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First commercial ITmk3 plant begins production
Jan 20, 2010
First production of iron nuggets
First production of iron nuggets
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The first commercial plant using the ITmk3 Process began production of iron nuggets in Hoyt Lakes, Minnesota, USA. ITmk3, which stands for “Ironmaking Technology Mark Three,” is a unique process that builds on the basic Fastmet Technology.
Kobe Steel and Steel Dynamics, Inc. (SDI) constructed the plant at Hoyt Lakes, Minnesota, USA. Production of iron nuggets, which are used in steelmaking, is anticipated to reach the facility's annual design capacity of 500,000 metric tons in mid-2010.
ITmk3 is an ironmaking process totally different in concept from the traditional blast furnace method. Since the discovery of the phenomenon in 1994, the process has undergone many stages of development resulting in the start of production of a commercial plant. The ITmk3 Process is noted for the following characteristics:
1. High-grade iron nuggets can be produced in an extremely short time of about 10 minutes.
2. The ITmk3 Process can use lower-cost iron ore fines and steaming coal, which are difficult to use in blast furnace ironmaking.
3. In comparison to pig iron produced in a blast furnace, the production of iron nuggets using the ITmk3 Process emits about 20% less carbon dioxide due to its good energy efficiency.
Following the completion of trials in July 2004 conducted at a demonstration plant in Minnesota, Kobe Steel and SDI formed a joint venture, Mesabi Nugget Delaware, LLC, to operate the commercial-scale plant. Full-scale construction of the facility began in November 2007. Mesabi Nugget Delaware will operate the ITmk3 Plant and sell the iron nuggets. Kobe Steel provided the ITmk3 process license, engineering services, primary production equipment, and technical support. The Mesabi Nugget plant will provide further data on plant and process operation.
"doughnut" type rotary hearth furnace with a diameter of 68 meters
"doughnut" type rotary hearth furnace with a diameter of 68 meters
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SDI plans to use the nuggets produced by the Minnesota ITmk3 Plant in its steel mills.
Kobe Steel is working on iron nugget projects in North America, Vietnam, India, Russia, Australia and other countries, a cumulative production capacity of several million tons of iron nuggets.
The ITmk3 Process, with its lower carbon-dioxide emissions and capital investment, is highly suitable for growing environmentally friendly steel industries in developing countries. Moreover, the ITmk3 Process can use cheaper low-grade iron ore and coal, which are difficult to use in blast furnace ironmaking, to keep raw material costs down for steel and mining companies. Along with these advantages, the real value of the ITmk3 Process is that it produces high-grade iron nuggets with better meltability than blast-furnace pig iron when used in the steelmaking stage.
The “doughnut” type rotary hearth furnace has a design capacity to produce 500,000 tons of iron
nuggets annually and an impressive diameter of
approximately 68 meters, making it the one of the largest rotary hearth
furnace installations in the world. The furnace features unique
combustion and burner systems specifically designed to provide efficient
heating for the ITmk3 process.
The ITmk3 Process
- Pulverized iron ore and pulverized coal are agglomerated into ball-shaped pellets.
- The pellets are fed into a rotary hearth furnace. Reduction, melting and slag separation occur in about 10 minutes.
- The resulting product is high-grade iron nuggets.
Advantages of the ITmk3 Process
- In comparison to pig iron produced in a blast furnace, the production of iron nuggets using the ITmk3 Process emits about 20% less carbon dioxide due to its good energy efficiency.
- Raw material pretreatment facilities (coke ovens, sintering plants and pellet plants) are unnecessary.
- ITmk3 is highly suitable for mining sites and can be profitable for even small mines.
- Operation is easy and production adjustments are also easy.
Features of the Iron Nuggets
- Iron nuggets are slag-free, high-purity iron units of the same quality as pig iron. They have a metallic iron content of 96% to 97%.
- Iron nuggets improve the productivity and energy efficiency of electric arc furnaces (EAFs). With better meltability than blast-furnace pig iron, iron nuggets can be continuously fed into EAFs.
- Iron nuggets are easy to transport and handle. High in density, they do not reoxidize or generate fines.
In addition, make sure to read these articles:
First commercial ITmk3 plant begins production
New 4-Strand Caster for Steel Dynamics, USA
Steel Dynamics Inc. orders medium section mill
Modernization of the CSP plant at Steel Dynamics
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