Professional Documents
Culture Documents
th
COREX
Adoption
Development
FINEX
Operation Philosophies
COREX
Presentation - Kurt Wieder
OPERATION COMPARISON AND DEVELOPMENT
Figure 2 6
th
COREX
Adoption
Figure 3 6
th
COREX
Technology
- Future Targets
COREX
Technology
COREX
PLANTS WORLDWIDE
SALDANHA
1 x C-2000
650,000 t/a
ISCOR
1 x C-1000
350,000 t/a
JINDAL
2 x C-2000
1,600,000 t/a
HANBO
2 x C-2000
1,500,000 t/a
POSCO
1 x C-2000
700,000 t/a
Figure 7 6
th
COREX
POSCO
-
implemented in a large integrated steel mill with BOF
-
7 years in operation
-
export gas utilization in CPP
COREX
SALDANHA
-
implemented in an integrated compact mill with EAF
-
combined operation with DR plant
-
mainly local raw materials
-
highest lump ore rate
-
more than 3 years in operation
COREX
JINDAL
-
2 COREX
Technology (1)
Small / medium capacity (operational s 1 mio. t/y, offered s 1,4 mio.t/y)
HM quality satisfying up to excellent: A, T, tap mass instable
Raw material qualities!
Plant availability: 93 - 95 %
Concern: refractory / stave system at char bed, shaft emptying,
wear DRI screws, tapping problems
Coals
- Wide range of coals usable
- Limited availability of best suitable qualities (coke rate, consumption,
hot metal quality)
- Utilization of undersize material important (30 - 50 %)
partial use in situ, coal briquetting - use in situ, cement industry, PCI,
power plants
- Consumption rather high (C
fix
~ 600 kg/t
HM
)
COREX
Technology (2)
Iron oxide
- High lump ore rates possible (80 85 %)
- Total undersize fraction can be used in situ
Coke consumption (0) 5 - 15 %, average too high, lower quality
requirements
Valuable export gas - economic utilization of utmost importance
- thermal utilization (steel plant, pelletizing plant, calcination plant, ......)
- generation of electric energy (CPP realised, CCPP gas quality suitable)
- production of DRI
COREX
Technology (3)
Slag rate high - utilization comparable to BF
High sludge rate (35 50 kg/t
HM
) - sludge granulation
technology developed
(partial recycling, cement industry, sinter and pellet feed)
Environment
- low emissions compared to BF route
hardly any bonus considered yet (soft fact)
- CO
2
emission as for BF route (gas utilization !)
COREX
Technology (4)
Campaign life (2) 5 years
defined by damages to stave system in char bed zone
upgrade installed: Reline POSCO/SALDANHA,
Upgrade JINDAL Mod. 2
Expected campaign life approx. 10 years
Operation costs are competitive
Higher investment compared to BF stand alone (European basis)
COREX
C-2000 / C-3000 175 / 225 million EURO
(ASU, gas utilization, coal briquetting, infrastructure excluded)
BF 1 / 1,4 million t/a 150 / 190 million EURO
(coking plant, sinter plant, infrastructure excluded)
COREX
C-2000
SALDANHA
Southafrica
ISCOR
South Africa
Vanderbijlpark
POSCO
South Korea
Pohang
Tata Iron & Steel
India
Jamshedpur
COREX C-2000
POSCO
South Korea
2 x COREX
C-2000
JINDAL
India
Blast furnace data are based on year 2000
POSCO
South Korea
Kwangyang
CST
Brazil
Vitoria
Bethlehem steel
USA
Burns harbor
CORUS
Netherlands
IJmuiden
KOBE steel
Japan
Kagogawa
Baosteel
China
Shanghai
COREX
- Economy
Comparison of Hot Metal Operation Costs Blast Furnace vs. COREX
Blast furnace data are based on year 2000
Figure 13 6
th
COREX
Technology (5)
Project realization time: 32 months
No Risk:
COREX
= Proven Technology
COREX
and DR plant
- C 3000 / DR: 1,4 / 1,1 mio. t/y already offered
- C 4000 / DR: 1,8 / ? mio. t/y under investigation
Average availability: > 95 %
(elimate shaft cleaning, screw- / down pipe blockages, ...)
Campaign life > 15 years
Wider spectrum of usable raw materials
- Quality
- Fines charging
COREX
: FINEX
Result:
Significantly Lower Operation and Production Costs than BF
COREX
Development
Figure 19 6
th
COREX
COREX
Development
Figure 20 6
th
COREX
Development
COREX
Development of Technology
Process
Plant
Pilot Plant
8 t/h
Kehl
(1980)
Test Results
Optimisation
Engineering
Bench Scale
Laboratory
C-1000
40 t/h
ISCOR
Commercial Plant
(1987)
C 2000 + DR
1
st
Generation
POSCO,
JINDAL
HANBO,
SALDANHA
Commercial Plants
80 100 t/h 100 110 t/h
C 2000 + DR
2
nd
Generation
80 -125 t/h 100 -125t/h
Available for Market
C 3000 + DR
145 -170 t/h 125 -140 t/h
Available for Market
+
+ +
Figure 21 6
th
COREX
Development
Figure 22 6
th
COREX
Development
Figure 23 6
th
COREX
C-2000 2
nd
Generation Design
- Optimized / upgraded equipment
- Increased capacity C-2000 125 t/h
- Reduced weight
+ Reduced total investment (- 20 % !)
