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ALTERNATIVE SR PROCESSESS FOR IRON MAKING: RELEVANCE TO INDIA

V.MOHAN 1011207008Y.S.R. ENGINEERING COLLEGE OFYOGI VEMANA UNIVERSITY

VISHNUMAHANTHY

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FUTURE CHALLENGESRESOURCE DEPLETION

RISING ENERGY DEMAND

ENVIRONMENTAL CARE

TOPICS, IRON MAKERS SHOULD CONSIDER.

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FUTURE RISKSRESOURCE DEPLETION

RISING ENERGY DEMAND

ENVIRONMENTAL CARE

INCREASING RAW MATERIAL COST

INCREASING ENERGY COST

ENFORCED ENVIRONMENTAL

LAWS

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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

EMERGING SCENARIO IN IRONMAKING

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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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INDIAN Raw Material Flexibility� 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

� Steel plant wastes

–

–

Dry fine wastes and metallic fines – used directly

E.g. mill-scale, steel-making slag, reverts, coke breeze

� Coal

–

–

–

Non-coking coals – ground to -3 mm and driedFrom coke breeze (low volatile) high volatile thermal coal (40%)

No blending, briquetting or coking required

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CONVENTIONAL BLAST FURNACE PROCESS

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Characteristics of Blast furnace processSTRENGTHS

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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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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COREX TECHNOLOGY

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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

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.

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Blast Furnace vs COREX

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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.

COREX: Process Features

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© HIsmelt Corporation 2008

FINEX TECHNOLOGY

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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.

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

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Blast Furnace vs FINEX

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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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FINEX - Advantages

production

pollutants

Blast Furnace FINEX

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④

Specific amount* Relative index

of CO2 emissions per ton of hot metal

② Reuse of FINEX top gas with CO2 removal

④ Reduction of cooling gas use

Note1 Average figure was calculated using estimated amount of CO2 emissions from blast furnaces at fourteen steelworks located in Asia and Europe

130 % Technologies applied to reduce CO2

① Production of hot compacted iron

③ Purverized coal injection

⑤ High pressure operation

106 %World average of blast furnace

at 100% note1

94 %

98 %Dec. 2006

1st Target 91 %2nd Target

FINEX Demo FINEX 1.5 Mt

CO2 emission trends of FINEX

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Hismelt Technology

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The Hismelt Process

Offgas

� Ore & coal are injected into the molten bath.

Raw MaterialsInjection Lances

Hot blast is injected into the top-space

Oxygen EnrichedHot Air Blast

Water cooledpanels

� Metal flows out continuously

ForehearthSlag

Notch

Metal Bath

Smelt Reduction Vessel(SRV)

Slag is batch tapped.

Higher Quality Iron: Compared

to blast furnaces

# 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

***

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 0.09 ± 0.02% * 0.02 ± 0.01% **

Sulphur 0.04 ± 0.02% 0.1 ± 0.05% #

Temperature 1430 - 1500°C 1420°C

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1.4

~10-20% loweroperating costs

1.2

1.0

0.8

0.6

0.4

0.2

0.0

Blast Furnace HIsmelt

Rel

ativ

e I

nd

ex

Ore Coal Other

Lower Operating Cost

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Hismelt’s Advantages for India

� Flexibility in Raw Materials� Lower Capital & Operating Costs

� Lower Environmental Impact

� High Quality Iron Product

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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.

Final conclusion

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QUESTIONS?

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THANK YOU