With support from Innovate UK, the KTP will see Teesside University’s Dr Venkatesan Krishnan work with Binding Solutions Ltd (BSL) to develop a cold agglomerated pellet (CAP) that can be deployed in direct reduction (DRI) and hydrogen reduction (HDR) furnace steelmaking processes.
Iron ore pellets are used in steel production as a substitute for sinters or lump ore in blast furnaces. Compared to sintering or induration, BSL’s patented CAP uses minimal heat and minimal energy. To make its product, BSL takes fine materials produced at mines and agglomerates them, or forms them into pellets.
“We formulate the binder formulations to be compatible with the client specification in relation to the Iron production plant,” said Richard Joyce, BSL’s head of Research & Development. “For example, we avoid any elements that can interfere with the ironmaking plant process or increase operational costs downstream to the steel smelter. We utilise iron ore concentrates from around the world which have been produced to meet the technical requirements of the Direct Reduction Process.”
Joyce added that the creation of a cold agglomerated pellet for DRI and HDR could play an important role in meeting the expected shortfall of high-quality iron ore pellets for those markets.
“As the steel industry moves to lower carbon methods of production, such as DRI or HDRI, higher quality iron ore is required,” said Russell Kaschula, COO at BSL. “However, the supply of suitable ore is limited with DR grade currently making up just three per cent of seaborne iron ore. There are also very few options to increase supply of high-grade ore due to a lack of new resources.”
Kaschula continued: “As production from DRI and HDRI grows, Bloomberg New Energy Finance forecast that the supply deficit for suitable pellets will rise from 15 million tonnes in 2030 to around 133 million tonnes by 2040. Our CAPs have significant advantages over traditional technologies, as they enable capex reductions of up to 86 per cent per 1Mtpa of production, use 70 per cent less energy and cut CO2e emissions by up to 70 per cent.”
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