This presentation discusses pulverized coal injection (PCI) in blast furnaces for ironmaking. It provides background on blast furnace technology and the roles of coke and PCI coal. Coke typically accounts for half of operating costs, so increasing PCI coal replacement of coke lowers costs. The presentation reviews global steel production trends driving coal demand and analyzes key coal importing regions. It also examines factors affecting PCI coal selection like volatile matter content and replacement ratio. Pricing dynamics and the cost savings from PCI coal substitution of coke are also addressed.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
Ferrosilicon productiion and submerged arc furnace (1)Nasser Harby
Ferroalloys, by definition, are alloys of two or more metals, of which one is Iron. The U.S. Bureau of Mines defines ferroalloy as an alloy of iron with at least one other element except for carbon.
The main indicator of the quality of a ferroalloy is its chemical composition and, above all, the content of the leading element. It is important to have Consistency in alloying element amounts in ferroalloys from heat to heat, allowing the manufacture of standard products
The smelting of ferroalloys is commonly performed in electric arc furnaces.
Although ferromanganese can be produced in a blast furnace in a manner similar to iron, the reduction of chromium and silicon from their oxides requires higher Process temperatures and lower oxygen potentials than can be achieved in a blast furnace
Raw materials are perhaps the most important factor for obtaining good furnace operation the first step towards improvements is to reduce the variations
The aim of this course is to present the basic principles for the production of ferrosilicon alloys processes, and a simple preview for submerged arc furnaces.
It is attended for Engineers working in this field, and students or metallurgists maybe find answers for their questions, because at the end of this course you will figure out that you have a preview for this manufacture and the main problems and solutions for the ferrosilicon production process. And having an overview for submerged arc furnaces design and operations.
.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
Ferrosilicon productiion and submerged arc furnace (1)Nasser Harby
Ferroalloys, by definition, are alloys of two or more metals, of which one is Iron. The U.S. Bureau of Mines defines ferroalloy as an alloy of iron with at least one other element except for carbon.
The main indicator of the quality of a ferroalloy is its chemical composition and, above all, the content of the leading element. It is important to have Consistency in alloying element amounts in ferroalloys from heat to heat, allowing the manufacture of standard products
The smelting of ferroalloys is commonly performed in electric arc furnaces.
Although ferromanganese can be produced in a blast furnace in a manner similar to iron, the reduction of chromium and silicon from their oxides requires higher Process temperatures and lower oxygen potentials than can be achieved in a blast furnace
Raw materials are perhaps the most important factor for obtaining good furnace operation the first step towards improvements is to reduce the variations
The aim of this course is to present the basic principles for the production of ferrosilicon alloys processes, and a simple preview for submerged arc furnaces.
It is attended for Engineers working in this field, and students or metallurgists maybe find answers for their questions, because at the end of this course you will figure out that you have a preview for this manufacture and the main problems and solutions for the ferrosilicon production process. And having an overview for submerged arc furnaces design and operations.
.
ELECTRIC ARC FURNACE AC (PART 2) The Raw Materials (steel, steelmaking, furna...Matteo Sporchia
A detailed report about the main raw materials used into the Electric Arc Furnace (EAF) based on the latest technologies of iron and steelmaking fields.
A presentation on furnaces, fuels, and fluxes in chemical metallurgy. Chemical Metallurgy is also known as extractive metallurgy or process metallurgy and it's concerned with all processes involved in the extraction of valuable metals from their ores. It has three main branches namely: hydrometallurgy, pyrometallurgy, and electrometallurgy. The use of furnaces is important in the area of pyrometallurgy to provide the necessary heat required to ensure the extraction of metals from their ores. Fuels are used to provide the adequate energy needed.
This is Blast Furnace ppt for steel plant.
this is my web site : http://btechadvanceproject.blogspot.in/
this is my Youtube - https://youtu.be/l0blxo-t_cg
Follow On Instagram : https://www.instagram.com/md.raza72/
My linkedin profle https://www.linkedin.com/in/md-raza-ansari-78a6ba116/
ELECTRIC ARC FURNACE AC (PART 2) The Raw Materials (steel, steelmaking, furna...Matteo Sporchia
A detailed report about the main raw materials used into the Electric Arc Furnace (EAF) based on the latest technologies of iron and steelmaking fields.
A presentation on furnaces, fuels, and fluxes in chemical metallurgy. Chemical Metallurgy is also known as extractive metallurgy or process metallurgy and it's concerned with all processes involved in the extraction of valuable metals from their ores. It has three main branches namely: hydrometallurgy, pyrometallurgy, and electrometallurgy. The use of furnaces is important in the area of pyrometallurgy to provide the necessary heat required to ensure the extraction of metals from their ores. Fuels are used to provide the adequate energy needed.
