The Siemens Industrial Solutions and Services Group (I&S) is equipping two new direct reduction installations of Saudi Iron & Steel Company (Hadeed), Saudi Arabia, and Qatar Steel Company (Qasco) with the Simelt Simpax optimization package on behalf of Midrex Technologies Inc. As a result, the quality of the direct reduced iron can be monitored and optimized online during the reduction process. This will thus ensure that the quality of the product remains constant and that power consumption is reduced.

Qasco operates an integrated steelworks and rolling mill in Mesaaid, 45 kilometers south of Doha. Hadeed belongs to the Saudi company Sabic Holding, Riyadh and is in the Jubail industrial zone. The two companies are currently building new direct reduction installations in which direct reduced iron can be extracted from pellets or iron ore with the help of natural gas.

Because the reduction process takes several hours and parameters such as metallization or carbon content cannot be measured directly, inhomogeneous properties of pellets or iron ore can severely affect the quality, productivity and energy efficiency of a direction reduction installation. This applies not only to the reduction process itself but also to subsequent processes.

The two new reduction installations of Hadeed and Qasco are therefore to be equipped with Simelt Simpax. The hybrid process model from Siemens incorporates combined analytical and data-driven sub-models as well as a neural network. With the help of measurable parameters and historical data regarding typical process operations in a given installation, Simelt Simpax provides prognoses concerning the DRI quality to be expected. Any deviations from the required properties can thus be detected and rectified at an early stage. This ensures a constantly high quality of the DRI produced. Moreover, Simelt Simpax ensures more efficient operation of the direct reduction plant. This reduces power consumption, lowers maintenance costs and increases availability.

Siemens is responsible for integrating the process model in the automation system in both installations as well as for optimizing ongoing production.