coal based sponge iron plant - newsletter road...

MECON LIMITED

ALTERNATE IRON MAKING ALTERNATE IRON MAKING -- KEY KEY DRIVER FOR INDIADRIVER FOR INDIA’’S FUTURE STEEL S FUTURE STEEL

GROWTHGROWTH

BY

M. K. DESHMUKH, P. BHATTACHARYA & A.K. AGRAWAL

CII STEEL SUMMIT, NEW DELHI, 4TH NOV., 2009


ALTERNATE IRON MAKING ALTERNATE IRON MAKING -- KEY DRIVER FOR INDIAKEY DRIVER FOR INDIA’’S S FUTURE STEEL GROWTHFUTURE STEEL GROWTH

Limitations of Blast Furnace Based Operation

Use of Metallurgical Coke requiring good quality coking coal

Severe shortage of good quality coking coal in India leading to large scale import

Global supply constraints and associated sharp price volatility

Environmental problems associated with sinter & coke making due to high level of harmful emissions.

Direct use of non-agglomerated ores and inferior quality raw materials indigenously available.

Higher capital & operating cost due to integrated nature of operation


Indian import of coking coal over the years

0

20

40

60

2004-05 2005-06 2006-07 2007-08

Year

In m

illio

n to

nnes

0

50

100

150

In R

s. B

illio

n

coking coal qty steel prod monetary value



PROCESS DIRECT REDUCTION SMELTING REDUCTIONReducing Agent

Ore Charge

Natural Gas / Syn Gas

Coal Coke

Lump Ore / Sinter / Pellet Midrex, HyL / Energiron

Rotary Kiln Blast Furnace Corex

Fior, Finmet, Circored, Iron Carbide

Circofer - HIsmelt, Finex, Romelt,

Ausmelt, Primus

Ore-coal composite pellets / briquettes

- Fastmet, ITmk3, Inmetco

- Fastmelt, Tecnored


Iron Making Processes at a glance under diverse Iron oxide / fuel Combination

Ore Fines

Coal



Salient Features of S-R Processes

Use of Metallurgical Coke requiring good quality coking coal

High smelting intensity and hence high productivity

Ability to use various types of non-coking coal

Environmental friendliness

Use of iron ore fines, slimes, etc.

Electricity generation from offgas or its alternative use

Hot metal quality, comparable to that produced in a BF



FASTMET-FASTMELT



ITmk3 PROCESS



COREX PROCESS



FINEX PROCESS

FINEX plant at POSCO



HIsmelt PROCESS



MIDREX PROCESS



HyL / Energiron PROCESS

Reactor

Iron OreIron Ore

Cold Cold DRIDRI

Hot Hot DRIDRI

HYTEMPHYTEMP®® SystemSystem

Transport Gas Make

up

ExternalCooler

EAF

Fuel

PG HeaterOxygen

CO2Removal

H2OPG

Compressor

Steam Reforming

water

fuelNatural

gas

H2O

~~

Steam Turbines

Reactor

Iron OreIron Ore

Cold Cold DRIDRI

Hot Hot DRIDRI


Transport Gas Make

up

ExternalCooler

EAF

Cold Cold DRIDRI

Hot Hot DRIDRI


Transport Gas Make

up

ExternalCooler

EAF

Cold Cold DRIDRI

Hot Hot DRIDRI


Transport Gas Make

up

ExternalCooler

EAF

Fuel

PG HeaterOxygen

CO2Removal

H2OPG

Compressor

Steam Reforming

water

fuelNatural

gas

H2O

~~

Steam Turbines



Coal Gasification –Shaft Furnace Combination


CONCLUSIONGlobal shortage of metallurgical coking coals & increasing concern for environment are key drivers for sustained search for adoption of alternate iron production technologies

The above facts are highly relevant for India as the country aims for trebling the steel capacity by 2020

S-R technologies, essentially using non-coking coal and oxygen, provide opportunities to carry out serious evaluation for adoption in the country

S-R technologies viz. Corex, Finex & HIsmelt have reached commercial stage. Romelt, Ausmelt remain at pilot stages. Except Corex, most of them have to go through different levels of scrutiny before adoption in the country.

India has, in the past, taken bold steps in adopting new technologies viz. LD process in RSP in fifties, Corex process at JSW plant in mid nineties and now, use of syn gas (coal gasification) for DRI production in JSPL’sAngul Project, Orissa


T H A N K S

http://www.1800flowers.com/product.asp?section_id=0&search_type=feature2&fc_track1=sectionid0andposition2&pcode=2929&cc=1001&sc=1001&body_sc=1001

coal based sponge iron plant - newsletter road...

Documents