Thermochemical modelling of the finex process to determine. In the first step the iron ore is reducedin a shaft furnace. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Structural and durability properties of concrete made with. The outstanding feature of the corex process is that it uses conventional coal instead of coking coal, the customary ingredient. Dec 02, 2009 corex process in iron making slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising.
Corex differs from bf production in using noncoking coal as reducing agent and energy source. It begins by tracing the history of iron and steel production, right from the earlier days to todays world of. 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. Presently, the majority of steel production is through the blast furnace which has to rely on ever decreasing amounts of coking coal. The direct iron ore smelting reduction process dios directly uses noncaking coal in a powder or granular form, and iron ore without the use of coke or a sintering process, which are normally required in blast furnace processes. 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. Arcelormittal is the worlds leading steel and mining. Emerging energyefficiency and carbon dioxide emission.
Iron ore processing for the blast furnace courtesy of the national steel pellet company the following describes operations at the national steel pellet company, an iron ore mining and processing facility. Emerging energyefficiency and co2 emissionsreduction. Direct reduction process is the only iron making technology. In iron making process, raw materials, iron ore and coals, are delivered from room temperature and its temperature increases inside reaction vessel for iron making over to seven degree celsius. Be able to understand basic layout of blast furnace, steelmaking shop and. Corex is a promising alternative to blast furnace ironmaking. Furthermore, the thermodynamic behaviour of volatile elements potassium, sodium, chlorine, fluorine and zinc is described in typical atmospheres for iron making processes. Corex process with other iron making processes like. 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. So heat energy required for ironmaking process is supplied. The finex process is an innovative ironmaking process which has been. In ironmaking process, raw materials are continuously delivered to reaction vessel and products, hot metal, are also tapped continuously.
Ironmaking ironmaking technologies can be divided into blast furnace technology, direct reduction iron dri technology, smelting reduction ironmaking corex, and so on. Primary air pollutant emissions and future prediction of iron. Extractive metallurgy, lecture notes, pdf, ebooks, attached files for direct. Iron containing materials, coal and flux, are fed, using weighhoppers, from relevant bins to the common conveyer. Romelt process description romelt process is the singlestage technique of continuous ironmaking from various iron bearing materials using inexpensive noncoking coal. Changes in the manufacturing process inevitably result in subtle. The corex process is estimated to use 15 to 18 gjtonne steel net energy consumption, while the ccf process is estimated to use gjtonne steel net energy consumption worrell and moore, 1997. 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. The finished steel is manufactured through the revolutionary corex iron making technology route.
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. This process, has been developed and is being marketed by voestalpine industrienlagenbau vai, austria. The outstanding feature of the corex process is that it uses conventional coal instead of coking coal. The future of energy efficiency in the steel industry bettadapura lakshminarayana, american iron and steel institute introduction steel is present in every aspect ofour lives, in all. Twg102 page 1 iuclid 5 composition and analysis guidance document.
This plant also yields a quenched slag called corex slag as a byproduct of the iron making. Corex vai midrex with 60% hot metal and 40% dri charge to eaf. Download this books into available format 2019 update. In addition, iron ore can be directly charged to the process in form of lump ore, pellets, and sinter siemens vai. Lawrence kavanagh, american iron and steel institute. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. The noncaking coal is directly fed to a smelting reduction furnace, while the iron ore is. Iron making process free download as powerpoint presentation. Co 2 abatement in the iron and steel industry 5 steel is basically an alloy consisting of iron, 0.
The corex process combines coking plant, sinter plant and blast furnace into a. The paper presents few aspects concerning the implementation of alternative iron making technologies in romania. The corex process is a smelting reduction process created by siemens vai as a more environmentally friendly alternative to the blast furnace. Most of the videos are added that to track the latest news in a steel industry.
The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic iron nickel. Included in this article also is a discussion of the mining of iron and of its preparation for. Energy use and carbon emissions in the steel sector in key. Spread over 3,700 acres of land and located in the heart of the highgrade iron ore belt, the plant is within easy access of bangalore and is well connected. Overview of corex plant in operation in the corex process, all metallurgical work is carried out in two separate process reactors. Corex enables the costefficient and environmentally friendly production of hot metal from iron ore and coal. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Furthermore, the thermodynamic behaviour of volatile elements. Ironmaking process alternatives screening study department of. Pdf optimum process conditions for the production of pig iron by. The present scenario of iron and steel sector is very much challenging. The general scheme of the romelt furnace is shown in figure 1. In addition, no sinter and therefore no sinter plant is necessary for optimal operation. 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 cost.
This thesis describes the most important smelting reduction processes, i. Corex is a smelting reduction process combining a melter gasifier with a reduction shaft. This was a simple method used from the iron age to medieval times where iron ore and charcoal were placed in a small furnace. 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. Iron making iron making technologies can be divided into blast furnace technology, direct reduction iron dri technology, smelting reduction iron making corex, and so on. The sponge iron is delivered as hot from the reduction shaft furnace by screw. Ironpdf is a commercial grade pdf generation library for the.
