Primetals Technologies, in partnership with Midrex Technologies, successfully delivered a state-of-the-art direct reduction plant for voestalpine Texas LLC, a subsidiary of the Austrian voestalpine group. Located near Corpus Christi, Texas, this facility represents the largest overseas investment of the voestalpine group and is designed to produce 2 million metric tons of hot briquetted iron (HBI) annually. Meanwhile, this plant was taken over by ArcelorMittal in 2022. The plant, which began operations in September 2016, is the largest single-module HBI production facility in the world.
Challenge
The primary objectives of building this plant were:
- Establish a facility capable of producing 2 million metric tons of HBI annually
- Ensure environmentally friendly operations by reducing carbon dioxide emissions compared to traditional blast furnace processes
- Enhance safety and efficiency in the transport and storage of HBI
- Achieve higher blast furnace productivity with lower specific coke consumption and reduced CO2 emissions by utilizing HBI in voestalpine’s blast furnaces
The project also required the integration of advanced technology and infrastructure to ensure a safe, clean, and sustainable ironmaking process. Additionally, the plant needed to meet the highest standards of operational efficiency and environmental compliance, reflecting voestalpine's commitment to sustainability.
Solution
The plant in Corpus Christi utilizes the MIDREX® direct reduction process, which removes bonded oxygen from pelletized iron ore at elevated temperatures using a reducing gas generated from natural gas. The reduction process takes place in a low-pressure reduction shaft, where iron ore pellets are reduced to metallic iron by a counterflow reduction gas. The reduced iron is then discharged and briquetted into high-quality hot briquetted iron (HBI). This process is considered environmentally friendly because it uses natural gas instead of coke as the reducing agent, significantly reducing carbon dioxide emissions compared to the traditional blast furnace route.
The plant’s design includes a natural gas reformer that generates the reducing gas, which is then used in the reduction shaft. The resulting HBI is compacted into a form that is safer to transport and store compared to direct reduced iron (DRI). Additionally, the plant features a captive briquetting system that ensures the highest iron yield by recycling fine iron ore dust and sludge into the production process. This approach not only maximizes material utilization but also contributes to the plant's overall efficiency and sustainability.
Primetals Technologies’ scope of supply for the project was extensive and included critical mechanical, electrical and automation systems. On the mechanical side, the plant was equipped with a furnace feed conveyor, a hot briquetting system, a hot fines recycling system, cooling conveyors, and a vapor removal system. Additional systems included a seal gas system, utilities such as a water treatment plant with seawater cooling towers, and a natural gas reducing station. Electrical and automation systems provided included power distribution and emergency power supply, medium voltage motors, Level 1 and Level 2 automation systems, instrumentation, and motor control centers.
Supporting infrastructure was also a key part of the project. This included a raw water treatment system using reverse osmosis, an air compressor station, and metallurgical services such as laboratory facilities. Maintenance cranes and hoists were provided to ensure efficient plant upkeep, and the balance of plant engineering ensured seamless integration of all systems. Basic engineering for buildings was also included in the scope of supply, completing the comprehensive project delivery.
The Corpus Christi plant represents a significant achievement in sustainable and efficient ironmaking. By combining advanced technology with a robust scope of supply, Primetals Technologies and Midrex Technologies delivered a facility that meets the highest standards of safety, environmental compliance, and operational excellence.
MIDREX®-plant at voestalpine Texas
Water treatment plant of the MIDREX® plant
Briquetting of DRI
DRI-tower and hot briquetted iron on stockyard
Hot briquetted direct reduced iron plant at voestalpine Texas, USA
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Benefits
- Environmentally friendly operations: The MIDREX® process leads to a significant reduction in CO2 emissions compared to traditional blast furnace processes.
- Enhanced blast furnace productivity: HBI usage in blast furnaces enables higher productivity and lower specific coke consumption.
- Safe transport and storage: HBI is safer to transport and store than DRI, reducing risks in logistics.
- High iron yield: The captive briquetting plant ensures maximum utilization of fine iron ore dust and sludge.
- Market expansion: The facility supports voestalpine’s internal steel production and supplies the merchant HBI market.
Conclusion
- Global benchmark in HBI production: The Corpus Christi plant is the largest single-module HBI production facility in the world, producing 2 million metric tons annually.
- Sustainability at its core: The MIDREX® process significantly reduces CO2 emissions, aligning with voestalpine's commitment to environmental responsibility.
- Enhanced steelmaking efficiency: HBI from the plant improves blast furnace productivity, reduces coke consumption, and supports safer transport and storage.
- Innovative collaboration: The partnership between Primetals Technologies, Midrex Technologies, and their clients demonstrates cutting-edge engineering and operational excellence.
