iBLUE® - Ironmaking reinvented

• Ability to process BF and DR grade pellets
• Regardless of gangue content, produce a slag saleable to cement industry
• integrated gas management - the CO rich furnace gas is recycled to the Energiron Process gas heater, reducing the overall plant energy requirements
• Ability to produce High Carbon Hot Metal for use in existing BOF
• The complete material handling, including batching plant can be designed
• Use of Tenova’s Patented dry gas cleaning technology, further reducing the environmental impact of the process plant

Both the DRP and OSBF technology, are Tenova in-house and own-developed technologies, ensuring deeply-interrogated process interfaces. Our own integrated plant automation and control system is ensuring not only optimal management of the process conditions between the two plants, but removing interfaces and any potential risk in different areas for responsibilities during the development and commissioning phases.

Utilising the unique ability of Energiron technology to produce high Carbon DRI, mitigates the need for recarburizing measures in the OSBF, thus reducing electrical energy demand and so MW setpoint substantially.

Safety is at the core of Tenova’s designs. Not only are physical barriers considered for moving areas, intelligent instrumentation is used to constantly monitor ambient air quality in the furnace building, and complex algorithms applied to determine potential upset conditions and proactively react.

Robotic technologies are also being implemented to remove workers from potentially risky areas such as casing welding, bath level measurement and even taphole drilling.

Access control is an integral design of the furnace building, to ensure no uncontrolled access to potentially hazardous areas.

A key differentiating factor for iBlue® is that the OSBF and Energiron® automation and control system is integrated, ensuring the combined process is controlled and process corrections are made to the most suitable parameters. There is no interface battery limit between the two technologies

Tenova AutoFurn® is Tenova’s an intelligent software system that provides an additional level of automation, above the SCADA and PLC. AutoFurn® is designed to be user friendly. It improves the efficiency of furnace operations by obtaining a higher power input to the furnace and maintaining stability and balance in teh furnace. It is suitable for new and can be easility retrofitted into existing furnaces. AutoFurn® can be configured to suit different ferroalloy processes, as well as other reduction processes such as base metals, mineral wool and platinum group metals

Data is presented to operators via responsive human machine interfaces, including reports and trends, accessed from compatible web browsers. This also enables the customer to make us of the innovative Tenova PyroMobile application from alternative locations.

Tenova uses cutting edge technology to ensure that environmental protection and compliance with legislation are integrated into the design of each smelting plant. Tenova’s patented dry gas scrubbing technology minimises the use of water, reducing not only operating cost, but more importantly the impact on the environment. The integrated smelter-gas cleaning system design delivers clean furnace gas with a significant chemical energy content – this energy rich gas is then used as a fuel in the DRP Process Gas Heater, reducing the external energy requirement, and negates the need to vent the cleaned gas to atmosphere – truly a win-win scenario.

The furnace is fitted with a secondary fume evacuation system that captures fugitive emissions around the furnace. Tenova recommends that a suitable Tenova gas cleaning solution be used to ensure optimal furnace performance. The slag tapped from the furnace is engineered to meet the same chemical composition as blast furnace slag – this provides an additional revenue stream to operators and negate the need to store slag at site.

Tenova Edge® is Tenova’s proprietary developed interface to facility all data management, giving customers peace of mind when sensitive data is exchanged.

Authentication an authorization of any data exchange can be defined and customized in compliance with each customer’s specific IT department policies.