This authoritative account covers the entire spectrum from iron ore to finished steel. Changes in the manufacturing process inevitably result in subtle differences between slags produced by either the blastfurnace or corex system. Corex, a smelting reduction process, is regarded as a costefficient and environmentalfriendly process, which produces hot metal from iron ore and coal 12. In the corex process, all metallurgical work is carried out in two separate process reactors the reduction shaft and the melter gasifier. The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic ironnickel. Iscors corex plant has a yearly capacity of 300 000 t. Pdf corex process in ironmaking elvis marca catachura. The future of energy efficiency in the steel industry bettadapura lakshminarayana, american iron and steel institute introduction steel is present in every aspect ofour lives, in all industrial, transportation sectors as well as in households in united states. Included in this article also is a discussion of the mining of iron and of its preparation for smelting.
When iron is reduced from iron ore, first it could be a solid state. The typical iron oxide mix for corex is 30% lump ore and 70% pellets. 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 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. Arcelormittal is the worlds leading steel and mining company. Iron fe is a relatively dense metal with a silvery white appearance and distinctive.
The benefits of pig iron granulation in integrated steelmaking have been discussed in depth earlier. Chapter 3 outlines requirements to quality of dri of some producers. Operational results proved stable operations with a lump ore fraction up to 80%. Extractive metallurgy, lecture notes, pdf, ebooks, attached files for direct download. Metallurgical engineering industrial production of iron ore ebook download pdf metallurgical engineering. Ferrous metallurgy is the metallurgy of iron and its alloys. This should be possible to perform at short notice and at the same pace as liquid iron is produced at the corex. A few reasons are analyzed for the apparition and development of such technologies. Iron ore processing for the blast furnace courtesy of the national steel pellet company the following describes operations at the national steel pellet company, an iron ore mining and processing facility located on the mesabi iron range of minnesota. Blast furnace iron production produced in china increased from 23% to nearly 60% of the worldwide from 2000 to 2010, while the dri production was less than 1% qi et al. The quality of the hot metal produced by the plant is similar to that of blastfurnace hot metal. Romelt process description romelt process is the singlestage technique of continuous ironmaking from various ironbearing materials using inexpensive noncoking coal.
Compared with the traditional iron making process via the blast furnace route, the corex process differs since non coking coal can be directly used for ore reduction and melting work, eliminating the need for coking plants. 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. Primary air pollutant emissions and future prediction of. New iron making processes have been extensively explored with a view to saving resources and energy, as well as reducing environmental pollution. Siemens is currently building the worlds largest corexbased plant in china. Emerging energyefficiency and carbon dioxide emissions. It is athe phenomenon of spontaneous interparticle percolation has twostage process that involves prereduction in ashaft furnace. The corex process is a twostage direct smelting process, consisting of. In case of steel making, the hot metal temperature delivered to steel making plant is about 17 degrees celsius. Experience of corex at jsw suggest that still 15% coke is required in the process to control vm of the input reductant. Creating steel from lowgrade iron ore requires a long process of mining, crushing. The corex process is a twostage smelting reduction process, in which hot metal can be produced from noncoking coal and iron ores.
Lawrence kavanagh, american iron and steel institute u. If you continue browsing the site, you agree to the use of cookies on this website. Use of pellet atleast partially is a must for corex process. Direct reduced iron dri, hot briquetted iron hbi, and iron carbide are all alternative iron making processes mcaloon, 1994. Ironmaking capability arguably deter mines the strength of. Corex vaimidrex with 60% hot metal and 40% dri charge to eaf. Similar to the blast furnace process, the reduction gas moves in counter flow to the descending burden in the reduction shaft. Pdf the corex process is being projected as an alternative for blast furnace iron making. Pdf minimization of exergy losses in the corex process. In the corex process, all metallurgical work is carried out in two separate process reactors the. This channel is about ferrous metallurgy and steel production.
Modeling the gassolid flow in the reduction shaft of corex. The corex process is the best known first generation process. In addition, iron ore can be directly charged to the. Our steel is at the heart of the modern world, forming the fabric of life tegrating processing steps and bring ing them under computer. The first metallurgical step is to reduce iron ore to metallic iron, a. Ironmaking and steelmaking metallurgical and materials. Consolidation of the iron and steel branches manifested itself in a significant increase of mergers and takeovers. The direct iron ore smelting reduction process dios directly uses noncaking coal in a powder or granular form, and iron ore without the use of coke or a sintering process, which are normally required. Corex process in iron making slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. To develop computational and mathematical abilities to be applied for process design and control. A special manufacturing process is making the production of iron much more environmentally friendly.
The bessemer converters increased in size from 5 tons to 30 tons, but the process was quickly rivalled by the siemens process and was finally superceded in the u. Sep 29, 2012 the bessemer converters increased in size from 5 tons to 30 tons, but the process was quickly rivalled by the siemens process and was finally superceded in the u. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. So heat energy required for ironmaking process is supplied by this coke and this is a source for carbon of hot metal. The american steel industry today can be counted among the most productive, efficient and.