The main reagents for the corex process are iron ore, noncoking coal, and oxygen. Iron making process, full notes, pdf, ebooks, results 1 to 1 of 1. This process is known as venting of core and is shown in fig. Finex can replace the blast furnace technology, the dominant steelmaking process for 100 yrs competitiveness over bf finex innovation case study 6 the worlds first commercialized new ironmaking process 1 finex completed in may 2003 annual production of the demo plant. The secondmost production of dri 23% is by the hylsa processes. 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. The most common process is the use of a blast furnace to produce pig iron which is about 9294% iron and 35% carbon with smaller amounts of other elements. Metals free fulltext comparison of energy consumption and. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. The present scenario of iron and steel sector is very much challenging. In the corex process, all metallurgical work is carried. Pig iron is divided into steel making 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 remelting. Elimination of preliminary processing is claimed to make the plant for finex less expensive to build than a blast.
The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic ironnickel. Fundamentals of iron and steelmaking 39 equal to its heat of formation, but of opposite sign. Any excess iron can then go back to be melted down again. Experience of corex at jsw suggest that still 15% coke is required in the process to control vm of the input reductant.
Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. In the next section, the blast furnace and corex processes are discussed. Coke is the most important raw material fed into the blast furnace in terms of its effect on blast furnace operation and hot metal. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. Pdf coal and energy consumption in the corex process can be.
Corus the chemistry of steelmaking student worksheet 2 other methods of making iron you dont always need a blast furnace to make iron. Iron making process, full notes, pdf, ebooks, popular topic for study. Ta ble 1 research and development progress 1988 1991 1992 1993. Iron making process iron coal free 30day trial scribd. Beneficiation of indian high alumina iron ore fines a case study. Oluwasegun abstractductile cast irons are materials having strength, impact toughness and ductility comparable to those of many grades of steel while exceeding by far those of standard gray irons. Slag, which floats on top of the iron, has the function of removing impurities from the iron and its chemical composition and temperature to a large extent determine the chemistry and hence quality of the iron. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. In this activity, you can find out more about two different methods of making iron that are often used in industry. The corex process is a smelting reduction process created by siemens vai as a more environmentally friendly alternative to the blast furnace. New iron making processes have been extensively explored with a view to saving resources and energy, as well as reducing environmental pollution. The process duration varies with the injection rate, hot metal chemistry, and desired final sulfur content, and is in the range of 5 to 30 minutes. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium bc iron was being produced from iron ores from at least greece to india, and more. An introduction to modern iron making by tupkary, r.
The molten iron has a dissolved carbon content of approximately 3. 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 remelting. The emitted gases from whole iron making process from blast furnace and. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. The corex process consists of two main parts a reduction shaft and a melter gasifier. The actual production condition in the field was given in the form of tables, including its. Metallurgical engineering iron production ebook free download pdf metallurgical engineering industrial production of iron ore ebook download pdf metallurgical engineering. Chapter 6 copper production technology the last boomin technological innovation for the copper industry occurred in the first two decades of this century, whenopen pit mining, flo tation concentration,and the reverberatory smelter were adapted to porphyry copper ores. All the excess iron from the process, the runners etc are cleaned off in a process known as fettling, which also includes grinding and shot blasting, to produce a finished casting. Schematic diagram of a corex plant reduction shaft.
Jan 18, 2014 finex process siemens vai and posco jointly developed the process. Direct reduced iron dri production plant nippon steel engineering co. Corex enables the costefficient and environmentally friendly production of hot metal from iron ore and coal. The corex process combines coking plant, sinter plant and blast furnace into a single iron making unit.
Ferrous metallurgy is the metallurgy of iron and alloys. Processing techniques and productions of ductile iron. Recent development of ductile cast iron production. Ironmaking, reduction of iron oxide, material balance introduction the blast furnace is essentially a continuous counter. Beneficiation of indian high alumina iron ore fines a case. After the iron has cooled in the moulds it is broken out. Sometimes, cores are reinforced with annealed lowcarbon steel wires or even cast iron grids in case of heavy cores to ensure coherence and stability. Recent development of ductile cast iron production technology. In iron ore, iron is presents in its oxidised form. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Pdf corex process in ironmaking elvis marca catachura. Materials balance in iron making introduction illustration key words. As a consequence of a tight raw material supply for the blast furnace, the corex process.
