2. “We see the Future” 3rd India International DRI Summit, Aug 2016 Paper presentation at 3 rd India International DRI Summit 2016 New Delhi, India August 19, 2016 Joachim D Souza, Acting CEO & GM SULB Steel Company, Bahrain Innovative Use of High Percentage Quality DRI in EAF & it’s Benefit in Cost Reduction

3. Steel Production and Per Capita Consumption * India is the 3 rd highest steel producer in the world The 12 th 5 year plan projected 91.46 MTPA in 2015-2016 Per capita consumption in India is 60kg which is one fourth of international average. 3 rd India International DRI Summit, Aug 2016 2

4. Mini – Mill concept based on DRI (Direct Reduced Iron) First commercial plant built by Willy Korf at Hamburg Stahlwerke / Germany in early seventies which was based on:  Process selected: Midrex Direct Reduction shaft furnace for iron ore reduction Continuous Feeding of highly metallized DRI into UHP-Electric Arc Furnace Continuous billet caster Wire/rod rolling mill  Other important features: Located close to sea for receiving iron ore directly by ship and shipping finished products or supplying into local market Availability of natural gas at competitive price Scrap supply either by ship or from closeby local market Close to power grid for supply of EAF Close to market for finished products 3 rd India International DRI Summit, Aug 2016 This was a major step to have fully integrated steelmaking based on a combination of Direct Reduction and scrap in various ratios depending on market prices of scrap/cost of producing DRI and melting in UHP-Electric Furnaces that revolutionized the world in the seventies. 3

5. Mini – Mill concept based on DRI (Direct Reduced Iron) In parallel, enormous developments in UHP-Electric Arc Furnaces starting in USA (Schwabe).  Further developed in Japan (water cooled side walls and foaming slag).  Perfected in Germany in the early eighties.  That pushed the share of Electric Furnace Steelmaking to close to 40% on world wide basis. Compare this to conventional Integrated Steelworks based on Coke ovens, Blast Furnaces and BOF-converters.  This new route allowed creation of new integrated steelmaking capacity based on: Much lower capital costs Shorter erection and commissioning time Less environmental issues Smaller incremental steps to start a new plant and to expand later Much less space required Closer to the market 3 rd India International DRI Summit, Aug 2016 However, this integrated steelmaking route based on DRI can only be justified in regions where cheap natural gas reserves are available. (Mexico, Venezuela, Middle East, Russia) 4

6. World DRI Production by Region 3rd India International DRI Summit, Aug 2016 million tons Source :www.midrex.com 5 India is the largest producer of DRI in the world (17.68MT)

7. Present status of DR processes 3rd India International DRI Summit, Aug 2016 6 India produce 17.68 Million tons of DRI and Iran 14.55 Million tons Large quantity of DRI made in India is by rotary kilns using Coal But compared to 2010 the coal based production down by 20% due to coal availability & Environmental cost.

8. Comparison between scrap and DRI properties Scrap: Large variation in quality, depending on source and processing (e.g. shredder, mill returns, baling scrap) Scrap selection and processing is required for more demanding steel grades (e.g. wire drawing, high carbon) Quality is mainly measured with regard to –Residual content (Cu, Ni, Cr, Mo…) –Density –Cleanliness Quality will influence all main conversion costs, yield and productivity on scrap based EAF-operation Scrap contains carbon and metallics that are oxidized during steelmaking, thereby contributing to additional chemical heating with oxygen DRI: Consistent quality depending on ore feed mix into DRI plant Virtually free of residuals (Cu, Ni, Mo) Very low in sulfur Ore supply determines amount and composition of gangue, S and P 3rd India International DRI Summit, Aug 2016 7

9. Advantages of DRI Can be continuously fed via roof into EAF High carbon supplies additional energy when reacting with oxygen (exothermic reaction) Nitrogen and hydrogen low because of continuous CO – boil Quality depends mainly on iron ore selected (Total Fe-content, gangue content and composition including P, S) and operation of DRI-plant (Metallization and carbon content) Better foaming slag and more stable and higher power input during continuous feeding. Low residual, high quality steel can be produced The development HOT DRI charge has revolutionized DRI melting in EAF 3rd India International DRI Summit, Aug 2016 8

