EURASIA – MENA Mining, Industrial Minerals and Mineable Energy Trade & Investment Summit MAY 16 TH...

EURASIA – MENA Mining,Industrial Minerals and Mineable Energy

Trade & Investment SummitMAY 16TH -17TH , 2012 Istanbul-Turkey

WORLD Coking Coal Supply for Integrated Iron and Steel Works and Possibilities of Erection of New Mines for

Production of Coking Coal

Dr.-Ing. Hayri ErgunIndependent Consulting Engineer

WORLD Coking Coal Supply for Integrated Iron and Steel Works

Miners who are involved in the production of coal, in the

carbonization techniques and in the iron and steel industry who know the importance of Coking

Coal for our Insutrial Development.


In our Days the Wonder Word “Clean Coal Technology”

is a Basic Assumption in Respect to cover the demand of the Iron

and Steel Industry , to CO2 as well as to Climatic Environmental

Discussion.


The Institutions of the Montan and Mining Industry are therefore Germ Cells for

the New Technologies and New Products.


The Readiness and the Courage for New Ways should

be further in the Future Driving Forces for the Industry.


Only so we could secure the competitiveness and

keep exisiting jobs and create new ones.


Therefore it should be one of our most important aimes to strengthen the Innovative Dynamic of the Economy


With the Coke Oven Schwelgern the Company ThyssenKrupp Stahl AG has

the most modern and clean Coke Oven of the World in the industrial Location

Duisburg in Germany since March 2003.


Coke Oven Schwelgern


The Construction of the Coke Oven Schwelgern at the Turning Point to the

3rd millennium is however not one under many.


By analogy to the altogether crisis - like development of the

Hard Coal Mining and the Iron and Steel Industry in

the past decades, also the number of the Coke Ovens were drastically decreased.


The term “ coal ” is comprising a very wide

palette of carbon containing raw materials, that can be classified after

the most varied viewpoints.


Bituminous Coal


If one bases on the respective age as characteristic

distinction features, one would designate the youngest coal as a turf coal and the oldest as

an anthracite coal.


The coal can be classified after appearance, fields of

application, chemical composition, carbonization

technological characteristics, or also after coal microscopic

viewpoints.


Corresponding to the age and the mineral deposit conditions, also the process technological

treatment of the coal is undertaken in order to be able

to use it for the Coke Production.


A Mineral Beneficiation Processing of the coal is basically necessary in

order to separate the Raw Material from mineral

contaminations.


The classification of coal is generally based on the

content of volatiles. However, the exact classification varies between countries.

According to the German classification, coal is classified as follows.

Coal Classification

German Classification

English Designation

Volatiles %

C Carbon

%

H Hydrogen

%

O Oxygen

%

S Sulfur

%

Heat content kJ/kg

Braunkohle Lignite 45-65 60-75 6.0-5.8 34-17 0.5-3 <28470

Flammkohle Flame coal 40-45 75-82 6.0-5.8 >9.8 ~1 <32870

Gasflammkohle Gas flame coal 35-40 82-85 5.8-5.6 9.8-7.3 ~1 <33910

Gaskohle Gas coal 28-35 85-87.5 5.6-5.0 7.3-4.5 ~1 <34960

Fettkohle Fat coal 19-2887.5-89.5

5.0-4.5 4.5-3.2 ~1 <35380

Esskohle Forge coal 14-1989.5-90.5

4.5-4.0 3.2-2.8 ~1 <35380

MagerkohleNon baking coal

10-1490.5-91.5

4.0-3.75 2.8-3.5 ~1 35380

Anthrazit Anthracite 7-12 >91.5 <3.75 <2.5 ~1 <35300

Percent by weight


Already in the Coal Preparation or later in the Coke Oven the grinding of

the coal is undertaken.


The grinding and comminution of the coarse particles of the coal should create the prerequisite out

of carbonization technological view point for

a good mixing ability of several coal components.


The comminution of the coal is however also

therefore necessary in order to control special

processes in the carbonization (like

expansion pressure).


Based on the worldwide shortage of the good quality

coking coal and the endeavoring emerging from

that to expand the raw material basis for the

carbonization, following procedure lines have been

developed for the coal blend:


•Optimization of the coal blend,•Conditioning through supplement of pitch and special grog, •Intensification through tramping,•Mixture through Partial Briquetting, •Formed Coke Production.

procedure lines developed for the coal blend


With the goal of increasing on the one hand the capacity of the coke ovens, on the other hand to reduce the harmful material emission, around through it to increase the environment contractual

situation, the following ways have been followed in the

course of the last decades:


•Reduction of the chamber width (1960-1970)•Reduction of the Runner Stone Thickness• Increase of the Flue Chamber Temperature•Pre-drying of the coal blend•Pre-heating of the coal blend•Intensification through special binders •Compacting through tramping• Coke Dry Quenching•Increasing of the chamber width (1980-1990)


Coal is a very inconsistent material. This heterogeneity is

to be attributed to the inconsistent genetic material

and in addition also on the different temporal and

geothermal influences with the Coalification. Already early was recognized that all coals do not

suit themselves to the Carbonization. Prerequisite for

a Coking Coal is a sufficient baking capacity.


