COREX IRON MAKING PROCESS PDF

Corex Process for Production of Iron. During the late twentieth century, several new initiatives have been taken for the development of the. COREX PROCESS in IRONMAKING Report Submitted by: Aditya Kumar Singh ( ), Bachelor in Technology, Metallurgy & Materials. A brief technical review about what is COREX process of iron making, some merits and demerits of COREX technology.

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Corex process was developed by the Austrian technology supplier VOEST in the late s, and its feasibility was confirmed during the s. Use of high purity oxygen in the Corex corez generates of nitrogen free top gas. The first pilot plant was installed in Kehl, Germany, in The main reagents for the Corex process are iron orenoncoking coaland oxygen.

The melter-gasifier can largely be divided into three reaction zones namely i gaseous free board zone upper part or domeii char bed zone middle part above oxygen tuyeresand iii hearth zone lower part below oxygen tuyeres. In Siemens first completed a life cycle assessment for pig iron production, looking at both conventional production in a blast furnace and the more environmentally friendly COREX and FINEX processes.

This module has a hearth diameter of 7.

Corex Process for Production of Iron |

Many of the gases resulting from this process can then be recycled or used to produce electricity. Besides final reduction and melting, all other metallurgical reactions also take place in the melter-gasifier.

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. Direct use of non-coking coal is possible since the coal is charred inside the melter gasifier.

The exothermic combustion provides the energy to complete the reduction of the hot DRI and to melt the slag and iron. Cyanide discharges in rpocess waste-water are completely eliminated in the Corex route. It is an industrially and commercially proven direct smelting reduction process which allows for cost-efficient and environmentally compatible production of hot metal directly from iron ore and non-coking coal.

The Melter gasifier has three main sections, the gaseous free board zone, the Char bed, and the iroj zone, and it has an effect on several stages in the process. Siemens claimed the COREX and FINEX processes can substantially reduce pollutant emissions when compared to traditional steel production, with its blast furnace and coking and sintering facilities.

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Corex Process

The export fuel gas is also being known as Corex gas. It takes only half an hour to stop the plant and procdss four hours to restart it. The air emissions are also lower than the conventional BF units.

However, this particular problem can be mitigated by using irob export gas in electricity production. The outputs can be used either by integrated mills or EAF electric arc furnace mills. Hot metal and slag are tapped as in conventional blast furnace practice. The high dome temperature exceeds 1, deg C which results into complete cracking ,aking the hydrocarbons released by the non-coking coal and avoids the formation of tar.

Phenols discharge is around 0. Articles created prlcess the Article Wizard. The first stage of the process takes place in the reduction shaft, where iron ore burden is reduced by gases emanating from the melter-gasifier and is converted to hot DRI. The rest of the hot gas is then cooled and sent into the reduction shaft resulting in the Corex export gas which is used to control pressure in the plant.

It is the first and the only commercially established smelting-reduction process based on non-coking coal which is available as an alternative route to the blast furnace for the production of hot metal. The volatile matter is driven off and shattered fixed carbon particles fall into the gasification zone where ccorex is injected through blast furnace type tuyeres to burn the carbon to carbon monoxide CO. Subsequently, the hot DRI around deg C and partially calcined limestone and dolomite are discharged into the melter-gasifier from the reduction shaft via speed controlled discharge screw conveyors.

Your email address will not be published. By using this site, you agree to the Terms of Use and Privacy Policy. Limitations of the Corex process include i optimized distribution of coal and Coex is needed in the melter-gasifier to avoid peripheral flow of hot gases, ii absence of post combustion results ptocess the loss of the chemical energy in the export gases resulting into high consumption of coal, iii many of the equipments such as cooling gas compressor are maintenance oriented, iv transfer makihg hot DRI and recycling of the hot gas are hazardous especially during their maintenance periods, vi melter-gasifier is subjected to high occurrence of pressure peaks cores account of use of raw coal with poor char bed conditions resulting into jamming of dust recycling systems as well as gas cleaning systems, vii sensitiveness of the process inputs quality parameters such as granulometry, percentage of fines in the inputs, decrepitation, and degradation behaviour of coal, iron ore and pellets at high temperature.

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During the late twentieth century, several new initiatives have been taken for the development of the smelting reduction technology which can become alternative route for the production of liquid irom hot metal since the conventional blast furnace BF ironmaking depends on metallurgical coal, which is required for producing BF coke needed for the production of hot metal in the msking furnace.

The general applicability of this first generation process was limited and a lot of technical problems had to be solved.

That is coal which has been cooked in order to remove impurities so that it is superior to coal. Of these higher capacity modules coorex numbers C C Because of many peripheral requirements, the total cost of a Corex project can be relatively high.

In a Corex process, the blast furnace concept is used but the blast furnace is virtually split into two halves at the cohesive zone interface Fig 3.

Corex Process for Production of Iron

Due to continuous gas flow through the char bed, there also exists a fluidized bed in the transition area between the char bed and the free board zone. Due to this increased gas utilization which is based on gas recycling, gas production in the melter gasifier can be significantly lowered, which is directly reflected in lower fuel and oxygen consumption. This page was last edited on 10 Mayat Typical analysis of hot metal from the Corex process consists of carbon — 4.

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This raises export gas utilization to a higher level and improves the overall economics of the process besides making it more environmentally friendly. Out of the above mentioned reactions, reactions for the reduction of iron oxide by hydrogen and calcination are endothermic, while the reactions for the reduction of iron oxide by CO gas and carbon deposition are exothermic in nature.

Low content of hydrogen sulphide of the top gas is important with respect to the further usage of the Corex gas.