10. Disadvantages of using DRI If quality of ore is low in particular Fe total, and if gangue contents high and mainly acidic, melting costs will increase substantially and yield drop because of high slag volumes There are no metallics that can be oxidized during melting. (e.g., Si, Al, Mn) to supply additional chemical heat with oxygen, only carbon is available for oxidation to CO Acid gangue components must be slagged with large additions of lime/dololime to achieve required basicity. There is always remaining FeO in DRI which must either be reduced with carbon (endothermic reaction) or it is lost in slag (reduction in yield). High percentage DRI usage up to 100% can only be economically justified when using highest quality DRI. High grade iron ore resources are limited and come with higher price 3rd India International DRI Summit, Aug 2016 9

11. DRI Processes A.Natural gas and coal are the two primary fuels used in DRI production. Whereas more than 90% of the global DRI plants use (lower grade) natural gas, production in India is primarily coal based. B. DRI processes can be divided up by the type of reactor employed, namely: Shaft furnaces (Midrex®, HyL) Rotary kilns (SL/RN process) Rotary hearth furnaces (Fastmet®/Fastmelt®, and ITmk3®) Fluidized bed reactors (Circored® (IPPC, 2009) In DRI production, India deserves special attention not only because the country is the larges producer of DRI, but also because production is primarily coal based. In India DRI plants can be easily erected with the help of local suppliers, and the investment in a 100 t/d capacity DRI plant can be recovered in 12 to 18 months. There is a large number of DRI producers in India, and their numbers are continuously increasing. 3 rd India International DRI Summit, Aug 2016 10

12. Coal vs gas based direct reduction How does it influence the conversion costs in EAFs 3rd India International DRI Summit, Aug 2016 11 Coal vs gas based direct reduction

13. Rotary kiln process – Main features Developed by Lurgi, Stelco and Krupp in the 1970s Maximum production: 180 000 tons/year Reduction kiln with peripheral air tubes for combustion of coal and reduction of ore Ore and 50 % of coal introduced on feeding side, 50 % of coal blown in from exit side Mostly lump ore used (8 – 16 mm) Reduction temperature 1050 °C in the bed, gas 1150 °C Courtesy of JRP Courtesy of Outotec 3rd India International DRI Summit, Aug 2016 12

14. Shaft furnace process – Main features Commercialised by Midrex & Korf (Hamburger Stahlwerke) Hyl (Mexico) initially worked with 3 stage retort process, later single shaft Reformer for converting natural gas to CO/H2 reduction gas required (with Ni-catalyst at Midrex plant) Oxygen enrichment to increase reduction temperature and gas heating with recuperators from 850 to over 1000 °C Mostly iron ore pellets and some lump ore to avoid sticking Carbon enrichment in cooling zone (up to 3 %!) Hot briquetting (HBI) Hot charging into adjacent EAF Upscaling from 400 000 t/a to over 2 500 000 t/a 3rd India International DRI Summit, Aug 2016 13

15. Shaft furnace process 3rd India International DRI Summit, Aug 2016 14

16. HYTEMP system for hot charging 3rd India International DRI Summit, Aug 2016 15

17. Iron Ore Quality Fe Total  Only ore with Fe Total > 66 % shall be used Gangue content and composition, basicity High basicity High MgO content Low Al2O3 content Sulfur and phosphorus content  Sulfur: Generally very low. May increas in rotary kilns depending on the used coal  Phosphorus: High contents may cause problems to end products with low P limitations 3 rd India International DRI Summit, Aug 2016 16

18. Iron Ore Properties TypeLump Ore Iron Ore Pellets SupplierKumbaLKABValeGIICSAMARC O South- Africa SwedenBrazilBahrainBrazil Fe tot 66.267.968.067.668.0 Gangue SiO 2 3.180.851.431.601.35 CaOCaO0.120.860.600.330.74 Al2O3Al2O3 1.210.250.550.470.40 MgO0.110.720.380.550.20 Basicity CaO/SiO 2 0.041.010.420.210.55 P0.0550.0260.0210.0300.043 S0.0140.0020.00150.002 3rd India International DRI Summit, Aug 2016 17

