraction

General view of Romelt furnace General view of Romelt furnace

RomeltRomelt furmacefurmace chimney stackchimney stack

Roof of Romelt furnace Roof of Romelt furnace

Wall cooling panels of 2Wall cooling panels of 2ndnd & 3& 3ndnd rows rows

End cooling panels of 1End cooling panels of 1ndnd & 2& 2ndnd rows rows

Technical staff trainingTechnical staff training

Myanmar traineesMyanmar trainees

Lecture on Lecture on RomeltRomelt process process

being delivered to Myanmar being delivered to Myanmar

traineestrainees

Using Romelt technologyUsing Romelt technology

Romelt shop arrangement and Romelt shop arrangement and

process traffic process traffic

Name of wastes

Annual g

enera

tion,

dry

(2012)

thou. to

nne

% fro

m a

ll waste

s

Chemical composition, (wt.%)

Fetot. FeO Fe2O3 SiO2 Al2O3 CaO MgO Na2O K2O ZnO C

1. B. Flue Dust 98.0 40.8 34.4 1.63 32.77 9.1 3.4 3.8 1.1 0.2 0.2 0.1 25

2. BF Sludge 44.7 18.6 36.4 7.42 28.98 10 5.36 5.18 2.1 0.1 0.1 1 25

Iron containing wastes generatedIron containing wastes generated

at Bhilai Steel Plantat Bhilai Steel Plant

2. BF Sludge 44.7 18.6 36.4 7.42 28.98 10 5.36 5.18 2.1 0.1 0.1 1 25

3. BF Ventilation Dust 10.0 4.2 25.13 2.8 22.33 8.4 2.6 24.9 6.1 0.1 0.1 0 20

4. THF Sludge 17.8 7.4 67.1 0.26 66.84 1.68 0 14.2 6.7 0 0 0 0

5. LD Sludge 59.5 24.8 82.9 50.0 30.0 3.04 0.26 1.4 1.5 0.2 0.2 2.5 2

6. Mill Scale 10.0 4.2 70 0 100 0 0 0 0 0 0 0 0

TOTAL: 240.0

Average composition 36.75 14.58 36.26 6.81 2.56 4.95 1.96 0.15 0.15 0.85 16.2

Proximate and ultimateProximate and ultimate

composition of coal* (wt.%)composition of coal* (wt.%)

Cfix 54.3

Ash 19.0

Stot. 0.96

Volatile Matter, incl.: 25.7

C 12.0

H 3.46

O 8.96

N 1.29N 1.29

Fe2O3 SiO2 Al2O3 CaO MgO MnO Na2O K2O TiO2 P2O5

5.2 57.8 29.6 2.3 2.0 0.08 0.53 0.71 1.56 0.21

Ash composition of coal (wt.%)Ash composition of coal (wt.%)

* Mixture of local and RSA coals, 50:50* Mixture of local and RSA coals, 50:50

Calculated composition of productsCalculated composition of products

of the Romelt furnaceof the Romelt furnace

Metal composition, wt.%Metal composition, wt.% Slag composition, wt.%Slag composition, wt.%

C 4.5

Si <0,1

Mn <0.1

P 0.002

S 0.028

SiO2 39.1

MnO 0.01

S 0.06

P2O5 0.014

FeO 3.0FeO 3.0

CaO 33.3

MgO 8.5

Al2O3 15.1

TiO2 0.26

Na2O 0.34

K2O 0.36

CaO/SiO2 0.85

Gas composition, vol.%Gas composition, vol.%

CO2 43.8

H2 2.6

CO 22,6

N2 10.5

H2O 20.5

Main technological indicesMain technological indices

Indices Value

Hot metal productivity 90 thou. tonne per annum

Granulated slag productivity 60 thou. tonne per annum

Electric power generation 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 complexMain units of Romelt complex

Romelt shop;

heat recovery power station (at the request of

the customer);the customer);

oxygen plant;

air compressor unit;

water treatment unit;

Capital cost of Romelt plant, ths.USDCapital cost of Romelt plant, ths.USD

part 1 Construction site development 452

part 2 Main objects, including 20 779

Romelt shop 20 779

part 3 Auxiliary and service objects 0

part 4

Power-producing objects, including 22 135

Oxygen plant 12 000

Heat-recovery power station (HRPS) 9 500

Air compressor unit 635

part 5 Transport and communication equipment 226

part 6 Power supply, water-supply engineering, water carriage, heat supply and others 1 355part 6 Power supply, water-supply engineering, water carriage, heat supply and others 1 355

part 7 Land improvement 226

part 8 Temporary construction 678

part 9 Other works and costs 2 259

part 10 Technical supervision 678

part 11 Personnel training 903

part 12 Design work, field supervision, know-how 4 517

TOTAL parts 1-12 54206

Contingencies reserve(3%) 1 626

TOTAL including contingencies reserve 55 832

Taxes-and-duties (10%) 5 583

TOTAL 61 416

TOTALTOTALCapital cost of Romelt plant

61.4 mln. USD61.4 mln. USD61.4 mln. USD61.4 mln. USD

Including co-products:

granulated slag and electric power 126

Estimate costEstimate cost value of Romelt value of Romelt

hot metal, USD/tonnehot metal, USD/tonne

granulated slag and electric power 126

Without co-products 163

Efficiency of Romelt complexEfficiency of Romelt complex

Economic indices

NPV for 15 year, mln. USD 75

IRR, % 29.2

Pay-back period, yearincluding construction time (2 years) 5.1

Discounting pay-back period, yearincluding construction time (2 years) 6.2

realization price of hot metal 400 USD/t

discounting rate 12 %

Dynamics of internal rate of return (IRR)Dynamics of internal rate of return (IRR)

30%

35%

40%

IRR

, %

15%

20%

25%

70% 80% 90% 100% 110% 120% 130%

IRR

, %

Capital cost Marketable products Process costs

Dynamics of payDynamics of pay--back periodback period

6

6.5

7

7.5

Pay-b

ack p

eriod, year

4

4.5

5

5.5

6

70% 80% 90% 100% 110% 120% 130%

Pay-b

ack p

eriod, year


Dynamics of dDynamics of discountingiscounting paypay--back periodback period

8

9

10

11

Dis

counting p

ay-b

ack p

eri

od, year

4

5

6

7

8

70% 80% 90% 100% 110% 120% 130%

Dis

counting p

ay-b

ack p

eri

od, year


MISA and Tyazhpromexport together

with other Russian and foreign

partners are ready to work out

process and design of Romelt units ofprocess and design of Romelt units of

various production rates as well as

perform construction, commissioning

and personnel training activities

romelt technology

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