presentation on alternative iron making smelting processess, relevance to INDIA.

1. ALTERNATIVE SR PROCESSESS FOR IRON
MAKING: RELEVANCE TO INDIA
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V.MOHAN 1011207008
Y.S.R. ENGINEERING COLLEGE OF
YOGI VEMANA UNIVERSITY
VISHNUMAHANTHY
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2. FUTURE CHALLENGES
RESOURCE
DEPLETION
RISING ENERGY
DEMAND
ENVIRONMENTAL
CARE
TOPICS, IRON MAKERS SHOULD CONSIDER.
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3. FUTURE RISKS
RESOURCE
DEPLETION
RISING ENERGY
DEMAND
ENVIRONMENTAL
CARE
INCREASING RAW
MATERIAL COST
INCREASING
ENERGY COST
ENFORCED
ENVIRONMENTAL
LAWS
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4. EMERGING SCENARIO IN IRONMAKING
More than 90% of world iron production is
through Blast furnace technology route.
 Driving forces: Alternative Iron making technologies:
 Costly and scarce coking coal: Need to look beyond
coking coal.
 Possibility to use iron ore fines directly.
 Environmental considerations.
 Eliminate pollution-intensive sintering and coke-making
processes.
 High capital cost
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5. Possible Solutions
 Direct Reduced Iron (DRI)
 Reduction of ferrous oxide in solid state.
 SL/RN, MIDREX, ITmk3 etc.
 Smelting Reduction of Iron
 COREX, FINEX, Hismelt etc.
 using non-coking coal.
 Obviating the need for coke oven batteries and
sinter plants.
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6. INDIAN Raw Material Flexibility
ƒ Iron ore
–
Dry fines (-6mm) and slimes (ultra-fines) – used directly
–
High phosphorus content possible
–
No blending or agglomeration necessary
–
Can be pre-heated / pre-reduced to increase process efficiency
ƒ Steel plant wastes
–
Dry fine wastes and metallic fines – used directly
–
E.g. mill-scale, steel-making slag, reverts, coke breeze
ƒ Coal
–
Non-coking coals – ground to -3 mm and dried
–
From coke breeze (low volatile)
–
No blending, briquetting or coking required
high volatile thermal coal (40%)
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7. CONVENTIONAL BLAST FURNACE PROCESS
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8. Characteristics of Blast furnace process
 STRENGTHS
 High energy efficiency
 High productivity
 Long service life
 LIMITATIONS
 Use of high grade raw materials
 Coke and sinter making processes required
 Generation of air pollutant such as Sox, Nox, Dioxin
and
dust.
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9. Available Smelting Reduction (SR)
Processes
SR technologies currently commercially exploited or ready for
commercial exploitation.
 COREX (Two stage): Operating commercially
 FINEX (Two stage): Operating commercially
 HISMELT (Single stage):Not being Operating commercially
at present.
• Single stage: Reduction & melting in the same vessel
• Two stage : Reduction in one vessel; melting in the 2nd vessel.
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10. COREX TECHNOLOGY
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11. COREX: Process Features
 Developed by Siemens VAI.
 Commercially most successful among SR technologies.
 Work is carried out in 2 reactors.
 Reduction shaft
 Melter-gasifier.
Commercial units in operation
Korea
: POSCO (COREX C-2000 – Capacity: 0.8 Mtpa)
India
: JSW Steel (2 Units) (COREX C-2000)
: Essar Steel ltd (2 units) (COREX C-2000)
South Africa: Mittal-SALDANHA, (COREX C-2000)
China
: Baosteel, (COREX C-3000) – Capacity 1.5 mtpa
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13. 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.
 Discharge screws convey the DRI
from the reduction shaft into the
melter –gasifier.
 In Melter-gasifier final reduction
and melting takes place.
 Hot metal and slag tapping are
done as in conventional blast
furnace practice.
 The gas leaving the reduction
shaft is cooled and cleaned and
is used for a wide range of
applications.

