superProDR - Direct reduction process operation with superior productivity

Initial situation:

  • The European steel industry faces the massive challenge of reducing its CO2 emissions by 55% by 2030 and becoming climate-neutral by 2050.
  • The transformation roadmaps envisage replacing the previous production chain via the blast furnace with direct reduction (DR).
  • Due to high natural gas and electricity prices in most European countries, however, it is difficult to operate the DR process competitively.
  • To withstand global competitive pressure, European steelmakers must operate their DR plants at an outstanding level of productivity.
  • This requires maximum throughput as well as high temperatures, which drastically increases the risk of the pellets sticking in the furnace.
  • At the same time, cost minimization forces the use of lower quality and cheaper raw materials, which additionally affects permeability in the process.

Project targets:

  • Enabling the European steel industry to operate DR processes at a superior level of efficiency and productivity while avoiding sticking.
  • Development of new, high-temperature-resistant pellet coatings to reduce the sticking risk.
  • Development of more realistic and standardized test methods to evaluate the sticking tendency of different raw materials and coatings.
  • Creation of validated simulation models that calculate the spatial sticking risk, particle movement, and gas permeability in the process in detail.
  • Development of new measurement concepts and digital tools for the early online detection of sticking and for optimal process control.

Innovative approaches:

  • Research on innovative SiO2-based and hybrid organic-inorganic silicon coatings for iron ore pellets.
  • First use of a high-temperature-resistant, gas-shielded shear cell reactor (Hot Shear Testing Reactor) for the realistic measurement of shear forces and sticking under DR conditions (up to 1000 °C).
  • Coupled DEM-CFD simulations (Discrete Element Method and Computational Fluid Dynamics) for the precise analysis of the interaction between local gas flow, particle movement, and agglomerate formation.
  • Transfer of the complex CFD-DEM findings into a fast FEM model (Finite Element Method), which acts as a "soft sensor" for online simulation of the DR shaft furnace.
  • Simultaneous thermochemical calculation of the interactions between iron ore, pellet binders, and coatings using FactSage®.

Benefits for the industry:

  • Productivity increase of the DR plants by an estimated 5% by safely enabling higher operating temperatures.
  • Significant reduction of operating costs (estimated 10 € per tonne of crude steel) through the flexible and efficient use of cheaper raw materials such as blast furnace pellets.
  • Avoidance of plant downtimes and process disruptions through the use of forecasting tools and precise early warning systems for sticking.
  • Support for strategic raw material procurement through new standards that accurately assess the sticking risk on a plant-specific basis.
  • Significant contribution to CO2 reduction (estimated 1 million tonnes of CO2 per year by 2035), which generates additional savings in emission allowances.
  • Promotion of digital, data-driven steel production, which strengthens competitiveness and job security in the EU.

Further information:

Project website: https://superprodr.eu/

LinkedIn: SuperProDR project

 

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