19. DRI Properties Degree of metallisation  High degree of metallisation decreases costs in EAF Gangue content, composition and basicity  The less gangue and the more basic, the better Carbon content  Coal based process: No carbon present in DRI  Gas based process: Deposited as Fe3C in cooling zone Hot charging  Only possible with gas based DRI (one of the main advantages) Hot briquetting (HBI)  Easy to handle, transport and ship  Only possible with gas based DRI  In most cases charging to EAF via scrap buckets 3rd India International DRI Summit, Aug 2016 18

20. Comparison of operating results EAF AEAF BEAF C Coal basedGas based 1 bucket charge 100 % DRI Production details Heats per day[1]202729 Daily production[tons/day]146022602416 Average tap weight[tons]74.683.783.3 DRI ratio[%]51.284.199.4 100 % DRI heat[1]0628 EAF yield[%]85.091.5 Time balance Power on[min]50.742.839.6 Turnaround[min]710.48.5 Delays[min]13.22.82.9 Tap-to-tap time[min]70.95651 Time utilization[%]71.576.477.6 Plant utilization[%]95.495.197.1 Consumption figures Energy[kWh/t]671548500 Oxygen[Nm³/t]23.714.032.5 Tap C[%]0.050.12 Tap O2[ppm]650348341 Foaming carbon[kg/t]5.55.015.0 Electrodes[kg/t]2.101.451.35 19

21. Comparison of operating results EAF AEAF BEAF C Coal basedGas based 1 bucket charge 100 % DRI DRI Quality Iron ore blending ratio[%]Sishen = 100LKAB = 50LKAB = 35 [%]GIIC = 20GIIC = 30 [%]Others = bal. Metallization[%]91.595.896.3 Carbon[%]0.11.92.7 Total gangue[%]6.53.8 Basicity of DRI gangue[1]0.050.770.64 Slag analysis and control Average FeO[%]28.024.921.0 Average MgO[%]13.015.818.5 Slag basicity[1]1.82.01.8 Consumption figures Energy[kWh/t]671548500 Oxygen[Nm³/t]23.714.032.5 Tap C[%]0.050.12 Tap O2[ppm]650348341 Foaming carbon[kg/t]5.55.015.0 Electrodes[kg/t]2.101.451.35 20

22. Compared to coal based DRI the following has been observed: Higher and consistent metallisation  Beneficial for energy consumption Lower total gangue with less SiO2 and higher basic components  High basicity is beneficial for energy consumption Continuous carbon boil results in lower nitrogen and hydrogen levels High carbon content in DRI is beneficial for chemical heating (up to 35 Nm³/t O2) Operating experience with gas based DRI from Midrex plant 3rd India International DRI Summit, Aug 2016 21

23. DRI – Quality parameters 1. Gangue in iron ore feed material  This is the largest factor and depends solely on the quality of the iron ore (cannot be influenced in DRI-plant) Fe total of iron ore – the higher the better Total gangue and composition of gangue  There is a large difference between acid/basic/neutral gangue which will influence steelmaking to a large degree.  Since EAF-steelmaking requires a basic slag of 1.6 – 1.8 (CaO/SiO 2 ) for phosphorus removal and 12~14% MgO for protection of refractories, substantial flux additions are required with lower quality ore.  Higher acid gangue ore will reduce Fe-yield and increase melting time and energy/electrode consumptions because of additions of nearly twice the volume of lime/dololime, which needs to be melted and is lost. 2. Degree of Metallization  Second most important parameter – the higher the better.  Qatar Steel aims to produce highly metallized DRI for use in steelplant because of downstream benefits regarding yield, energy, electrode and refractory consumption (95.5 – 96.5%) 3. Carbon in DRI  Third most important factor – between 2.5-3.0% depending on oxygen usage  Carbon is in form of iron carbide (Fe 3 C) which is exothermic when combined with oxygen, supplying additional chemical energy  Some carbon is used up to reduce remaining FeO in DRI, remaining carbon available for oxygen blowing.  Contributes to continuous CO – boil, good foaming of slag and low nitrogen/hydrogen in steel. 3rd India International DRI Summit, Aug 2016 There are three main quality aspects that have largest influence on steelmaking productivity/conversion costs. 22

24. Effect of DRI Metallization on Melting Power (QS BOP 2004) + 1% Metallization will result in + 15 kWh/ton of melting power. This will change to +20 Kwh/t when the Metallization goes below 94% 3rd India International DRI Summit, Aug 2016 23