This is Blast Furnace ppt for steel plant.
this is my web site : http://btechadvanceproject.blogspot.in/
this is my Youtube - https://youtu.be/l0blxo-t_cg
Follow On Instagram : https://www.instagram.com/md.raza72/
My linkedin profle https://www.linkedin.com/in/md-raza-ansari-78a6ba116/
19 Final Slide Ideas for Concluding Your PresentationStrongpages
How should you end your presentation? What should your "last slide" display? This deck shows 19 different ideas to give your presentation the right conclusion. Produced by http://www.strongpages.com/
Presentation given by Paul Fennell of Imperial College London on "The Integration of Power Generation, Cement Manufacture, Biomass Utilisation and Calcium Looping." at the Alternative CCS Pathways Workshop, Oxford Martin School, 27 June 2014
The extensive use of pulverized coal injections in blast furnace worldwide, calls for higher coke quality. On the other hand, as coking coals become more expensive, with volatile price and relative availability, coke producers look for the introduction of cheaper coals in the blend. One of the answers to either of these drivers is stamped charging, initially oriented to the use of high volatile poorly coking coals.
Briefly, the technique of charge preparation consists in preparing a cake with the coal blend in a metallic box, then charging it in the coke oven. The higher charge density implies better coke quality when compared with conventional charging. So, depending on the situation, either better coke quality may be obtained, or poorer coking coals may be included in the blend.
The process has been around since the early XX century. As an example, Coed Ely coke plant, in South Wales, UK, operated two batteries of 30 ovens each, built by Coppe Company in 1914, 34’ long, 8’ 6” high and 50’ width, with a stamping station located in the space between the two batteries. Straw was used as an aid to cake strength. Straw was used as a binder and a specially designed charger car/ram built to load the charge into the oven from the back. Coke made by the stamp charging process was of a denser and larger variety than that made in other ways, making its use ideal for ironmaking in foundries where strength is an important factor. Another advantage noted was that a much larger range of coals could be coked with the limits of (high) volatility and coking properties much increased [1]. Also, other plants in West and East Europe adopted the technique: Germany, France, Poland, and Ukraine.
Modern process development took place in Fuerstenhausen Coke Plant, Völklingen, Germany, focused in the use of high volatile Sarre basin coal. In 1978, after intensive research and development the first 6 meters high cake was produced, overcoming a bottleneck for the economical implantation of this technology. The first plant of this dimension was started-up in 1984, at what is called today ZKS Zentralkokerei Saar, Völklingen, Germany [2].
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After immersing yourself in the blue book and its red counterpart, attending DDD-focused conferences, and applying tactical patterns, you're left with a crucial question: How do I ensure my design is effective? Tactical patterns within Domain-Driven Design (DDD) serve as guiding principles for creating clear and manageable domain models. However, achieving success with these patterns requires additional guidance. Interestingly, we've observed that a set of constraints initially designed for training purposes remarkably aligns with effective pattern implementation, offering a more ‘mechanical’ approach. Let's explore together how Object Calisthenics can elevate the design of your tactical DDD patterns, offering concrete help for those venturing into DDD for the first time!
SAP Sapphire 2024 - ASUG301 building better apps with SAP Fiori.pdfPeter Spielvogel
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• How a better user experience drives measurable business benefits
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Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
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Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
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The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
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Bob Boule
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The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
Download the full report from here:
https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
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PCI update May 2012 Ross Stainlay
1. PCI Coal (2012 presentation)
1
How market conditions affect PCI
coal selection and usage
Ross Stainlay – M Resources
rstainlay@mresources.com.au
2. Agenda
• Set the Scene (and terminology !)
