BUSINESS
DRI
ThyssenKrupp’s concept of a direct reduction plant with a melting unit
DRI for the Future, Part II: ThyssenKrupp, Salzgitter
T
he green transformation of ThyssenKrupp Steel, Germany’s largest steel producer, is taking shape with a concept for the construction of the first direct reduction plant with an integrated melting unit (blast furnace 2.0) at the group’s mill complex in Duisburg. Above all, ThyssenKrupp is focusing on hydrogen: tests are currently being conducted to use hydrogen in conventional blast furnace operation to reduce the CO2 footprint of steel production in the short term and produce the first batches of CO2-neutral steel. The next milestone will be the construction of a novel integrated direct reduction plant, allowing significant reductions in emissions. The development of direct reduction plants (DR plants) represents a key change. DR plants operate using gases. If hydrogen is used, they release no emissions. Since carbon-neutral hydro-
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gen will not be available in sufficient quantities in the foreseeable future, natural gas can also be used temporarily. This will lead to a significant reduction of emissions as compared to the coalbased blast furnace route. ThyssenKrupp Steel will commission the first largescale DR plant in 2024.
melting units produce a liquid product. As a result, the new plants can be seamlessly integrated into existing metallurgical plants. The great advantage is that the existing and proven processes in the Duisburg-based BOF melt shops can be maintained. The liquid product is processed into the proven steel grades there.
Integration of DR plants into the existing steel mill
Electrical hot metal from blast furnace 2.0
In contrast to the blast furnace, DR plants do not produce hot metal, but solid sponge iron (“Direct Reduced Iron”, DRI). It must be melted down into a hot metal product for further processing into high-quality steel. Together with manufacturers, ThyssenKrupp Steel claims that it is developing a completely new plant to optimise the hot metal system. It is a power-operated melting unit, which is combined with the DR plant. Like a blast furnace, direct reduction plants with
This currently unique concept offers several advantages. It is largely based on the existing structures of Europe’s largest integrated steel production site, which means that considerably less investment and operating costs are involved. Another important advantage for customers is the maintenance of the complete product portfolio, as the existing steel mills and processes can still be used. One innovation, in particular, enables this path towards climate-neutral-
September 2020 / MPT International
Source: ThyssenKrupp
In case you haven’t noticed, there is no question mark to the headline ‘DRI for the Future?’ anymore. Things seem to be happening fast in this respect, both in Germany and beyond. In August alone, ThyssenKrupp came up with a timetable for a direct reduction plant, Salzgitter announced a feasibility study.