In addition, the corex process can use iron oxides containing up to. The reducing gas is a mixture majority of hydrogen h2 and carbon monoxide co which acts as reducing agent. Appropriate beneficiation process has to be advanced to reduce the waste generation in mines and for the sustainable growth of the iron ore industry some. Alternative iron making processess linkedin slideshare. Stidies on process kinetics intensification of dri making and improvement in prouct. Finex process siemens vai and posco jointly developed the process. Slime in these tailing ponds contains iron values in the range of 4560%. Unlike the blast furnace the corex process does not use a hot blast of nitrogen, thereby greatly reducing nox gas emissions, but instead uses oxygen. The ancient process of iron making is still in existence in a few. The second principle is that discovered by hess 1840. To develop computational and mathematical abilities to be applied for process design and control. The typical iron oxide mix for corex is 30% lump ore and.
Co2 emissions in the iron making process decreased by 4 to 5%. Iron making process free download as powerpoint presentation. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Corus the chemistry of steelmaking notes for teachers. Ironmaking and steelmaking metallurgical and materials.
Use of pellet atleast partially is a must for corex process. Coal consumed, 730750 kg per 1 ton of molten iron production, equivalent to that of the blast furnace process. Rio tinto has for many years been a trusted supplier to the worlds iron and steel industry, particularly in south east asia, where its australian mines offer costeffective raw material. The emitted gases from whole iron making process from blast furnace and coke plant and sinter plant are not good at the environment. The ore obtained after mining contains iron in the form of iron oxide. Feed material the iron ore fines sample was collected from the spiral classifier overflow of a typical iron ore beneficiation plant of noamundi, india. The sponge iron is delivered as hot from the reduction shaft furnace by screw.
So heat energy required for ironmaking process is supplied by this coke and this is a source for carbon of hot metal. Coke production for blast furnace ironmaking by hardarshan s. How iron is made material, manufacture, making, history. The presence of alternative iron making technologies will be a benefit for metallurgic, economic, social and environmental reasons. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. The balance is split between slrn 3%, finmet 2% and other predominately corex at 5%. Development of blast furnace for iron making allows the best production of iron.
Most of furnaces used by tribal for extracting iron have many features in common. When iron is reduced from iron ore, first it could be a solid state. Molten iron is produced directly using iron ore fines and noncoking coal rather than traditional blast furnace methods through sintering and reduction with coke. With the technology of bottom air pulsation added with modern process control features and improved product discharge mechanism, batac jig of humboltz wedag have been successfully installed. Most exciting iron making technology on the market today.
Basic concept or summary s16 u a direct reduced iron dri production plant is a shaft reduction furnace to produce dri with large metal iron content by directly reducing iron ore or iron ore pellets with reducing gases. Dec 02, 2009 ii absence of post combustion means that much chemical energy is lost in the exit gases and consequently the coal consumption in corex is much higher than in any other iron making process. The global steel industry is using about 28 to 30 percent of alternative iron like drihbi, merchant pig iron and hot metal to produce quality steels. Two alternative ironmaking processes, top gas recyclingoxygen blast furnace tgrobf and corex, can reduce co2 emissions and coking coal. This section basically explains the system function in detail. The iron ore concentrate is now mixed and ready for the pelletizing process. Directreduced iron dri, also called sponge iron, is produced from direct reduction of iron ore in the form of lumps, pellets or fines by a reducing gas produced from natural gas or coal. However, the blast furnace and the iron making process causes some trouble. 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 supplied from the melter gasifier, which is the main reactor of the corex plant. Valia, scientist, ispat inland inc introduction a world class blast furnace operation demands the highest quality of raw materials, operation, and operators.
Iron ore is converted into various types of iron through several processes. Corex process distinguishes itself from the blast furnace route by i. The reduced iron will melt and slag will form at the surface. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. The dri process has the ability to use low grade coal that is unacceptable for conventional iron making. Consolidation of the iron and steel branches manifested itself in a significant increase of mergers and takeovers. Based on the direct use of noncoking coal and fine ore. Otherwise, the core may shift from its original position when the molten metal is poured.
Finex is the name for an iron making technology developed by former siemens vai now primetals technologies and posco. Vss university of technology burla, sambalpur, odisha, india768018 ph. Iron ore beneficiation current practices in india first iron ore jig was installed in barsua iron ore mine of sail. Pig iron has only limited uses, and most of this iron goes on to a steel mill where it is converted into. It constitutes 5 percent by weight of the earths crust, and it is the. Of the alternative direct iron reduction processes, 67% of the dri is produced by the midrex shaft furnace dri processes.
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