• Technology and Replacement Ratio
• Trade and Consumption
• Pricing and VIU
• Concluding Remarks
2
3. 3
Source: ANZ
Iron Ore Consumption Intensity –
Future Production Levels to Rise
4. Blast Furnace Dominates
Other – 32%
Blast
furnace
68% Global
(China 90%)
Liquid steel – by origin
• The blast furnace
remains the primary
source of liquid steel
• “Other” is EAF,
induction furnace,
COREX and others
• [>95 % of virgin iron
units derived from BF]
4
Coking / PCI coal cost can amount to ~ half the
operating costs for a modern BF
5. BF Hot Metal Production (Mtpa)
1,600
1,400
1,200
1,000
800
600
400
200
0
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2021
Asia
Oceania
Africa
S America
N America
CIS
Other Europe
EU-28
5
Forecast
Source – compilation
6. Main European Met Coal Importing Countries
Jul 2005-Dec 2011
(Blast Furnace – Hot Metal Mt pm)
7
6
5
4
3
2
1
0
Aug-05
Dec-05
Apr-06
Aug-06
Dec-06
Apr-07
Aug-07
Dec-07
Apr-08
Aug-08
Dec-08
Apr-09
Aug-09
Dec-09
Apr-10
Aug-10
Dec-10
Apr-11
Aug-11
Dec-11
Millions
Total EU (8 countries) Source - WSA
UK, France Germany, Turkey,
Sweden/Finland, Belgium,
Netherlands, Spain
6
7. Main South American Met Coal Importing
Countries Jul2005-Dec 2011
(Blast Furnace – Hot Metal Mt pm)
0
0.5
1
1.5
2
2.5
3
3.5
4
Aug-05
Dec-05
Apr-06
Aug-06
Dec-06
Apr-07
Aug-07
Dec-07
Apr-08
Aug-08
Dec-08
Apr-09
Aug-09
Dec-09
Apr-10
Aug-10
Dec-10
Apr-11
Aug-11
Dec-11
Millions
Brazil
Argentina
7
Source - WSA
8. Main Asian Met Coal Importing Countries
Jul 2005-Dec 2011
(Blast Furnace – Hot Metal Mt pm)
0
2
4
6
8
10
12
14
16
Aug-05
Dec-05
Apr-06
Aug-06
Dec-06
Apr-07
Aug-07
Dec-07
Apr-08
Aug-08
Dec-08
Apr-09
Aug-09
Dec-09
Apr-10
Aug-10
Dec-10
Apr-11
Aug-11
Dec-11
Millions
Taiwan
South
Korea
India
Japan
8
Source - WSA
9. Agenda
• Set the Scene
• Technology and Replacement Ratio
• Trade and Consumption
• Pricing and VIU
• Concluding Remarks
9
10. THE BLAST FURNACE
The blast furnace is designed to reduce iron
oxide to liquid iron, whilst maintaining hot
metal quality and temperature.
All this at the minimum possible cost.
Coke performs the following roles in the BF:
Chemical
- Reductant
FeO + C Fe + CO
Fe2O3 + CO 2FeO + CO2
- Carbon dissolved in hot metal (5%
approx)
Thermal
- 2C + O2 2CO
Physical or Structural
- Support burden
- Gas and liquid permeability 10
11. Advantages of PCI
• PCI into the blast furnaces offers the following
advantages for blast furnace operation:
– Coal is less expensive than coke, resulting in lower fuel costs.
– Coal injection in conjunction with other parameters may
improve productivity.
– A wide range of coal types can be injected.
– Coal injection rates are higher than oil or natural gas, thus lower
coke rates are achieved.
– Coal supplies are more stable due to extensive reserves.
– Coal injection systems are less costly than new coke plants.
– Coal grinding and injection systems are non-polluting, and may
offer a CO2 reduction opportunity
11
12. PCI Rates and Records
94
100
90
80
70
60
50
40
kg/thm across all BFs
1995 1996 1997 1998 1999 2000
PCI records over time
– Dunkirk 143 kg/thm (1984)
– Thyssen 200 kg/thm (1992)
– Kobe 224 kg/thm (1998)
– Baosteel 260 kg/thm (1998?)
– NKK 266 kg/thm (1998)
– Current sustainable best
practice appears to be around
200 kg/t PCI along with 285
kg/t coke. With one
important exception ….
12
Source: CRU International
14. TM
CO gas & tar
Breeze
Dry coke at BF
1 tonne dry, useful coke
requires ~ 1.5 tonne of
coking coal – as shipped
(24% VM coking coal - 10 % TM)
14
Coking Coal and Coke
1 tonne of coking coal – as
shipped.
