However, in this arena blast furnace bf technology is considered as proven and the dominant one. Gasification and the midrex direct reduction process by. However, the sharp drop in gas prices due to the marcellus shale development has led to resurgence in interest in gas based dri production. Corex is the first commercially operating alternative to the blast furnace for hot metal production, and hismelt is the worlds first commercial smelting process for making iron straight from the ore. Advantages of the corex process include i reduction in the specific investment cost compared with conventional blast furnace route of production, ii lower production cost, iii better environmental performance because of lower irpn and discharges, iv higher calorific value of export gas makes it suitable for use in a wide range of applications, v flexible with regards to the raw material uses since a wide variety of iron ores and coals can be used, vi.
Corex smelting reduction process primetals technologies. Consolidation of the iron and steel branches manifested itself in a significant increase of mergers and takeovers. Corex economic and environmental friendly iron production. Iron ore lump ore, pellets, or a mixture thereof is charged into the reduction shaft, where it is reduced to direct reduced iron dri by the reduction gas in counterflow. Accordingly a corex plant has shaft unit, where iron ore pellets with or without some closely sized lump ore is reduced by gases emanating from the second unit to make hot sponge iron first stage. The itmk3 process is similar to fasmelt except that there is no melting process and therefore the product will be in the form of pig iron nugget. Meanwhile, a new technology named corex has emerged in this field. Advantages of the corex process include i reduction in the specific investment cost compared with conventional blast furnace route of production, ii lower production cost, iii better environmental performance because of lower irpn and discharges, iv higher calorific value of export gas makes it suitable for use in a wide range of applications, v flexible. The high dome temperature exceeds 1,000c, resulting in entire cracking of the coals relieved hydrocarbons and avoiding the formation of tar.
Degradation behaviour of weathered coal during handling for the corex process of iron making. The hot metal produced has carbon and silicon contents similar to blast furnace hot metal. The finex process is an innovative ironmaking process which has been developed by siemens vai and posco. Steel works faced increasing demand to minimize the emission of ghgs. The corex process is being projected as an alternative for blast furnace iron making. Of the alternative direct iron reduction processes, 67% of the dri is produced by the midrex shaft furnace dri processes. Degradation behaviour of weathered coal during handling. Originally the corex export gas was utilized for pellet production, for internal steel works use and for power generation. Raw materials for corex and their influence on furnace. The balance is split between slrn 3%, finmet 2% and other predominately corex at 5%. Environmentfriendly corex, finex and midrex ironmaking. Alternative iron making processess linkedin slideshare. The coal consumption of the corex process is large with a net fuel rate ofkgtone of hot metal thm. In meltergasifier final reduction and melting takes place.
The secondmost production of dri 23% is by the hylsa processes. Jul 02, 20 hismelt process of ironmaking hismelt is short for high intensity smelting. In the corex process, a combination of lump ore, pellets, and sinter is prereduced to about 90% metallization sponge iron in the reduction shaft furnace by a gas containing co and h 2 supplied from the melter gasifier, which is the main reactor of the corex plant. Use of pellet atleast partially is a must for corex process. Pdf coal and energy consumption in the corex process can be. Schematic diagram of a corex plant reduction shaft. Global demand for iron and steel is constantly growing, while at the same time prices for raw materials, energy, and transport continue to increase. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. Process description with corex, all metallurgical work is carried out in two separate process reactors the reduction shaft and the melter gasifier. The weathered coal samples after 1, 3, 6, 9 months and a year of.
To develop computational and mathematical abilities to be applied for process design and control. First class refereed papers from the international iron and steel community cover all stages of the process, from ironmaking and its attendant technologies, through casting and steelmaking, to rolling, forming and delivery of the product, including monitoring, quality assurance and environmental issues. Corex gas, corex process, dome, dri, export gas, hot metal, iron ore lump, meltergasifier, non coking coal, pellets, reduction furnace. Rob cheeley senior sales engineer, midrex direct reduction corporation introduction the production of direct reduced iron dri, a basic raw material for making steel, is concentrated in a few countries in the middle east and latin america. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Pores are left behind in the dri after oxygen has been removed. Comparison of co2 emission between corex and blast furnace. The iron nugget is an excellent raw material for eaf or bof steelmaking. Comparing to conventional blast furnace ironmaking system, direct co 2 emissions of corex is higher. Overview of corex plant in operation, development in operating. Corex process charge is charged into a reduction shaft where they are reduced to direct reduced iron dri by a reduction gas moving in counter flow.