+ COREX
C-2000 2
nd
Generation = Basis for Upscaling
COREX
Development
Figure 24 6
th
COREX
Development
COREX
Tower
Mass Flow Bins
Simplified Coal Line (1 Coal Screw)
Optimized Duct Dimensions
Optimized Lining Thickness
Scrubber with internal Demister
Redesign Cast Houses
Double Pocket Lift
etc.
Melter Gasifier )
Reduction Shaft ) refer separate slides
Dust Recycling )
Figure 25 6
th
COREX
Development
Figure 26 6
th
COREX
, DR plant
COREX
Development
Figure 27 6
th
COREX
Development
Figure 28 6
th
COREX
Development
Equipment
Raw Material
Flexibility
Lower
Consumption
Less
Coke
Campaign
Life
+
Coal distribution ++ + ++ +
+
DRI distribution + + + +
+
Bosh angle + ++ ++
+
Char bed height +
oxygen burners
+ +
+
Sump + tap length ++
Figure 30 6
th
COREX
Development
Melter Gasifier - Dynamic DRI Distribution
Tiltable Distribution Flap
Figure 31 6
th
COREX
Development
Melter Gasifier - Dynamic Coal Distribution
Collecting Chute 1
1
Tiltable Rotating Chute 3
3
Drive Unit 4
4
Leverage for Chute Adjustment 2
2
2
Figure 32 6
th
COREX
Development
1
Improved Material Distribution
Rotating Feeding Bin
Mass Flow
min. 12 Distributor Legs
1
2
One Top Gas Duct
2
3
Upper Shaft Inclination
3
4
Gas Inlet (2
nd
Bustle, Areal Gas Load,...)
4
5
Lower Shaft
ADM + ADW
Shorter Screws
5
Figure 34 6
th
COREX
Development
Export Gas Utilization
Figure 36 6
th
COREX
Development
Figure 37 6
th
COREX
Export Gas
Gas Heater
Gas Cleaning
Reduction
Shaft
DRI
Reduction
Shaft
Melter
Gasifier
Gas Cleaning
DR
Export Gas
DR Recycle Gas I
DR Plant COREX
Plant
Hot Metal
and Slag
O
2
Coal
Additives/
Ore/Pellets
Ore/
Pellets
Top Gas
CO
2
Removal
DR Recycle Gas II
Figure 38 6
th
COREX
Development
Figure 39 6
th
COREX
Development
Figure 40 6
th
COREX
Gas
Heater
Compressor
Figure 41 6
th
COREX
Development
Figure 43 6
th
COREX
Development
Figure 45 6
th
COREX
Process
Sankey Diagram for Zn in the COREX
Process
nFactor
Figure 48 6
th
COREX
Upscaling
COREX
Development
Figure 49 6
th
COREX
Up - scaling of COREX
\
C
3.5 m
C
2 m
C
5.5 m
C
5 m
C
7.3 m
C
7 m
C
8.8 m
C
8.3 m
C-1000 C-2000 Pilot Plant
C-3000
6 - 8 t/h
145 - 170 t/h 80 - 125 t/h 40 - 50 t/h
60,000 t/a
300,000 -
400,000 t/a
600,000 -
1,000,000 t/a
1,200,000 -
1,400,000 t/a
Figure 50 6
th
COREX
Figure 51 6
th
COREX
COREX
Development
Figure 52 6
th
COREX
Technology (1)
FINEX
Figure 55 6
th
COREX
Demo Plant
FINEX
Demo Plant
COREX
C-2000
Figure 57 6
th
COREX
Technology (2)
Important Development Steps
- Fluidized bed reduction Demo Plant
- Hot DRI fines handling
1
st
step: Hot briquetting Demo Plant
2
nd
step: Pneumatic conveying / fines charging (?)
- Melter Gasifier operation
1
st
step: DRI briquettes, coal briquettes Demo Plant
2
nd
step: DRI fines (?)
FINEX
Figure 58 6
th
COREX
Technology (3)
Status = FINEX
Demonstration Plant POSCO Pohang
- Commissioning May 2003
- Achieve stable industrial production 2004/5
- Major challanges - Operation practice
- Availability
- Sticking behaviour of metallic fines
- (Melter gasifier operation with HCI)
Vision = FINEX
Commercial Plant 1 mio.t/y Direct Hot
Fines Charging
- Precondition for development: Successful Demo Plant operation
- Add. major challanges: - Pneumatic transport of hot DRI-fines
- Melter gasifier operation with 100 %
DRI-fines
FINEX
Figure 59 6
th
COREX
Commercial Plant
Export Gas
Hot Metal
Slag
Figure 60 6
th
COREX
versus FINEX
Economic Evaluation
COREX
C-2000
FINEX
F-2000
HCI
FINEX
Vision
F-2000
Direct Charg.
