Primetals Technologies signs agreement with RHI Magnesita to develop new solution specifically for green steelmaking

2022-11-04

Nov. 3, 2022 - Most of the CO2 emissions in steelmaking comes from the blast furnace process (BF), which is today still the main production route. Primetals Technologies is developing a new green technology to replace BF plants, and recently signed a cooperation contract with RHI Magnesita, the global leader in refractory innovations. Primetals Technologies and RHI Magnesita will push the development forward together by combining the steel plant technology know-how of Primetals with the extensive experience of RHI Magnesita in the refractories sector.

One goal: Minimum CO2 emissions
The new solution is called SMELTER, a furnace powered by electricity used for melting and final reduction of direct reduced iron (DRI). Operated together with a direct reduction (DR) plant and an LD converter (BOF), the SMELTER is producing liquid metal for the steel plant and liquid slag which can be used in the cement industry. During direct reduction iron ore is reduced by a reducing gas, while the LD converter takes care of all the refining works. The conventional BF – LD converter route is resulting in almost two tons of CO2 per ton of liquid steel. Thanks to this new technology the CO2 amount will be reduced by a factor of six, to 0.33 ton of CO2 per ton of liquid steel.

Transferring existing integrated plants without downtime
The SMELTER provides two main cost related benefits for steel producers: The DR - SMELTER – LD converter route can be used especially for low grade iron ores, as it handles the generated slag well. Additionally, the LD converter is kept and therefore steel producers who operate integrated plants have an ongoing process without modifications of the remaining production chain without having to renew certifications when they invest in a SMELTER.

It will also be possible to keep the blast furnace running while installing the SMELTER.

Developing together
An important part of the SMELTER, the refractory material contains liquid content at very high temperatures protecting the furnace shell.

Consisting of bricks, it expands when heated and endures extremely high temperatures. The performance of the refractory material is determined by a number of factors, such as size, quality, mechanical furnace design, and cooling solutions. RHI Magnesita and Primetals Technologies are putting their heads together to find the best possible refractory solution for the SMELTER that will ensure high productivity and long lifetime.

"If you are serious about green steel, you have to start with the blast furnace processes, i.e. where CO2 emissions are massive. RHI Magnesita has been working closely with both steel and non-ferrous industries worldwide for years. We are proud that we are an integral part of pushing further the green steel development together with Primetals, not only as supplier of refractories but also as a technology partner. Hereby we contribute with our know-how and experience directly where our customers, but also the environment, will benefit from," says Constantin Beelitz, President Europe, CIS & Turkey of RHI Magnesita.

“We believe that direct reduction, starting with natural gas and later using hydrogen, will play a crucial role in the reduction of the CO2 emissions from the iron and steel production. With the Smelter we are developing a new technology that will allow to use also low-grade irons ores, which is the majority of the global iron ores, for direct reduction. RHI Magnesita and Primetals Technologies have long lasting experience in development of new technologies, an excellent base for successful cooperation!“ says Gerald Wimmer, Vice President Converter Steelmaking, Primetals Technologies.

The cooperation has been running for some time and several simulations were already made. Therefore, the SMELTER is soon ready for the market. Over the coming years, more and more steel producers will want to invest in green steel technology. The SMELTER solution provides a rational and still environmentally friendly option for existing integrated steel plants, as the steelmaking plant will be kept with just some minor adjustments necessary.