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. Solubility of mgo in new ironmaking processtyped slags. It begins by tracing the history of iron and steel production, right from the earlier days to todays world of. Pdf corex process in ironmaking elvis marca catachura. The quality of the hot metal produced by the plant is similar to that of blastfurnace hot metal. New iron making processes have been extensively explored with a view to. Iron making process, full notes, pdf, ebooks, results 1 to 1 of 1. Included in this article also is a discussion of the mining of iron and of its. Nonblast furnace iron making technology total materia. Direct reduction process is the only iron making technology currently adopted in south east asia. However, the sharp drop in gas prices due to the marcellus shale development has led to resurgence in interest in gas based dri production. The invention provides a method for both disposing of an environmentally undesirable material comprising petroleum coke and the sulfur and heavy metals contained therein and of providing. 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. 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.
Iron making process, full notes, pdf, ebooks, popular. 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 re. Corex process distinguishes itself from the blast furnace route by i direct. 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. All the alternative emerging ironmaking technologies eliminate energyintensive coke production. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. The high dome temperature exceeds 1,000c, resulting in entire cracking of the coals relieved hydrocarbons and avoiding the formation of tar. Ferrous metallurgy is the metallurgy of iron and its alloys. Overview of corex plant in operation in the corex process, all metallurgical work is carried out in two separate process reactors. Improving the desulphurization in corex3000 process by. Ironmaking and steelmaking metallurgical and materials. A small amount of electricity is required, 60 kwhtonne. High fraction of lump ore the typical iron oxide mix for corex is 30% lump ore and 70% pellets.
Operational results proved stable operations with a lump ore fraction up to 80%. Fine coal generation during handling for the corex process of iron making. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Pdf minimization of exergy losses in the corex process. Steel is made by refining liquid iron and then cooling and shaping it in a mold. This process, has been developed and is being marketed by voestalpine industrienlagenbau vai, austria.
Corex enables the costefficient and environmentally friendly production of hot metal from iron ore and 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. The first metallurgical step is to reduce iron ore to metallic iron, a. In the twostage operation of the process dri produced from a shaft furnace is charged into a meltergasifier for smelting. Rio tinto has for many years been a trusted supplier to the worlds iron and steel industry, particularly in south east asia, where its. Fine ore is preheated and reduced to dri in a four stage fluidised bed system. Alternative emerging ironmaking technologies for energy.
Valia, scientist, ispat inland inc introduction a world class blast furnace operation demands the highest quality. Similar to the blast furnace process, the reduction gas moves in counter flow to the. Furthermore, wastewater emissions from the corex process are far lower than those in the conventional blastfurnace route. Introduction to iron ore pellets and pelletizing processes. Pelletizing is a process which involves mixing of very finely ground particles of iron ore fines having a size which is less than 200. So far, corex, a smelting reduction process, has emerged as one of the most promising. Us5380352a method of using rubber tires in an iron. Conventional iron and steel production and smelting reduction technology the conventional production routes the production of iron is the first step in the production process of steel. Degradation behaviour of weathered coal during handling. Ironmaking capability arguably deter mines the strength of the steel industry. Degradation characteristics of weathered south blackwater coal were tested by using a drop apparatus to minimize the fines generation during handling at the gladstone port for the. Corex process in iron making slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The increasing role of direct reduced iron in global.
Sintering process sinter making is a method of fusing iron ore fines into larger particles suitable for charging into the blast furnace. Fine coal generation during handling for the corex process. There are two basic methods for making liquid iron. The corex process is a twostage smelting reduction process, in which hot metal can be produced from noncoking coal and iron ores. The corex process combines coking plant, sinter plant and blast furnace into a single iron making unit. The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from.
In the corex process, all metallurgical work is carried out in two separate process. Iron making process free download as powerpoint presentation. Wo1994008055a1 iron making process using petroleum coke. In the first step the iron ore is reducedin a shaft furnace. The results showed that above 3 m critical heights replacing large drops with a number of smaller. Corex is a smelting reduction process combining a melter gasifier with a reduction shaft. The corex process is a smelting reduction process created by siemens vai as a more environmentally friendly alternative to the blast. This authoritative account covers the entire spectrum from iron ore to finished steel. Accordingly a corex plant has shaft unit, where iron ore pellets with or without some closely sized lump ore is reduced by gases emanating from the second unit to make hot sponge iron first stage. 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. 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. This article is a summary of some papers presented at seaisi conferences and limited to a short description of the iron making technologies.
The coal consumption of the corex process is large with a net fuel rate ofkgtone of hot metal. 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. Ore smaller than 14 is pumped in slurry solution to the wet cobber magnetic separator, which begins the process of. Coke production for blast furnace ironmaking by hardarshan s. Iscors corex plant has a yearly capacity of 300 000 t. Bhagat introduction the process of sinter making originated from a need to make use of fines generated in mines and.
Be able to understand basic layout of blast furnace. Smelting reduction process is that process which is based on smelting. As results, growing concerns are expressed over the limebased slags containing signi. In addition, no sinter and therefore no sinter plant is necessary for optimal operation. Iron making in mini blast furnace mbf the blast furnace ironmaking process had, until recently, been the unchallenged method of making hot metal on a large scale. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover. The corex process is being projected as an alternative for blast furnace iron making. Unlike the blast furnace, smelting reduction processes are typical smaller and use coal and oxygen directly to reduce iron ore into a usable product.