25. Effect of DRI Metallization on Electrode Consumption + 1% Metallization will result in + 0.07Kg/ton to 0.12Kg/t of electrode consumption. The consumption goes higher when the Metallization goes below 94% 3rd India International DRI Summit, Aug 2016 24

26. Effect of DRI Metallization on Power on Time + 1% Metallization will result in + 2~3 minutes per heat power on time. 3rd India International DRI Summit, Aug 2016 25

27. Effect of DRI Acid Gangue on Melting Power + 0.5% Acid gangue in DRI result in approximately + 20 Kwh/t melting power in EF 3rd India International DRI Summit, Aug 2016 26

28. Effect of DRI Acid Gangue on Electrode Consumption + 0.5% Acid gangue in DRI result in + 0.09 kg/t Electrode consumption in EF 3rd India International DRI Summit, Aug 2016 27

29. Effect of DRI Acid Gangue on Power On Time + 0.5% Acid gangue in DRI result in approximately + 2~4 minutes of Power On time 3rd India International DRI Summit, Aug 2016 28

30. Advantages of 100% DRI- Heats with Liquid Heel No opening of roof for charging a bucket (reduce heat losses) Faster Turnaround after tapping to start next heat Much smoother melting when starting on higher liquid heel  With liquid heel start-up, stable arc is established within short time – Higher Cos Phi Improved Foaming of slag right from start – Higher O 2  This allows to increase power level faster – Less Power On time Reduced Refractory consumption  Refractories are protected all the time by foamy slag and will last longer with more even wear. No electrode breakages due to scrap cave-in or too slow electrode regulation. Much less stresses on mechanical equipment with less wear and tear because electrodes hardly move up and down Less electrical flicker disturbances on supply line No damage to water cooled panels in side walls/roof due to arcing, backflash etc. Much easier power program, only variable is DRI quality and liquid heel. 3rd India International DRI Summit, Aug 2016 29

31. Advantages of 100% DRI- Heats with Liquid Heel Lower electric energy consumption  Because roof is not opened in between heats, and turn-around time after tapping is much shorter  Arc is better protected in foamy slag which increases effective power input and reduces radiation losses.  Higher Time Utilization and less power-off times/ delays  Higher productivity (t/h) Lower electrode consumption  Less side oxidation because electrodes are two thirds under roof within a CO-rich reducing atmosphere  Electrodes are less exposed to mechanical stresses with up and down movements,  Arc length can be increased during continuous feeding of DRI because of excellent foaming. Better prediction and more constant Tap to Tap times which makes planning of downstream LF and CCM easier. Increase in Roof delta life  Less radiation from open arcs during initial melting of scrap and better foamy slag Lower average Nitrogen levels  Because there is continuous carbon boil from beginning and foamy slag protection, no open arc melting. 3rd India International DRI Summit, Aug 2016 30

32. Care to be Taken with 100% DRI & Heel Liquid heel must be larger, can be as much as 40% of tapping weight, but the distance between burner and steel level is to be taken care of. Selection of Oxy Jets - Must be effective in early stages because of larger distance to lower bath level( For Supersonic & Coherent flow effect) DRI feeding to be controlled carefully not to over heat or cool down liquid heel especially start up after tapping. As the wall life increases the Hot Heel can be increased by another 5 tons Furnace to be tilted 3 O Tap side till 50% of DRI feed to retain slag(less flux) Temp through wall by Laser is helpful tool to have closed door operation. When the liquid heel is increased by lowering the hearth thickness, the bottom shell temperature to be monitored for a few refractory campaigns 3rd India International DRI Summit, Aug 2016 31

33. Carbon in DRI, Hot Heel & Foamy Slag For Cold DRI melting EAF, the Content as high as 3% is favorable. But for Hot DRI 2.5% is optimum, since there is limit for the decarburization rate for safe DRI melting operation. Decarburization rate is measured as CO generation in steel bath which is 12CO Nm 3 /min/m 2 max. This results in Carbon reduction of 300kg/h/m 2 The max carbon in DRI to be calculated, considering the time required for decarburization in particular designed EAF and the “power on” time. Decarburization time must not be larger than the ‘Power On” time. Liquid hot heel can be around 40% of Tapping weight which will enable faster arc stabilization, faster Foamy slag generation and quick start of Oxygen/Carbon injection resulting in shorter Power On times. Good foamy slag will help in submerging the arc in the bath, reduce refractory erosion, increase Cos phi, facilitates higher power input, thereby reduces the Tap to Tap time Slag sample once a shift will have better control over the slag chemistry 3rd India International DRI Summit, Aug 2016 32

