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.

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

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

Different Process
Reductant
Natural Gas,Gassified
Coal

DRI/HBI/HDRI
Gas Based Process

Technology
Shaft Furnace (Moving Bed)
1. Midrex
2. HYL-III
3. NSC
4. Iron carbide
5. Ghaem
6. Circored

Reductant
Non-Coking Coal

DRI

Technology
Kiln Process
1. Krupp Rein
2. Krupp CODIR
3. SL/RN (Outocompu)
4. ACCAR
5. DRC

DRI vs. HBI

Two different forms of the same

product:
DRI is the traditional form, 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,
usually by sea

Gas Based Processes

In

the gas based processes, the reduction of

iron oxide is carried out by a mixture of CO &
H2 at a temperature of about 750-950C.

The

reducing gas is produced by reformation

of natural gas. The reformation is partial
oxidation of hydro-carbons. To enhance the
reformation process, normally a catalyst is
used.

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

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, product storage &
handling system
q) Repair shop and laboratory

Raw Materials
SL. NO

ITEM

PELLET

IRON ORE LUMP

Fe

66.57%

66.50%

SiO2

2.25%

0.71%

Al2O3

0.28%

1.66%

0.017%

0.015%

0.011%

0.005%

CaO

2.10%

_______

MgO

0.08%

_______

Quality of Products
SL.NO

ITEM

DRI

HBI

Fe total, %

90-91

90-91

Degree of
metallisation, %

92-94

92-94

Carbon, %

1.5-2.5

1.0

Gangue, %

3.5-4.0

3.5-4.0

Bulk density,
t/m3

1.8

2.7

Nominal
volume, cm3

_______

30X60X100
or,
30X60X90

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

HYL Process Cont.

1. Pre-heating of the charge along with partial (secondary)
reduction by hot gases coming out of the primary reduction
step.
2. Primary reduction, where the partially (secondary) reduced
charge is further reduced by the strong reducing gas coming
from the cooling stage.
3. Cooling of the reduced charge by fresh gas which itself gets
pre-heated and is available for primary reduction. This step
completes reduction and allows controlled carbon deposition
(1.5-2.25%).
4. Discharging the sponge and re-charging the reactor with
fresh
charge to start the process all over again.

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

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

HYL III Process

Available Module Size

Typically HYL offers the following module sizes :
i) 250,000 tpa module
ii) 500,000 tpa module
iii) 750,000 tpa module
iv) 1,000,000 tpa module

ADVANTAGES
Product flexibility: High-C,
Higher product quality
High-Carbon

Cold and/or Hot DRI, 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

Conclusion
The

HYL Micro-Module is a low cost, high quality

option for small steel producers or merchant
suppliers to produce high quality, High Carbide Iron.
The independent operation of the HYL Process has
enable this dramatic reduction in DR plant size,
while maintaining quality and reliability.