15. BF Input & Output – Typical JSM
BF : 5150 cu m – 15.0 m dia - 4.1 Mtpa hm (11000 +tpd) - productivity 2.4
COKE:
370 kg/t
11-12 % ash
60-65 CSR
PCI (1 to 3 coals) :
130 kg/t
9 % ash
0.85 RR
3% O2
1100 deg Blast T
ORE / SINTER / FLUXES
1580 kg/t
70 % sinter
1 tonne hot metal
+ Slag : 300kg/t
COKE BATTERIES
- 125 ovens
- 1.5 Mt coke pa
- CMC – ½ CDQ
Other: TRT – bell less top
– HM P 0.12 % -
Coking coal -
(8-12 coals)
- 520 kg
15
16. General Flowsheet – PCI System
Fine Coal
Storage
Raw Coal
Stove Off Gas
Fuel Gas
Injection
Vessels
Pulverizer
M
M
M
M
M
Distributor
Nitrogen
Blast Furnace
Air
Courtesy of BMH
16
21. PCI Coal Entering the BF
A single injection lance is most common, options
include double lance, oxygen annulus, pre-heating
of coal
21 Source: Kuttner
22. Pulverized Coal Injection into Blast
Furnaces
Coke
PCI
Coal
Coke Ovens Blast Furnace Coal Grinding and
Injection System
Courtesy of BMH 22
23. PCI Plant – Brazil
Injection capacities
at 200 kg coal/thm
üBF 2. 37 t/h
üBF 3. 79 t/h
Mill Capacity:
ü2 x 60 t/h
23
25. High volatile v. low volatile coal
Fixed Carbon
Volatile Matter
Ash
Inherent Moisture
Free Moisture
FC
FC
FC
FC
FC
VM
VM
VM
VM
A
IM
A
A
A
FM FC
IM
FC
FC
FC
FC
VM
VM
VM
VM
VM
High vol PCI / SSCC Lo vol PCI coal
A
A
A
A
IM
FM
IM
AR
AD
DRY
DAF
“COKE”
28. Properties of selected PCI coals
AUS 1 AUS 2 AUS 4 AUS 5 CAN 1 AUS 6 AUS 7 FUTURE AUS HV
Property Basis AUS 3 AUS 8 1
TM % ar 9.0 8.0 9.0 9.0 9.0 8.0 8.0 10 11.0 10.0 10.5
IM % ad 2.0 1.5 1.2 1.5 1.1 1.0 1.5 1 2.0 1.5 3.5
Ash % ad 10 10.5 9.0 7.5 8.5 8.5 10.0 9.5 9 8.5 6
VM % ad 9.5 12.2 12.5 12.7 13.0 14.0 14.5 19.5 19.5 15.0 35.4
VM % daf 10.8 13.9 13.9 14.0 14.4 15.5 16.4 21.8 21.9 16.7 41.0
FC % ad 78.5 75.8 77.8 78.3 77.4 76.5 74.0 70.0 69.5 79.2 53.4
TS % ad 0.65 0.7 0.50 0.50 0.45 0.5 0.65 0.5 0.51 0.6 0.35
Phos % ad 0.070 0.090 0.080 0.070 0.080 0.050 0.050 0.03 0.085 0.080 0.002
CV (kcal/kg) % ad 7450 7500 7750 7910 7775 7765 7550 7500 7620 7650 7375
CV (kcal/kg) % daf 8466 8523 8630 8692 8601 8580 8531 8400 8562 8500 8150
HGI 68 78 80 77 84 65 85 85 90 85 50
Carbon % daf 91.7 90.9 90.5 91.0 90.7 91.1 89.5 88.0 89.1 88 82.7
28
29. Low Vol PCI Coal High Vol PCI Coal
Hot Blast:
Equal or
Slightly Higher
Hot Blast:
Equal or
Slightly Lower
O2 Rate:
Equal or
Lower
O2 Rate:
Equal or
Higher
Low VM Coal High VM Coal
Permeability:
Equal or
Slightly Lower
Permeability:
Equal or
Slightly Higher
Gas Reduction:
Lower
Gas Reduction:
Higher
RAFT: Higher RAFT: Lower
Combustion
Efficiency: Lower
Combustion
Efficiency: Higher
Fuel Ratio: Lower
Coke Ratio: Lower
Fuel Ratio: Higher
Coke Ratio: Higher
Top Gas Vol.: Lower
Calorific Value: Lower
Top Gas Vol.: Higher
Calorific Value: Higher
Dust : Equal or
Slightly Higher
Dust : Equal or
Slightly Lower
Impact of PCI Coal Type on BF
Operation
29
30. The PCI advantage (4 Mtpa HM)
High Vol PCI
Coking Coal* 543 kg/tHM @ $U193/t
Yields 388 kg/tHM Coke
* 70:30 HCC : SSCC
PCI 150 kg/tHM
RR 0.75 & $US135/t
Coal Cost = US$125 /tHM
= US$ 501 million pa
Savings US$ 24 million pa
No PCI
Coking Coal * 700 kg/tHM @ $US188/t
Yields 500 kg/tHM Coke
* 80:20 HCC : SSCC
Notes: All coal prices fob basis – coke blend of HCC & SSCC coals
Excludes value of by-products, coke oven gas and coke breeze
Basis HCC $205, SSCC $147 /t fob. Values rounded. Fuel rate 500 kg/t
Coal Cost = US$131 /tHM
= US$525 million pa
Low Vol PCI
Coking Coal* 511 kg/tHM @ $US193/t