34. 33 3rd India International DRI Summit, Aug 2016 Why of Foamy Slag Important Note: When energy is not transferred to the steel, it is either goes to furnace wall refractory and panels or to the offgas

35. Slags in EAF Steelmaking 3rd India International DRI Summit, Aug 2016 34

36. Benefits of Slag on furnace operation Shorter tap to tap times Better heat transfer to the load & less losses to the w/c panels, protection of the refractory Higher average power input Lower electrode consumption Lower currents Shorter tap to tap times Cleaner steel Removal of Nitrogen & Hydrogen due to gas bubbling (CO) Pick up / absorption of Oxides in the slag Removal of inclusions Phosphor & Sulphur removal 3rd India International DRI Summit, Aug 2016 35

37. Efficiency = 35% Steel 0% Slag Efficiency = 90% 100% Slag Efficiency = 60% 50% Slag Efficiency of electric energy transfer with foaming slag 3rd India International DRI Summit, Aug 2016 36

38. The Gas: Depending on the (literature) source, the oxidation of Iron in the bath & the subsequent reduction of the Iron-Oxide in the slag by Carbon according to O 2 + 2 Fe = 2 (FeO) and (FeO) + C = Fe + CO gaseous is considered the main contributing factor for foaming or the direct Oxidation of Carbon in the bath is also taken into account : 3rd India International DRI Summit, Aug 2016 37

39. Slag foamability (continued) : This means that these "optimum" slags are not completely liquid ("watery") but are saturated with respect to CaO (Ca2SiO4) and/or MgO (Magnesia -wustite solid solution). These second phase particles serve as gas nucleation sites, which lead to a high amount of favourable small gas bubbles in the foaming slag. The term effective viscosity was defined to relate the amount of second phase particles in the slag and viscosity as follows:  e =  (1 –1.35  )-5/2  e - effective viscosity of the slag  - viscosity of the molten slag  - fraction of precipitated solid phases 3rd India International DRI Summit, Aug 2016 38

40. & FeO 3rd India International DRI Summit, Aug 2016 39

41. Remember: Take care of your slag & the steel will take care of itself... 40

42. Direct Reduction Plant – Qatar Steel 3rd India International DRI Summit, Aug 2016 SULB DR Module Cold DRI 41

43. Qatar Steel EAF #4 Commissioned in 2007 Qatar Steel EAF #4 Commissioned in 2007 Design Details Furnace Type80 EBT -Danieli Nominal steel capacity80 t Holding capacity100 t (Increased to 115 tons) Shell diameter6.1 M Transformer rating78 MVA Primary voltage33 kV Tap to tap time 45 mins per charge (Design 56’) Charge mix10% scrap+90% DRI or 100% DRI Hot heelDesign 20t, increased to 35t Electrode dia600 mm Power on time37 min Oxygen34Nm3/t Injection carbon18kg/t 3rd India International DRI Summit, Aug 2016 42

44. 3rd India International DRI Summit, Aug 2016 EF4 Designed 3 Layer Bottom Bricks for 20 t Hot heel 43

45. 3rd India International DRI Summit, Aug 2016 Modified 2 Layer bottom Bricks for 35 ton Hot heel (Bottom shell temp monitored initially) 44

46. Arc Stability: SBR & Liquid Heel 3rd India International DRI Summit, Aug 2016 45

47. Effect of Hot Heel on EAF Parameters (Qatar Steel EF4:Tap weight 80 tons) 3rd India International DRI Summit, Aug 2016 46

48. Hot Heel Performance in Plant “A” in KSA (Tap weight 140 tons & 150 MVA Trafo) 3rd India International DRI Summit, Aug 2016 47

