Co2 emissions in the iron making process decreased by 4 to 5%. 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. Environmentfriendly corex, finex and midrex ironmaking. The quality of the hot metal produced by the plant is similar to that of blastfurnace hot metal. Discharge screws convey the dri from the reduction shaft into the melter gasifier. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. 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. 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. Jul 02, 20 hismelt process of ironmaking hismelt is short for high intensity smelting.
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. Finex is based on the direct use of iron ore fines and noncoking coal and eliminates the cokemaking and the sintering processes which are. The down lying melter gasifier receives the pre reduced iron ore with certain degree of metallization from the reduction shaft through the screw conveyers. Operating line prediction of corex ironmaking process using.
Overview of corex plant in operation in the corex process, all metallurgical work is carried out in two separate process reactors. 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. The making of iron with animations and diagrams duration. The corex process combines coking plant, sinter plant and blast furnace into a single iron making unit. The corex process offers high smelting intensity and hence higher productivity, ability to use various types of noncoking coals, use of iron ore fines to an extent, low net operating cost. 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. In the first step the iron ore is reducedin a shaft furnace. 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. 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 corex process is being projected as an alternative for blast furnace iron making. Environmentfriendly corex process of iron and steel making. Pores are left behind in the dri after oxygen has been removed. Corex is a smeltingreduction process developed by vai, for costefficient and environmentally friendly production of hot metal from iron ore and low grade coal. 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.
Operating line prediction of corex ironmaking process. Dec 14, 2017 iron making provides a vital engineering input in the process of steel production. The process takes lump iron ore or pellets, noncoking coal, and oxygen. Pdf corex process in ironmaking elvis marca catachura. The corex process consists of two separate reactors namely melter. Presently, the majority of steel production is through the blast furnace which. In addition, no sinter and therefore no sinter plant is necessary for optimal operation. The highlight of the process is it does not require coking coal. So heat energy required for ironmaking process is supplied by this coke and this is a source for carbon of hot metal. Alternative emerging ironmaking technologies for energy.
A special manufacturing process is making the production of iron much more environmentally friendly. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Iron ore pellets including a core comprising iron ore, a first coating comprising lime, and a second coating comprising cement, wherein the first coating is disposed between a surface of the core and the second coating. Process description with corex, all metallurgical work is carried out in two separate process reactors the reduction shaft and the melter gasifier. Gasification and the midrex direct reduction process by. It constitutes 5 percent by weight of the earths crust, and it is the. The process was developed to industrial scale by siemens vai. These pores, if filled with water, for example, can cause the iron to reoxidize with.
Alternative iron making processess linkedin slideshare. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Ironmaking capability arguably deter mines the strength of. The coal consumption of the corex process is large with a net fuel rate ofkgtone of hot metal thm. 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.
Fine coal generation during handling for the corex process of iron making. 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. An itmk3 plant can be placed either at the iron mine site or near steelmaking facilities. Commercial sponge iron powder production dates back to 1903 with the invention of the sieurin process in sweden.
The sponge iron is delivered as hot from the reduction shaft furnace by screw. Wo2017006200a1 coated iron ore pellets and a process of. Finex process is a fluidized bed based process using ore fines instead using iron ore lumps and pellets. Definitions of the process technologies considered herein can be. Pdf minimization of exergy losses in the corex process. 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. The process reduces iron ore using a reforming gas made from natural gas. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process.
Degradation behaviour of weathered coal during handling. When iron is reduced from iron ore, first it could be a solid state. This process, has been developed and is being marketed by voestalpine industrienlagenbau vai, austria. Raw materials for corex and their influence on furnace. Us5380352a method of using rubber tires in an iron. It is the first and the only commercially established smeltingreduction process based on noncoking coal. Operational results proved stable operations with a lump ore fraction up to 80%. Corex is an industrially and commercially proven sr process that allows for production of hot metal directly from iron ore and noncoking coal.
If you continue browsing the site, you agree to the use of cookies on this website. This requires huge investment and hence, selection of an appropriate ironmaking technology is very crucial in a capital scarce country like india. The corex process consists of two main parts a reduction shaft and melter gasifier 4. Iscors corex plant has a yearly capacity of 300 000 t.
