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NEW IRON MAKING ALTERNATIVES

Why Alternative iron ore making technologies are being used

Costly and scarce coking coal


Land-constraint
Environmental consideration - Eliminate pollution
Intensive sintering and Coke-making processes
Water Scarcity
High Capital Cost
Scientific and engineering knowledge

Possible Solutions: Alternatives for Iron making


1] Production of non-liquid Iron (DRI)
Direct-reduced 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. The reducing gas is a mixture, the majority of which is hydrogen (H2) and
carbon monoxide (CO) which act as reducing agents. This process of reducing the iron
ore in solid form by reducing gases is called direct reduction.

Alternatives for
iron making

Non liquid(DRI)

Coal Based

Gas Based

liquid based

Smelting
Reduction

coal

Coal Gasification

Gas

Direct Reduced Iron (DRI) has emerged as an excellent substitute for scrap
for electric furnaces.
Coal Based DRI
In a coal based plant the reactor for the reduction reaction is a inclined horizontal
rotary kiln. The carbon of the coal acts as a reducing agent in the process.
Coal-based DRI plants are flexible as to plant location, because coal is widely
distributed in large deposits and is easy to transport. This has significantly
increased the production of coal-based DRI. Coal-based reduction processes allow
the use of iron ore fines and do not require a pelletizing plant. The processes are
applicable to various types of ores including those from small-scale mines. Coalbased direct reduction processes are expected to diversify the sources of raw
materials, since they are coke-less processes and flexible as to raw materials. This
will stave off an oligopoly by mining giants and ensure a stable supply of raw
materials for the steel industry. Having a stable supply of clean iron produced by a
coal-based reduction process will make up for the shortage of high grade scrap,
while scrap quality is expected to deteriorate in future. This will promote the
conversion to the scrap-based EAF process and eventually decrease CO2 emissions
in the steel industry.

GAS BASED DRI

DRI is successfully manufactured in various parts of the world through either


natural. Iron ore is reduced in solid state at 800 to 1,050 C (1,470 to 1,920 F) by
reducing gas (H2+CO) More than 90% of the global DRI plants use (lower grade)
natural gas. The energy consumption in natural gas based DRI production is well
known and established to be 10.4 GJ/t-DRI. Natural gas based DRI production also
leads to lower CO2 emissions, with emissions ranging from 0.77 to 0.92 ton of
CO2 per ton of steel, depending on the type of electricity used. The most common
technologies used for DRI production are MIDREX and HYL III, both using
natural gas . Direct Reduced Iron (DRI), also known as Sponge Iron, offers an
alternative steel production route to BF-BOF and Scrap-EAF routes. In DRI, iron
ore is reduced in its solid state unlike BF process where a liquid metal is formed
during reduction. DRI can then be transformed to steel in electric arc furnaces. As
there is no melting and no slag phase in DRI production, all gangue elements of the
iron ores remain in the DRI and need to be separated via a slag in the EAF. This
increases the electrical energy consumption of the EAF compared to steel scrap
melting. If hot DRI is immediately transferred to the EAF melt shop, the heat from
the direct reduction process lowers the cost of melting the DRI in the EAF,
significantly cutting these energy costs
Alternative method:
Liquid Iron (Hot Metal)
Smelting Reduction Process
Smelting reduction processes are the latest development in pig iron production. These
processes combine the gasification of coal with the melt reduction of iron ore. Energy
intensity of smelting reduction is lower than that of blast furnace, as the for coke
production is not needed and the need for ore preparation is reduced.
This process uses the Non Cooking Coal. This type of process need smaller land ,area.
Iron ore fines can be used directly .It is a lesser Polluted Process.

Corex

Finex

Hismelt

Romelt

Corex:
The Corex Process is a smelting reduction process created by Siemens VAI as a more
environmentally friendly alternative to the blast furnace. Presently, the majority of steel
production is through the blast furnace which has to rely on ever decreasing amounts of
coking coal. That is coal which has been cooked in order to remove impurities so that it
is superior to coal.

COMMECIAL UNITS USING COREX


Korea
POSCO (COREX C-2000 Capacity: 0.8 Mtpa)
India
JSW Steel, India (2 Units) (COREX C-2000)
South Africa
Mittal-SALDANHA, (COREX C-2000)
China
Bao steel, (COREX C-3000) Capacity 1.5 mtpa

Finex
Finex is a fluidized-bed smelting reduction process, and is considered to be a more
advanced form of Corex process. Its core plant consists a melter-gasifier which melts
the DRI and gassifies the coal and a series of successive fluidised beds that reduce
ore fines to DRI. The technology utilizes fine ore and non-coking coal. Iron ore is first
pre-reduced in fluidized-bed reactors by reducing gas coming from melter gasifier.
Subsequently, hot metal is produced in the melter gasifier. Coal and oxygen are
supplied in the melter gasifier.

Hismelt
Hismelt, short for high-intensity smelting, is the world's first commercial direct smelting
process. It produces premium quality pig iron directly from iron ore. HIsmelt technology
brings many advantages to the steelmaking industry, such as lower operating costs,
lower capital intensity, lower environmental impact, and greater raw material and
operational flexibility.
First industrial HIsmelt Plant (capacity 600,000 tpa) commenced operation in Kwinana,
Australia in 2005.

Rosmelt
Unlike COREX and most other SR processes, the strength of this process is that it is a
single stage concept. It is developed by Moscow Institute of Steel and Alloys (
MISA in mid 1980s) ROMELT is a robust and simple process, which is also very much
environment-friendly, since it operates under a slight negative pressure. As a result the
area around a ROMELT plant is extremely clean

Coal Gasification
Coal gasification is the process of producing syngasa mixture consisting
primarily of methane (CH4) carbon monoxide(CO), hydrogen (H2), carbon
dioxide (CO2) and water vapor (H2O)from coal and water, air and/or oxygen.
Historically, coal was gasified using early technology to produce coal gas (also
known as "town gas"), which is a combustible gas traditionally used for municipal
lighting and heating before the advent of industrial-scale production of natural gas.
Example: Angul Plant of JSPL at Orissa
The DRI-BF-EAF technology would be adopted for Steel Production. The
DRI Plant has a unique features of using syngas from the coal gasification
plant as a reductant.
JSPL agreement with Sasol technology company,South Africa for coal
gasification technology.

ITMK3 Process
Kobe Steel has developed the ITmk3 Process, which produces high-purity granular iron
by utilizing iron ore concentrate and non-coking coal. The ITmk3 Process is distinctive
with reduction, carburizing, melting and slag separation occurring promptly at lower
temperature.
The ITmk3 Process completely bucks conventional concepts of iron making. Kobe Steel
regards it as the third generation of iron making technology, following the current major
blast furnace-basic oxygen furnace (BF-BOF) process and the direct reduction (DR)
process represented by the Midrex Process. The ITmk3.Process can make reduction
reaction take place in approximately 10 minutes, compared with 8 hours by the BF-BOF
process and 6 hours by the DR process.

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