Investment Millon EUR 175 270 230 *)
HM Operation Cost EUR/tHM
(excl. Capital Charges)
105 - 3 % - 8 % *)
HM Production Cost EUR/tHM
(incl. Capital Charges)
115 + 3 % - 4 % *)
*) Target figures
Basis: Europe
Export Gas credit: 5,6 EUR / GJ
FINEX Demo Plant: Adapted COREX
Operation
Operation Philosophies (1)
POSCO JINDAL SALDANHA
+
Production rate
moderate (90 t/h) maximised (110 t/h) relativ max. (85 t/h)
+
Raw material
-
Philosophy
best qualities
(min. coke rate)
max. local portion
(min. coke rate)
max. local portion
max. lump ore rate
min. coke rate
-
Availability coal
coke
lump ore
pellet
additives
own production
local
local
local, own production
local
local
local
local
+
Fines utilization
-
coal, coke
-
oxide
-
coking plant, PCI,
briquetting
-
sinter plant
-
CPP, part. in situ
-
pellet plant, in situ
-
cement-/brick
industry
-
export, (part. in situ)
+
Export gas utilization
-
CPP
-
CPP, pellet plant,
heating, lime
calcination plant
-
DR plant , heating
-
max./stabilized
production for
DR plant
Figure 63 6
th
COREX
Operation
Operation Philosophies (2)
POSCO JINDAL SALDANHA
+
General operation
-
Oxygen input
total (m
3
/tHM) STP
to tuyeres (m
3
/tHM) STP
to burner (m
3
/tHM) STP
additional oxygen burners
570
440
130
---
530
380
150
in progress
620 (95 %)
450 (95 %)
170 (95 %)
planned
-
Coke rate (%)
addition to
(< 5) 12 - 18
gasifier
13 - 20
shaft / gasifier
10 - 15
shaft / gasifier
-
Material distribution
coal
DRI
shaft
in progress
(adj. radius), 6 legs
static
basic, static
(adj. radius), 6 legs
static
enhanced, (dynamic)
(adj. radius), 12 legs
-
Steam / water addition
to tuyeres
to generator gas
steam
(steam)
---
water
water
water
Figure 64 6
th
COREX
Operation
Operation Philosophies (3)
POSCO JINDAL SALDANHA
+
Tapping pratice
alternating tapping alternating tapping alternating tapping
+
Dust line operation
open line open line open line
+
Specialities
-
tuyere brightness measurement
---
-
longer tuyeres ---
(tests)
-
coal briquetting
--- ---
-
coal particle size measurement
--- ---
-
sludge granulation / utilization --- / cement industry ---
/ cement industry
-
minimized N2 consumption --- ---
(CG booster)
-
iron granualtion --- ---
-
TG / EXG recycling --- ---
-
elevated exportgas pressure ---
-
fines charging
- coal ---
---
- oxide ---
)
-
development towards FINEX
--- ---
Figure 65 6
th
COREX
Operation
POSCO (2002) JINDAL 1 (2002) JINDAL 2 (2002)
SALDANHA (after
relining)
Melting rate 80 100 t/h 85 110 t/h 100 115 t/h 85 90 t/h
Plant pressure 2,8 3,6 barg 3,3 3,6 3,4 3,6 3.3 3.5 bar g.
Spec. Fuel consumption 1000 1100 kg /tHM 1000 1100 kg /tHM 980 1060 kg/tHM 1150 kgtHM
Coke rate 10 20 % 10 - 20 13 20 % 10 15 %
Ore rate 0 % 80 83 %
Spec. O2 total
560 - 580 m
3
/tHM
(99 % O2)
520 550 m3/tHM
(99 % O2)
510 - 550 m
3
/tHM
(99 % O2)
620 m3/tHM
(95 % O2)
Spec. O2 tuyeres 430 450 m3/tHM 370 400 m3/tHM 360 400 m3/tHM 430 460 m3/tHM
O2 Dust burner 2800 3200 each 3800 4200 each 3800 4200 each 3900 4000 each
Dome temperature 1000 1030 1050 1080 C
Reduction gas temp. 750 (- 800) C 820 840 C (800) 850 C 845 C
CO2 CG 6 8 8 11 % 7 10 % 7 10 %
Spec. TG Flow 1050 m3/tore 10801130 m
3
/tore 10601150 m
3
/tore 1100 1150 m3/tore
Fine ore addition 0 kg/tHM 50 200 kg/tHM 50 200 kg/tH0 - 6. 0 20 kg/tHM
Grainsize of fine ore 0 6.3 mm 0 6.3 mm 6 12 mm
Hot metal: T 1500 1520 C 0.4 0.7 %
Si 0.8 2 %
Figure 66 6
th
COREX
JINDAL COREX
POSCO COREX
SALDANHA
The Success of COREX
Realization of
taylor-made Plant Concepts and specific Operation Philosophy