The corex process combines coking plant, sinter plant and blast furnace into a single iron making unit. The process reduces iron ore using a reforming gas made from natural gas. Extractive metallurgy, lecture notes, pdf, ebooks, attached files for direct download. Operating experiences with corex and blast furnace at jsw. Economical iron making basis for a new steelworks in an isolated area with limited access to fuel gas. The corex process consists of two main parts a reduction shaft and melter gasifier 4. Apr 18, 2020 corex process distinguishes itself from the blast furnace route by i direct use of noncoking coal as reducing agent and energy source, ii iron ore can be directly and feasibly charged to the process in form of lump ore, and pellets, and iii use of pure oxygen instead of nitrogen rich hot blast. Dec 14, 2017 iron making provides a vital engineering input in the process of steel production. Pdf corex process in ironmaking elvis marca catachura. This section basically explains the system function in detail.
Generically, the later product type is called direct reduced iron dri. A comprehensive static model for corex process jstage. When iron is reduced from iron ore, first it could be a solid state. The process differs from the conventional blast furnace route in that low grade coal can be directly used for ore reduction and melting work, eliminating the need for coke making units. And the corex has completed the transformation to the industrial production. Corex is a smelting reduction process and uses noncoking coal as the primary fuel along with small amount of coke.
So heat energy required for ironmaking process is supplied by this coke and this is a source for carbon of hot metal. Rob cheeley senior sales engineer, midrex direct reduction corporation introduction the production of direct reduced iron dri, a basic raw material for making steel, is concentrated in a. Iscors corex plant has a yearly capacity of 300 000 t. New iron making processes have been extensively explored with a view to saving resources and energy, as well as reducing environmental pollution. The process gasifies noncoking coal in a smelting reactor, which also produces liquid iron. Iron ore lump ore, pellets, or a mixture thereof is charged into the reduction shaft, where it is reduced to direct reduced iron dri by. The corex process consists of two main parts a reduction shaft and a melter gasifier. This requires huge investment and hence, selection of an appropriate iron making technology is very crucial in a capital scarce country like india. The corex process combines coking plant, sinter plant and blast furnace into a single iron. Pig iron is divided into steelmaking pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. The hisarna ironmaking process is a direct reduced iron process for iron making in which iron ore is processed almost directly into liquid iron or hot metal. The process was developed to industrial scale by siemens vai. During the late twentieth century, several new initiatives have been taken for the development of the smelting reduction technology which.
The coke is of course the source of reduction of iron ore by providing carbon to iron ore and when it burns, and it also generates a lot of heat. It constitutes 5 percent by weight of the earths crust, and it is the. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. A special manufacturing process is making the production of iron much more environmentally friendly. Dec 02, 2009 ii absence of post combustion means that much chemical energy is lost in the exit gases and consequently the coal consumption in corex is much higher than in any other iron making process. Nonblast furnace iron making technology total materia. Comparison of co2 emission between corex and blast furnace iron making system s117 table 1 sustainable development target of world steel work in 2004 and 2005 indicator 2004 2005 investment in new processes and 6.
The present scenario of iron and steel sector is very much challenging. Our solution corex dr combination consisting of two corex c2000 plants with a total annual output of 1. Considering the credits of export gases for power generation, the total. An ideal concept for economic and environmental friendly steel production. Jul 18, 20 the corex process has been developed as an alternative to bf ironmaking, which uses noncoking coal and a small amount of coke as fuel, and pelletlump ore as ironbearing feed. Presently, the majority of steel production is through the blast furnace which. Rio tinto has for many years been a trusted supplier to the worlds iron and steel industry, particularly in south east asia, where its australian mines offer costeffective raw material. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. Ta ble 1 research and development progress 1988 1991 1992 1993.
Corex process for production of iron cirex is coal which has been cooked in order to remove impurities so that it is superior to coal. Ironmaking capability arguably deter mines the strength of. The sponge iron is delivered as hot from the reduction shaft furnace by screw. Those that produce a molten hot metal product and those that produce a solid product. The main reagents for the corex process are iron ore, noncoking coal, and oxygen. In a nutshell, corex is a coal based sr smelting reduction process of making hot metal or pig iron by direct use of noncoking coal. The corex process is a twostage smelting reduction process, in which hot metal can be produced from noncoking coal and iron ores. Co2 emissions in the iron making process decreased by 4 to 5%. Iron fe is a relatively dense metal with a silvery white appearance and distinctive.