49. Furnace #5 Commissioned in Feb 2014 Furnace #5 Commissioned in Feb 2014 EAF Design Details Nominal steel capacity110 t –SVAI EOBT Holding capacity150 t Transformer rating125 MVA Shell diameter6600/6500mm Tap to tap time 44 mins per charge with cold DRI Charge mix 80% DRI(50%) or 100% DRI(50%) Hot heel40t, increased to 45 tons Electrode dia600 mm Power on time36 min Oxygen37Nm3/t Productivity (tons per hour) 150 tons per hour with cold DRI Annual Production1,200,000 t/y (Cold DRI) 3rd India International DRI Summit, Aug 2016 48

50. DRI Performance in Middle Eastern Plants ItemQS Cold DRI Hot DRI (Benchmark) Sulb Future Target DRI Metzn95.5%>95% Acid gangue2.7%2.9%<3.0% Carbon2.8%2.1%2.5% DRI Ratio80 or 100%100% DRI Temp o C30 ~ 45600 Power On (min/ ch)37 (64.5MW)34.0(103.3MW)31.6 (95MW) Power Off(min/ ch)810.58.0 Tap to Tap(min/ ch)4544.539.6 Melting Kwh/t485385 Tap weight(t)82152130 Oxygen Nm 3 /t3434.832 Carbon Kg/t181310~15 Electrode Kg/t1.070.8<1.0 Transformer78 MVA130 MVA120 MVA (?) 3rd India International DRI Summit, Aug 2016 49

51. Future for 100% DRI Operation Optimization of Process – Consistency & Reproducibility Material recovery – Yield with Improved aux equipment design – Oxygen injectors, Burners, Flux injectors, foamy slag injectors, temp/oxy probes Closed door operation to retain slag & minimize fluxes, minimize air ingress into furnace & door cleaning equipment without loosing time. Further reduction of turnaround time – power on during tap and EBT maintenance with power on. Gunning robots will reduce repair times Furnace bottom shell designed for high hot heel to reduce tap to tap time Technology for hot heel measurement & Off gas measurement online MIDREX has to develop high C% DRI which will reduce cost in Meltshop Good Operator training tools 3rd India International DRI Summit, Aug 2016 50

52. INDIAN STEEL INDUSTRY-Challenges DRI is the preferred raw material for special steels By 2020 the projected steel production is 180 million tons, 2 nd to China 60% BF-BOF, 33% DRI-EF/IF & 7% other routes. Iron ore & Coal together make up 72% of Input material The increase in cost of input materials is a great challenge There is shortage of good quality Iron ore & shortage of non coking coal Inadequate supply of natural gas Poor infrastructure & transport facilities 3rd India International DRI Summit, Aug 2016 51

53. INDIAN STEEL INDUSTRY-Challenges It is favorable to adopt DRI-BF-EAF route, Rotary hearth Furnaces & vertical shaft furnaces to produce DRI in India Gas based DR Plant in India is uneconomical with the present prices Extensive use of hot metal will reduce expensive Electricity consumption New technologies provide alternatives for NG & Metallurgical Coke. DR Plants – Midrex & HYL (Energiron), Corex, Finex, Hismelt, Fastmelt/Fastmet & ITmk3 are a few examples favorable for India as they can utilize lower quality input materials. Use of COG as reducing gas in DR Plants is an alternative like JSW & JSPL Alternative fuels like Syn-gas, CBM, Shale gas, Corex export gas & coke oven gas are good options & cost effective 3rd India International DRI Summit, Aug 2016 52

54. INDIAN STEEL INDUSTRY-Challenges Shale gas scenario, total CBM reserve & UCG are future hope for gas based DRI Plants. Use of indigenous high ash, low rank non coking coal for syn gas is a cost effective measure. Beneficiation and agglomeration of input materials is the need of the hour Use of 40 to 50% hot metal will reduce power consumption below 380Kwh/tls Coke consumption to be reached below 300 kg/t of hot metal. Recent innovations adopted in coke making at Tata Steel has reduced cost, increased productivity and environment friendly. Adoption of latest technologies in all aspects of production facilities will cut down cost considerably. Tata Steel, JSPL Angul, JSW Ispat and ESSAR are good example to follow 3rd India International DRI Summit, Aug 2016 53