Yields 365 kg/tHM Coke
* 70:30 HCC : SSCC
30
PCI 150 kg/tHM
RR 0.90 & $US153/t
Coal Cost = US$ 122 /tHM
= US$ 487 million pa
Savings US$ 38 million pa
31. Agenda
• Set the Scene
• Technology and Replacement Ratio
• Trade and Consumption
• Pricing and VIU
• Concluding Remarks
31
32. QLD LV PCI coal exports
30
25
20
15
10
5
0
Mt
Production Year
Middlemount
Vermont
Isaac Plains
Baralaba
Carborough
Poitrel
Millennium
Capricorn
Curragh
Yarrabee
Foxleigh
Coppa/Moor
SWC
Jellinbah
Source M Resources
33. PCI Coal Demand Predictions
33
140
120
100
80
60
40
20
0
Mt
PCI
Growth in demand arises from :
- New blast furnaces coming on line
- Installation of PCI to existing furnaces
- Increased rates of injection
34. LV PCI – Seaborne Traded
50
45
40
35
30
25
20
15
10
5
0
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Mt pa
ROW
Australia
* = all other
Met coal
405 *
Mt
Source M Resources
ROW countries include:
Canada, Russia /
CIS, China
215
* Mt
Forecast
34
35. Agenda
• Set the Scene
• Technology and Replacement Ratio
• Trade and Consumption
• Pricing and VIU
• Concluding Remarks
35
36. Model outcomes – Replacement
Ratios – F-TeCon data
1
0.9
replaced)
0.8
coke t 0.7
kg/(RR 0.6
0.5
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AABB CC Coal brand
36
37. 180
160
140
120
100
80
60
40
20
0
Model outcomes – Replacement
Ratios – F-TeCon data
0.95
0.9
0.85
0.8
0.75
0.7
0.65
0.6
0.55
0.5
Assumed: LV PCI ~$153 /t RR 0.90
A C E G I K M O Q S U W Y AA CC
Calculated price based on VIU - $/t fob
RR (kg/t coke replaced)
Coal brand
37
38. Coal and Coke Pricing 2012 Q2
$350
$300
$250
$200
$150
$100
Coke
Hard Coking Coal
LV PCI
LV PCI – hi ash
Thermal coal
38
43. Coal in the Blast Furnace
Coking coal - blend
of up to 15 coals
470 kg/thm
350 kg/thm
By Products
Coke Ovens
PCI coal
(1 to 3 coals)
150 kg/thm
Coal Mill
Blast Air
Coke
150 kg/thm
SLAG CONTRIBUTION:
Sinter + breeze
Say 1500 kg @ 16%
“minerals” = 225 kg
Coke 350 kg @12% ash
(minerals) = 42 kg
PCI 150 kg
a) 8.5% ash > 13Kg
b) 12 % ash > 18 kg
BUT b) Need to increase
rate to compensate say
Sinter 155 kg/t > 18.6 kg
Coke
PCI
Slag
contrib’n
A 1% abs incr. in PCI ash = 0.3 % increase in combined [coke + PCI] ash = +3-5 kg
coke = $1-1.50 costs + … heat loss – productivity impacts etc
45. Recent price forecasts
Source: Macquarie Bank & UBS Apr/ May 2012
300
250
200
150
100
50
2010 2011 2012 2013 2014 2015 2016 2017
USD/t fob
m_HCC
m_LV PCI
m_SSCC
m_Thermal
u_HCC
u_LVPCI
u_SSCC
u_Thermal
f Low VM PCI - $125 - $175
in near term?
46. Agenda
• Set the Scene
• Technology and Replacement Ratio
• Trade and Consumption
• Pricing and VIU
• Concluding Remarks
46
47. The Future
• Demand for traded PCI coal is a function of:
– BF hot metal production (coastal plants)
– PCI rate (kg/t)
– Number of BF fitted with injection
– Also depends on price competitiveness relative to alternative fuels
(thermal coal, oil and gas)
• Immediate outlook is for continuing strong demand with
measured production increases from existing mines along with
new capacity
• When BFHM production is reduced – buyers have more options.
Locking in a ratio of PCI coal to HCC is simplistic
47
48. THANK YOU
48
TRADING
Coking coal
PCI
Thermal
CONSULTING
Coal quality
Utilisation and
blending
Value-in-use
Specification
development
Resource
evaluation
Brisbane - Australia
www.mresources.com.au
Acknowledgments: CRU, Macquarie
Bank