LEC 4: SMELTING REDUCTION PROCESS

COREX Process

Coal Reduction Extraction

2-stage smelting reduction process

Reduction Shaft Furnace

In COREX Process, where does Direct Reduction happens?

Melter-Gasifier

In COREX Process, where does coal enters?

Magkapatong ang Shaft Furnace at Melter-Gasifier

Structure of COREX Process

Iron Ore is first reduced in a shaft furnace and then melted and finally in a melter-gasifier using non-coking coal

smelting reduction process of COREX

Non-Coking Coal

COREX Process use this to eliminate coke making and lower emission

Iron Ore Lump or Pellets

Feed for Reduction Shaft Furnace

CO and H2 from melter-gasifier

Reducing Gas for Reduction Shaft Furnace

800-900 C

Temp for Reduction Shaft Furnace

Direct Reduction Iron (DRI)

Product of Reduction Shaft Furnace

Melter-Gasifier

melts DRI into liquid hot metal

final reduction of FeO

generates reducing gas for shaft furnace

Wustite

What does Melter-Gasifier melt?

DRI, non-coking coal, oxygen

Melter-Gasifier feed

1400-1600 C

Melter-Gasifier temp

1538 C

Melting Point of Fe

Gaseous Free Board Zone

CharBed

Hearth

Parts of Melter-Gassifier

100 C

Drying of Coal temp

CO2 + C = 2CO

Boudouard Reaction

H2O + C = CO +H2

Water Gas Reaction

CO + H2O = CO2 + H2

Shift Reaction

Coal Drying

Limestone Decomposition

Melter-Gasifier Top

Gaseous Free Board Zone

Melter-Gasifier Head

CharBed

coal burns in front of tuyeres and residual oxides reduced

Hearth

melting and formation of hot metal & slag

FINEX Process

Fine Ore Reduction

smelting-reduction ironmaking process

Fluidized Bed

What does FINEX Process use?

Iron Ore Fines and Non-coking Coal

What does FINEX Process use to produce liquid hot metal?