55. CONCLUSION - i Lurgi Gasification technology with Midrex Direct Reduction Process is a viable solution in India due to: Uses well-proven Lurgi Gasification and Rectisol® technologies. The Lurgi Gasifier can readily use the low rank, high ash domestic Indian coals as feed material. Uses well-proven Midrex direct reduction process. This technology can readily use domestic Indian iron oxides as feed material. 3rd India International DRI Summit, Aug 2016 54

56. CONCLUSION - ii Produces DRI with quality comparable to natural gas-based Midrex plants The DRI can be hot charged into a nearby EAF to significantly reduce electricity requirement and significantly increase EAF productivity. The Lurgi Gasification plant + Midrex plant combination can be paired with an EAF- based minimill to produce high quality long or flat steel products. No coke, coke ovens, or sinter plant required. 3rd India International DRI Summit, Aug 2016 55

57. CONCLUSION - iii Lower specific capital cost than BF – BOF Plants Lower air emissions than integrated plants Ability to capture high purity CO2 Much larger capacity than Rotary kilns(~2.5MT) Higher quality DRI product than rotary kilns 3rd India International DRI Summit, Aug 2016 56

58. 3rd India International DRI Summit, Aug 2016 New Technologies to Improve Productivity and Cost in DRI-EAF 57

59. Gunning Robot in Operation 3rd India International DRI Summit, Aug 2016 58

60. Overview of the Gunning Robot 3rd India International DRI Summit, Aug 2016 59

61. Laser Measurement of Furnace Wall 3rd India International DRI Summit, Aug 2016 60

62. Scanning Wall Contour EF Yield % Metallization % 3rd India International DRI Summit, Aug 2016 61

63. ItemBefore RobotAfter RobotRemarks Wall Ref Life275 heats in 2004 1215 heats in 2014March 2014 Wall Ref Kg/t0.96 kg/tls0.28 kg/t Cost of Ref (Gunning, fettling & Bottom) *US$ 3.64/tUS$ 2.17/t *RHI Contract EF turnaround14 mins/heat8 mins/heat Results 3rd India International DRI Summit, Aug 2016 62

64. Other Benefits 1.The exact thickness of bricks in EF is available 2.Turnaround time is less due to high discharge rate and precise area of repair, thanks to laser scanner 3.Wall brick erosion is maintained uniform 4.The hot heel can be estimated and compared to eye estimation 5.EAF Safety as the sudden breakout of metal is eliminated 6.Relaxed operation for the Operator. 3rd India International DRI Summit, Aug 2016 63

65. On line Temp - principle 3rd India International DRI Summit, Aug 2016 Burner Flame Supersonic Oxygen / Inert Gas Stream Water Cooled RCB Oxygen / Inert Gas Optical Sensor Gas / Oxy Online Temperature through the Wall The system can be used as burner, O 2 injector and temperature measurement 64

66. Good reasons for Adoption-1 3rd India International DRI Summit, Aug 2016

67. Good reasons for Adoption-2 3rd India International DRI Summit, Aug 2016

68. Good Reasons for Adoption-3 3rd India International DRI Summit, Aug 2016

69. 68 Tires Charging in DRI Melting EAF 1.Environmental Considerations of disposal problem of used tires in Qatar 2.To use scrap tires as a source of chemical energy & charge carbon 3.Recovery of carbon, energy and the steel in tires. OBJECTIVE

70. 69 Tires from Qatar Municipality

71. 70 Weight content of used tires Carbon black21.5% Elastomeric compound 47.0% Steel 16.5% Textile5.5% Zn Oxide1% Sulfur1% Others10%

72. 71 Shredding of Tires

73. 72 Mean values in Dust & Fumes (Dust & Stack)

74. 73 Mean values in Dust & Fumes (Dust & Stack)

75. 74 Mean values at Furnace working Floor

76. 75 Method of charge in Basket

77. April 2010 1 “We Recycled Everything of Value in a Tire but the HOLE” 14,000 Tons tires Charged

78. April 2010 THANK YOU 3rd India International DRI Summit, Aug 2016 Special thanks to: 1. Yousef Q Al Emadi, Qatar Steel 2. Bernd Strohmeier of Strohmeier Consulting 3. Jeremy T. Jones & Ms. Sarah Anderson (USA) 4. Said Alameddine of Graftec & now at Sangraf 5. Amit Chatterjee, Deependra & Chinmoy from India