14. Blast Furnace vs COREX
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15. COREX: Process Features
 Strengths





Hot metal quality.
Economic benefit .
Ecological benefit.
non-coking coal can be used.
generation of highly valuable export gas.
 Limitations
 Can't use ore fines directly.
 Restriction on non-coking coal.
VM of carbonaceous material to be maintained at 25% .
 Net export gas (CV:1800 Kcal/Nm3) to be utilised very
economically, the process becomes un-viable.
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16. FINEX TECHNOLOGY
© HIsmelt Corporation
2008
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17. FINEX PROCESS
 Siemens VAI and POSCO jointly developed
the process.
 FINEX R&D since 1992.
 FINEX demo of 600 Kt/y since June 2003.
 FINEX of 1.5 Mt/y in May 2007 (1st
commercial plant).
 Based on the direct use of non-coking coal
and fine ore.
 Most exciting iron making technology on the
market today.
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18.  Fine iron ore is preheated and
reduced to fine direct reduced iron
(DRI) in a three or four stage fluidized
bed reactor system.
 The fine DRI will be compacted and
then charged in the form of hot
compacted iron (HCI) into the melter
gasifier.
 The charged HCI is subsequently
reduced to metallic iron and melted.
 The generated FINEX export gas is a
highly valuable product and can be
further used.
 The hot metal and slag produced in
the melter gasifier is frequently
tapped from the hearth as in blast
furnace or COREX® operation

19. Blast Furnace vs FINEX
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20. Advantages of FINEX Technology
‰
Flexibility in Raw Materials
 Elimination of sintering & coke-making processes.
 No blending of ore &coal.
 Use of Low-grade ore &low-ranked coal.
‰
 Easy &Flexible Operation
 Independent control of reduction &melting processes.
 Easy &hassle-free operational control.
‰
 Environmental Friendliness

Far less emission of Sox.
 Nox & dust.
‰
Cost
Competitiveness
 Lower cost in both capital investment &operation vs. BF
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21. FINEX - Advantages
Blast Furnace
FINEX
production
pollutants
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22. CO2 emission trends of FINEX
Specific amount of CO2 emissions per ton of hot metal
* Relative index
130 %
Technologies applied to reduce CO2
Production of hot compacted iron
Reuse of FINEX top gas with CO2 removal
Purverized coal injection
Reduction of cooling gas use
High pressure operation
106 %
98 %
World average of blast furnace
at 100% note1
Dec. 2006
94 %
1st Target
91 %
2nd Target
FINEX Demo
FINEX 1.5 Mt
Note1 Average
figure was calculated using estimated amount of CO2 emissions from blast furnaces
at fourteen steelworks located in Asia and Europe
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23. Hismelt Technology
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24. The Hismelt Process
 ƒ Ore & coal are injected
into the molten bath.
Offgas

Oxygen
Enriched
Hot Air Blast
Raw Materials
Injection
Lances
Hot blast is injected into
the top-space
 ƒ Metal flows out
continuously
 Slag is batch tapped.
Water
cooled
panels
Foreheart
h
Slag
Notch
Metal
Bath
Smelt Reduction Vessel(SRV)
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25. Higher Quality Iron: Compared to blast furnaces
Typical Analysis
Blast Furnace
Carbon
4.5%
4.4
0.15%
Silicon
0.5
0.3%
<0.01%
Manganese
0.4
0.2%
<0.02%
Phosphorus
Sulphur
Temperature
#
*
**
0.09
0.04
0.02% *
0.02
0.01% **
0.02%
0.1
0.05% #
1430 - 1500 C
1420 C
Dependant on sulphur input (mainly from the coal). With hot metal de-sulphurisation
treatment
(known technology) sulphur levels are easily able to be reduced to <0.05%.
Low Phosphorus Ore
High Phosphorus Ore

26. Lower Operating Cost
1.4
~10-20%
lower
operating
costs
1.2
Relative Index
1.0
0.8
0.6
0.4
0.2
0.0
Blast Furnace
HIsmelt
Ore
Coal
Other
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27. Hismelt’s Advantages for India
ƒ Flexibility in Raw
Materials
ƒ Lower Capital & Operating Costs
Impact
ƒ Lower
Environmental
ƒ
Quality Iron Product
High
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28. Final conclusion
Developing markets mainly led by china and India
pulling the global steel demand.
Restricting growth factors are:
 Scarcity of high grade raw materials.
 Global environment problems and concerns.
Development of innovative alternative iron-making
process technologies.
Low grade, low cost resources and to reduce the
level of air pollution.
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29. QUESTIONS?
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30. THANK YOU
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