Decarbonizing Steel Production: Metso Outotec Launches Next Generation of the 100% Hydrogen-Based Circored Process for Fine Ore Reduction

Finding new solutions to decarbonize the steelmaking value chain is a must for the industry to become fossil-free and to help limit global warming to 1.5 °C. To support the efforts, Metso Outotec is introducing the next generation of its Circored^TM process for the direct reduction of iron ore fines. The game-changing process uses hydrogen as a reducing agent instead of CO produced from fossil fuels, allowing the iron and steel industry to efficiently tackle the decarbonization challenge. Circored^TM is part of Metso Outotec’s Planet Positive portfolio.

The flexible Circored^TM process produces highly metalized DRI (direct reduced iron) or HBI (hot briquetted iron) that can directly be used as feed material in electric arc furnaces for carbon-free steelmaking.

“We are very excited about the Circored^TM process. It is an emissions- and cost-efficient alternative to traditional steelmaking routes. This innovative process eliminates the need for costly and energy intensive pelletizing, and its functionality and performance have been proven in an industrial-scale demonstration plant. Now our team of experts has evolved the process further, and we will present the updated technology at the 2021 Dubai Steel & Raw Materials Hybrid Conference on December 8th. Additionally, during the first quarter of 2022, we will be revealing further ground-breaking additions to Circored^TM capabilities - the key word being low-grade ore – so please stay tuned for these exciting developments,” explains Attaul Ahmad, Vice President, Ferrous and Heat Transfer at Metso Outotec.

Circored^TM Process is Based on Extensive Knowledge

The Circored^TM process is based on the extensive fluidized bed knowledge and experience developed and applied by Metso Outotec over decades in hundreds of plants for different applications. The process applies a two-stage reactor configuration with a circulating fluidized bed (CFB) followed by a bubbling fluidized bed (FB) downstream. The typical plant capacity is 1.25 Mt/y per line. Two or more lines can be combined using joint facilities and utility areas. In stand-alone plants, the produced DRI is briquetted to HBI to enable further handling and safe transport.

If a Circored^TM plant is integrated into an existing steelmaking facility, energy efficiency can be further increased by direct hot feeding of the DRI to an electric arc furnace.

As a general rule, the Circored^TM process can handle feeds with a particle size of up to 2 mm. However, depending on the decrepitation behavior, particle sizes of up to 6 mm are possible. For processing ultrafine (< 50 µm) ores or process reverts like scrubber dust, Metso Outotec has patented a simple microgranulation process.

Circored^TM Process Benefits in Brief

• No fossil fuels required for reduction of fines, 100% hydrogen based
• Energy-intensive and costly pelletizing step is eliminated
• HBI or DRI can be fed directly to an electric arc furnace, improving energy efficiency
• Proven performance in industrial-scale demonstration plant using established fluidized bed process

More information on the Circored^TM process is available on our website.