So it is necessary to contrast the development and technology of two kinds smelting reduction ironmaking process. The finex is the latest addition and an optimized fineore smelting reduction sr iron making process based on the direct use of the coal and iron ore fines. The blast furnace concept has been used, virtually splitting it into two at the cohesive zone interface. Discharge screws convey the dri from the reduction shaft into the melter gasifier. The process combines two process units, the cyclone converter furnace ccf for ore melting and prereduction and a smelting reduction vessel srv where the final reduction stage to liquid iron takes place. May 20, 2008 environmentfriendly corex, finex and midrex ironmaking processes essential in todays changing scenario a discussion. The attractiveness of the corex process is due to i hot metal quality suitable for steelmaking, ii low investment and operational costs due to the elimination of coke ovens and by product plant, iii low process related emission rates, iv use of a wide variety of iron ores and especially noncoking coals, and v generation of a highly. Corex is a smeltingreduction process developed by vai, for costefficient and environmentally friendly production of hot metal from iron ore and low grade coal.
This is a process with great potential with regard to productivity and the low. Corex is an industrially and commercially proven sr process that allows for production of hot metal directly from iron ore and noncoking coal. Smelting reduction process is that process which is based on smelting reduction technology and hence in this process the production of hot metal. Corex and cosri smelting reduction ironmaking process could directly use coal as reductant. The co 2 emissions of corex and blast furnace ironmaking system were compared. Iron making process, full notes, pdf, ebooks, results 1 to 1 of 1. These pores, if filled with water, for example, can cause the iron to reoxidize with. Pdf corex process for pig iron production is a commercially proven process, and is currently considered as the main competent to blast furnace for pig. Developments in iron making and opportunities for power generation page 4 of 19 october 20, 1999 broadly speaking, there are two classifications of iron making processes. Ironmaking provides a vital engineering input in the process of steel production. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Nov 28, 2017 ferrous extraction iron making overview lecture 1 everything metallurgy duration. Hismelt process of ironmaking hismelt is short for high intensity smelting. The dri is used mainly as the raw material for electric arc furnaces eafs, as a clean iron source substitute for scrap iron.
Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Coal consumed, 730750 kg per 1 ton of molten iron production, equivalent to that of the blast furnace process. The outputs can be used either by integrated mills or eaf electric arc furnace mills. This requires huge investment and hence, selection of an appropriate ironmaking technology is very crucial in a capital scarce country like india. Direct reduction process is the only iron making technology. Our solution corexdr combination consisting of two corex c2000 plants with a total annual output of 1. Ironmaking and steelmaking metallurgical and materials. This means that capital investment and production costs are both lower than with classic blast furnaces, and fewer resources are.
Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Ferrous extraction iron making overview lecture 1 everything metallurgy duration. The corex process is a smelting reduction process created by siemens vai as a more environmentally friendly alternative to the blast furnace. Alternative emerging ironmaking technologies for energy. Pig iron is divided into steel making pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. A comparison of blast furnace and corex routes for iron. Iron making process, full notes, pdf, ebooks, popular topic for study. The corex process has been developed as an alternative to bf ironmaking, which uses noncoking coal and a small amount of coke as fuel, and pelletlump ore as ironbearing feed.
It is a direct smelting process for making liquid iron straight from the iron ore. The process has been developed to treat iron ore fines with minimum pretreatment, making the process more flexible in terms of the quality of iron ore it can treat. Finex process is a fluidized bed based process using ore fines instead using iron ore lumps and pellets. An itmk3 plant can be placed either at the iron mine site or near steelmaking facilities. The outstanding feature of the corex process is that it uses conventional coal instead of coking coal, the customary ingredient. Molten iron is produced directly using iron ore fines and noncoking coal rather than processing through a sinter plant and coke ovens as traditional blast furnace route. Early idea of smelting reduction technology is a new ironmaking technology, that does not need to iron ore powder block, do not use the. The introduction of corex process development scientific. Pdf optimum process conditions for the production of pig iron by. Jan 18, 2014 corex process charge is charged into a reduction shaft where they are reduced to direct reduced iron dri by a reduction gas moving in counter flow.
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