Primetals Technologies and voestalpine Texas LLC jointly implemented a project for a fines recycling plant installed at the voestalpine HBI plant in Corpus Christi, Texas, USA. Mainly, the pellet fines, dusts, and sludge generated in the MIDREX® process are briquetted in the plant and charged directly to the HBI plant as a pellet substitute. After 15 months of project execution, the plant started operation successfully in early 2017. In 2022, ArcelorMittal acquired the HBI plant together with the fines recycling plant from voestalpine Texas.
Challenge
In Corpus Christi, Texas, voestalpine Texas LLC installed an HBI plant. The by-products, such as pellet fines, dusts, and sludge generated by the MIDREX® process, if not recycled, would lead to high dumping and transportation costs and would not be in line with the circular economy. Therefore, a solution needed to be developed to recycle the fines generated in the plant.
Solution
Primetals Technologies developed a solution for fines recycling that was implemented together with voestalpine Texas LLC at the HBI plant in Corpus Christi, Texas, USA. The by-product fines generated in the direct reduction plant, mainly iron ore pellet fines and dewatered sludge with an average iron content similar to that of iron ore pellets, are collected in the HBI plant complex and briquetted in the fines recycling plant located centrally within the plant complex. The by-products are generated in the production process next to the fines recycling plant, and the mixture of the by-products is briquetted using an inorganic binder. After curing, the briquettes are added directly to the charging conveyor of the HBI plant as a raw material substitute.
3D Rendering of the fines recycling plant at Corpus Christi in Texas, United States
Fines recycling plant at Corpus Christi in Texas, United States
Fines recycling plant at Corpus Christi in Texas, United States
Pillow-shaped briquettes of fines recycling plant
Benefits
- Recycling of pellet fines, sludge, and dust generated in the plant and charging directly back into the main process plant as a raw material substitute
- Saving of raw materials by partially substituting pellets with the ferrous briquettes produced in the fines recycling plant
- Avoiding dumping costs and transport of by-products
- Semi-automatic operation, minimizing manual operation and transport of materials
- Low manpower requirements for operating the plant
Conclusion
- Successful development, installation, and commissioning of a fines recycling plant
- Pioneer project setting new standards in recycling fines in a direct reduction (HBI) plant
- Integrated modern automation systems for optimized operation
- Collaborative effort between Primetals Technologies and voestalpine leading to an innovative solution for the utilization of by-product fines
