The FINEX Process,

Emerging at New Steel Era

Agust 2010

KANG, Chang-Oh
Graduate Institute of Ferrous Technology, POSTECH

The FINEX Process,

Emerging at New Steel Era

What is FINEX ?
Why FINEX ?
Final Remarks

 What is FINEX ?
Conv. BF based Ironmaking Process

Iron Ore

Fine Ore

Sinter

Sintering Plant
Molten Iron

Coal

Coking Coal

Coking Plant

Coke

Blast Furnace

What is FINEX

Characteristics of BF based process

Strengths
High energy efficiency
High productivity
Long service life

Weaknesses
Use of high grade raw materials
Coke and sinter making processes required

Generation of air pollutant such as Sox, Nox, Dioxin and dust

What is FINEX

Alternative Ironmaking Process

Lump Ore/
Pellet

COREX

(1.5)

MIDREX

(1.5)

HYL (1.5)

FINEX (1.5)
Fine-Ore

ITmk3 (0.5)

FINMET (0.5)

RK/SAF (0.15)
Ore
Reducing
Agent

Coal
(Iron/DRI)

Natural Gas
(DRI/HBI)
* ( ) capacity : Mt/y

 Blast Furnace vs FINEX

What is FINEX

FINEX

Blast Furnace
Fine Ore

Coking Coal

Fine Ore

Fine coal

Sintering Plant Coking Plant

Sinter

Coke

Coal
Briquetter

Fludized Bed
Reactors

HCI

Melter
Gasifer

Blast Furnace
6

What is FINEX

Key Process Technologies of FINEX

Fine Ore

Fluidized Bed
Reduction
Fine Coal

Coal
Briquetting
HCI

Hot DRI
Compaction

Briquetted
Coal

HCI Melting &

Coal Gasification
7

What is FINEX

FINEX Process Flow

Non-Coking
Coal

Fine Ore

Hot DRI
Compacter

R4

Coal
Briquetter

R3
R2

Reactors

CO2
Removal

R1

Power Plant

PCI

Melter
Gasifier
O2

Oxygen Plant

What is FINEX

Scale-up History of FINEX Plant

No.3 FINEX (Planned)
(2.0M)

Annual production

No.2 FINEX
(1.5M)

No.1 FINEX
(0.6M)

FINEX R&D
Kick-off

Model Plant
(15t/d)

1992

1996

Pilot Plant
(150t/d)

1999

2003

2007

2012

What is FINEX

1.5MT FINEX Plant in operation

Operation Started in April 2007

10

The FINEX Process,

Emerging at New Steel Era

What is FINEX ?
Why FINEX ?
Final Remarks

11

 Why FINEX ?
Up-grade Operation Performance After Startup
4400

880
Target : 4,300 T/D (1.5 MT)

830

3800

780

3500

730

3200

680

May
2007

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Jan
2008

Feb

Mar

Apr

May

Jun

(kg/THM)
RATE
COAL
(kg/THM)
COAL

(T/D)
(T/D)
PRODUCTION

4100

Jul

12

 Operational Performance

Why FINEX

Averaged over May~July, 2008

Indices

Pohang BF4

1.5MT FINEX

Production

t/y

3.2 M

1.5 M

Availability

97.7

96.8

kg/thm

750

710

Kg/thm

166

160

[S]

0.03

0.03

[Si]

0.48

0.65

Coal Rate
PCR

Hot
Metal

PCR : Pulverized Coal Injection Rate

13

Why FINEX

Plant Availability
Days of Continuous
FBR Operation
350

Fine Ore

300

300

R4

R3
R2
Cyclone
Stand
R1
Pipe
Distributor

Gas

Stick- and

250

Clog-Free

200

200

150

FBR Operation

83

100
50

37
2005

2006

2007

Demo Plant

2008

1.5 MT
Plant

Plant availability is now on par with blast furnaces

14

Why FINEX

Investment Cost

BF : 3Mt/Y 1
FINEX : 1.5Mt 2

120
100

100

etc.

100

etc.

Sinte
r

Oxygen

85

Oxygen

70
BF

Raw
Mat.
Handling

Raw
Mat.
Handling

Coke

Power
Plant

Power
Plant

BF

FINEX

BF

FINEX
Main

Subsidiary

BF

FINEX
Total

15

Why FINEX

Production Cost Trend

Cost Ratio (%) : 1.5 MT FINEX / 3.2 MT PBF4
200

Fixed Cost
Variable Cost

Cash Cost

150

100

50

May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul

2007

2008

16

Why FINEX

Environmental Friendliness
Fine Ore [S]
Flux

Desulfurization
in Fluidized-Bed
SOx

Reactors

BF

No Atmospheric
Combustion like
Reduction
Gas

H2S
in Gas
Oxygen

Dust

100

CaS
into Flux

Coal [S]

NOx

Sinter and Hot Stove

Sinter

50
28%

Coke

Ironmaking Without
Sinter and Coke
Making Processes

3%

1%

0
BF

FINEX BF

FINEX

BF

FINEX

17

 Co2 Mitigation

Why FINEX

FINEX

TGR-BF, ULCOS

To CCS

Coke
Pellet

Power
plant

Fine
Ore
Tail
CO2
Removal

Gas

CO2
Removal

Gas Heater

Recycling
Gas

Tail
Gas

to
CCS

Recycling
Gas
Coal

Oxygen
&
PCI
Hot Metal

Oxygen
&
PCI

Hot Metal

18

The FINEX Process,

Emerging at New Steel Era

What is FINEX ?
Why FINEX ?
Final Remarks

19

 Final Remarks
New Steel Era has been emerged

1.3 billion tons

Developing markets mainly led by China

1,000 -

have been pulling the global steel demand

dramatically since 2000

Led by BRICs

800 -

700 -

However, restricting growth factors are :

Scarcity of high-grade raw materials

Global environmental problems & concerns

1970

1980

1990

2000

2008

20

Final Remarks

Anticipating Industry Directions

Developed Markets : W. Europe, USA, Japan
No further expansion of BF capacity
Gradual conversion to scrap-based EAF
Focus on securing virgin-iron
BF mills : Focus on high grade, high-margin products
EAF mills : Expand product portfolio

21

Final Remarks/ Industry directions

Developing Markets :
China, India
Costal Regions : large scale BF mills using imported raw materials
Inland Regions : Small-medium scale innovative & alternative
processes using regional resources

Other Low-grade Resources-rich Markets

Innovative alternative processes using regional low grade materials

22

Final Remarks

Anticipating Technology Directions

Exploration, mining, mineral dressing

Development of innovative alternative iron-making process technologies
to use low grade, low cost resources and to reduce the level of air pollution
New, low-cost process technologies to secure virgin iron for EAF
Continuing development of high-grade, high-margin steel products
for BF mills to differentiate their markets from EAF mills

23

Final Remarks

Tomorrows Integrated Steelmill Configuration

Fine Ore

Fine Coal

Hot Metal

FINEX Process

LD Converter

CEM Process

24

Thank You