In 1957, after years of research and development, Hylsa started up the world's first successful direct reduction plant. This technology provides virgin iron units for steelmaking, thus improving steel quality by eliminating the residual elements commonly found in steel scrap.

The process has evolved over the years and today the HYL Process is a continuous reduction technology based on natural gas (with or without an external reformer), capable of producing high quality direct reduced iron as DRI (Direct Reduced Iron), HBI (Hot Briquetted Iron) and HYTEMP Iron for direct hot charging to an electric furnace.

Commercial interest in DRI for solving cost and quality problems associated with steel scrap has increased the demand for this technology. Together with our E&C associates, HYL actively develops projects for direct reduction plants worldwide under the Energiron brand name. Plants have been built around the world to help satisfy the demand for this high-quality feedstock for steel production.

As the only direct reduction technology supplier that is also part of a steelmaking company, Tenova HYL has also developed significant expertise in EAF steelmaking. Technologies and services for steelmaking, including "Hands-On" training, are provided by Tenova HYL to companies worldwide.

1957

Start up of the first commercially successful gas-based direct reduction plant, Hylsa 1M, using the HYL Process.

1957

Production of flat products via the EAF, based on the use of DRI. 1958 Batch charging of DRI to the EAF at 600°C.

1958

Batch charging of DRI to the EAF at 600°C.

1965

Use of more than 30% DRI in an EAF charge, eventually increasing in stages up to 100% by 1972.

1968

Continuous feeding of DRI to the EAF.

1968

Computerized EAF process control system put into use.

1969

Use of Foamy Slag practices.

1970

Design of pellets for direct reduction.

1970

First full scale testing and use of DRI as a BF-BOF feed.

1972

Production of extra-deep drawing steels in EAF using DRI.

1980

Start up of the HYL III Process continuous shaft furnace in Monterrey.

1984

HYL carries out first pilot operation of a direct reduction plant without external gas reformer.

1988

Use of cement coating of pellet/lump ores for direct reduction.

1993

HYTEMP pneumatic transportation system and hot DRI feeding to the EAF.

1993

First Zero kWh direct reduction plant begins operation at Vikram Ispat- Grasim HYL III plant, India.

1994

Production of high carbon DRI (3.0-4.5%).

1995

Production of ultra thin (<1mm) hot rolled coils via continuous strip processing minimill in Monterrey.

1997

World's first dual-discharge (DRI and HBI) plant design put into operation, Vikram Ispat-Grasim, India.

1998

Startup of HYL Self-reforming Process plant, Hylsa 4M, Monterrey.

1998

Hot and cold DRI charging to the world's largest twin-cathode DC EAF.

1999

HYL III Plant with water producing option starts up at Hadeed, KSA.

2000

First plant to successfully use 100% lump ore charge on a routine basis (Usiba HYL plant, Brazil).

2000

Vikram Ispat becomes the second in 2006.

2001

Successful economical design of Micro- Module (200,000 tpy) plants based on HYL ZR reformerless technology.

2003

Successful design of HYL ZR process plants based on coal gasification and COG.

2005

First coal gasification-based Energiron DRI plant for Jindal Steel, India. This 2 Mtpy module is the largest plant of this kind ever to be built in the world.

2006

Energiron: Techint, Tenova HYL and Danieli team up to promote and develop the new technology for direct reduction plants.

2006

First 1.4-Mtpy integrated DRI-based minimill complex for GHC Group, including a 1.6 Mtpy Energiron DR plant with HYTEMP System.

2006

First HYL Micro-Module plant built, Al Nasser Industries, Abu Dhabi, UAE.