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MSC directly charges iron ore agglomerates into Direct Reduction Unit’s Mega-modules

Capable experts and staff members of Shahid Kharrazi’s Direct Reduction Unit (No. 2) – an affiliate of Mobarakeh Steel Company (MSC) – have succeeded in directly charging iron ore agglomerates into the furnaces used in the direct reduction process. The move, the first in the country, was carried out on an experimental basis.
Head of the Direct Reduction Unit No. 2 at Mobarakeh Steel Company, Mohammad Reza Fathi, broke the news and said that pellets account for about 15 percent of the materials used in direct charging operations. “In terms of quality, the test results showed that the process is acceptable – as far as metallization and carbon are concerned – and conform to the required standards.”    
He further said in light of the fact that the country faces pellet shortages – the raw material used in direct reduction units – the project was defined and implemented early last year (ended on March 20, 2017) to identify pellet mines and replace part of pellets used in iron making unit with iron ore agglomerates.
Fathi went on to explain the processes involved in the implementation of the project and said, “As a first step four mines with iron ore agglomerate deposits which are usable in the direct reduction modules were identified and sampled. Then the agglomerates underwent lab tests and finally based on test results one source was selected for additional field tests to provide agglomerates.”  
Thanks to the designing of the Direct Reduction Unit No. 2, the stage is now set to independently charge agglomerates into one of the mega modules of the unit, he said.  
To that end, as much as 10,000 tons of agglomerates was bought from the mine in question by the company’s Raw Material and Energy Purchase Department and was used on several occasions in the mega modules, Fathi said. “Following efforts to review the existing problems and carry out research, changes were introduced to chute paths, the way agglomerates are coated with lime water, procedural parameters, features of agglomerates, and so on. These measures helped us carry out the subsequent field tests successfully.”        
On the economic aspects of the project, he said that the Direct Reduction Unit No. 2 needs about 4.5 million tons of pellets annually, adding replacement of around 10 percent of the pellets with iron ore agglomerates will be remarkably cost-effective for the company.  

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