Corex enables the costefficient and environmentally friendly production of hot metal from iron ore and coal. The metals freed from combustion of the rubber tires is contained in the molten iron and sulfur freed from. The corex process is a smelting reduction process created by siemens vai as a more environmentally friendly alternative to the blast furnace. 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 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. The typical iron oxide mix for corex is 30% lump ore and 70% pellets. Experience of corex at jsw suggest that still 15% coke is required in the process to control vm of the input reductant. Corex process in iron making slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising.
The weathered coal samples after 1, 3, 6, 9 months and a year of. Pdf coal and energy consumption in the corex process can be minimised. Ta ble 1 research and development progress 1988 1991 1992 1993. In meltergasifier final reduction and melting takes place. Corex process the corex process is considered as friendlier to environment than the blastfurnace process. This is a process with great potential with regard to productivity and the low. Since 1911 the hoganas corporation has continuously manufactured sponge iron, although the early use for this product was as a feedstock for steel making. Ironmaking and steelmaking metallurgical and materials.
The corex process consists of two separate reactors namely melter gasifier and reduction shaft. Degradation behaviour of weathered coal during handling for the corex process of iron making. Corex is a smelting reduction process combining a melter gasifier with a reduction shaft. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. 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. Corex economic and environmental friendly iron production. Coal consumed, 730750 kg per 1 ton of molten iron production, equivalent to that of the blast furnace process. Hismelt process of ironmaking hismelt is short for high intensity smelting. The iron nugget is an excellent raw material for eaf or bof steelmaking. To develop computational and mathematical abilities to be applied for process design and control.
This requires huge investment and hence, selection of an appropriate iron making technology is very crucial in a capital scarce country like india. The normal unweathered coal samples were exposed to the weathering condition for 1month, 3 months, 6. 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. The main reagents for the corex process are iron ore, noncoking coal, and oxygen. The outstanding feature of the corex process is that it uses conventional coal instead of coking coal, the customary ingredient. The coal consumption of the corex process is large with a net fuel rate of kgtone of hot metal thm. Meanwhile, a new technology named corex has emerged in this field. 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. New developments in iron making process, smelting reduction technology. The corex process is the best known first generation 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. Corex differs from bf production in using noncoking coal as reducing agent and energy source. This was a simple method used from the iron age to medieval times where iron ore and charcoal were placed in a small furnace. However, in this arena blast furnace bf technology is considered as proven and the dominant one.
The dri is used mainly as the raw material for electric arc furnaces eafs, as a clean iron source substitute for scrap iron. Direct reduction process is the only iron making technology. 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. The corex process is a twostage smelting reduction process, in which hot metal can be produced from noncoking coal and iron ores. 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. May 20, 2008 environmentfriendly corex, finex and midrex ironmaking processes essential in todays changing scenario a discussion.
Reduction process direct reduced iron drihot briquetted iron hbieaf routes to the new innovative alternative iron sources aisssteelmaking routes such as the fastmet process, the itmk3 process, fasteel, fastox, corex and hismelt. Besides corex, finex is the only commercial proven alternative iron making process to the blast furnace bf route, consisting of blast furnace, sinter plant and coke oven, generating hot metal. The invention provides a method for both disposing of an environmentally undesirable material comprising rubber tires and the sulfur and metals contained therein and of providing fuel for a process of making molten iron or steel preproducts and reduction gas in a melter gasifier. The schematic diagram of the corex process is shown in fig. 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 differs from the conventional blast furnace route. 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. A process for manufacturing the iron ore pellets whereby the first coating is applied to the core to form a coated core, the surface area coverage of the first coating is. Selvakumar, in reference module in materials science and materials engineering, 2017. Ironmaking provides a vital engineering input in the process of steel production. Fine coal generation during handling for the corex process. Use of pellet atleast partially is a must for corex process. New iron making processes have been extensively explored with a view to saving resources and energy, as well as reducing environmental pollution. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned.
The coke is charged to the melter gasifier, along with coal which gets. The finex process is jointly developed by posco, korea and primetals technologies, austria. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. It is a direct smelting process for making liquid iron straight from the iron ore. The corex process consists of two main parts a reduction shaft and melter gasifier. A comparison of blast furnace and corex routes for iron. 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. Overview of corex plant in operation, development in operating.
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