The special characteristic to form a firm baked

residue, is to be found only in certain bituminous coals and since beginning of the

20th century again and again object of numerous

research & investigations.

A Bituminous Coal SEAM IN Pennsylvania, USA

Coastal Exposure of the Point Aconi

Seam

Transportation of Coal by Rail Cars

Coke Oven in Wales, UnitedKingdom

A Coal Mine in Wyoming / United

States.

The United States

with the world's largest

coal reserves

Proved Recoverable Coal Reserves at 2008 (million tons (teragrams)

Proved recoverable coal reserves at end-2008 (million tons (teragrams))

CountryBituminous &

AnthraciteSubBitumin

ousLigni

teTOTA

LPercentage of World Total

United States

108,501 98,61830,176

237,295

22.6

Turkey 529 01,81

42,343 0.3

Germany 99 040,600

40,699

4.7

China 62,200 33,70018,6

00114,5

00 12.6

Russia 49,088 97,47210,4

50157,0

10 14.4

Australia 37,100 2,10037,2

0076,50

0 8.9

Indonesia 1,520 2,9041,10

55,529 0.6

Proved Recoverable Coal Reserves WHERE IS COAL FOUND?

Coal is stacked onto a stockpile

COAL STATISTICS

Coal provides 29.6% of global primary energy and generates 42% of the world's electricity

COAL STATISTICS

World Total Coal Production

(including hard coal and lignite)

7 229 Mt (2010) 6 823 Mt (2009) 4 677 Mt(1990)

COAL STATISTICS

World Total Bituminous Coal Production

6 185 Mt (2010): 891 Mt coking coal + 5

294 Mt steam coal 5 789Mt (2009):

782Mt coking coal + 5 007 Mt steam coal 3 493Mt (1990):

598Mt coking coal + 2 894 Mt steam coal

Coal & Steel

Approximately 13% of total hard coal production is currently used by the steel

industry and over 60% of total global steel production is dependent on coal.

International Hard Coal Trade

Steam: 676 Mt Coking: 262 Mt

Total: 938 Mt

Coal Trade for SteelProduction

The Way from Coking Coal to Steel

Coal & Steel Worldwide Coking Coal Deficit is estimated to

approximaetly 200 MT/a.

For the year 2015 it is estimated that the

coking coal deficit of China and India will be together around 200

MT/a.

Coal & SteelCoking coal price surged to US $ 300 per

tonne in the first quarter of

the calendar year 2011.

Supply disruptions caused by

flooding over Christmas in

Australia influenced also the coking coal

price.

Coal & Steel

Because of Shortage of Coking Coal worldwide the possibility of utilizing of

non-coking coals for metallurgical coke

production especially by Advanced Carbonization

Technologies like Formed Coke processes are gaining on increasing

importance.

The sucessfull application of the

proposed formed coke processes would result in considerable saving by the substitution of essential amounts of coking coals through

non-coking coals.

Advanced Carbonization Techniques

The Briquetting of the coal blend under aid of pitch is the first level

the Formed Coke Production.


FORMED COKE PRODUCTION

Herewith the components are usually finely ground up, mixed

through well and brought by presses in

close contact.


FORMED COKE PROCESS

The briquettes as such could be carbonized if

formed coke is supposed to be

produced

Advanced CarbonizatiON Techniques

FORMED COKE PROCESS

The Carbonization cannot take place in the

Horizontal Chamber Coke Oven because the

Coke Cake has no sufficient Stability.


FORMED COKE PROCESS

For this reason new coke oven reactor had to be

developed for the formed coke production; this is based partially upon the old vertical type coke

oven technology.


FORMED COKE PROCESS

Non- coking coal continuously to compact and to

carbonize, busied the profession already in

the '1950's.


FORMED COKE PROCESS

With Formed Coke, that was produced in a

Vertical Chamber Coke Oven, industrial attempts were

accomplished in a Blast Furnace in Japan

whereby the Formed Coke ratio amounted to

up to 25%.


FORMED COKE PROCESS

Dr.-Ing. Hayri ErgunIndependent Consulting Engineer

Possibilities of Erection of New Mines for Production of

Coking Coal

Metallurgical coal is an essential raw material in the production of steel

which is used in buildings, household items and other goods and services

that modern societies need.

Possibilities of Erection of New Mines

for Production of Coking Coal

As an Example for increasing Coking Coal production-

BHP Billiton Mitsubishi Alliance (BMA) owns and operates seven Bowen

Basin mines – Goonyella Riverside, Broadmeadow, Peak Downs, Saraji, Norwich Park, Gregory Crinum, and

Blackwater – and the Hay Point terminal near Mackay.

The mines are located in the coal-rich Bowen Basin of Central Queensland,

which covers an area of 75,000km² of Permian Age

BHP Billiton owns 50 per cent of BMA..


Coking Coal

Possibilities of Erection of New Mines

for Production of Coking Coal

Opening New Coal Mines needs big Investments and long time periods for preparation of the Mine:

Remote Continuous Miner HM21 Joy Used for Underground Coal Mining .


Coking Coal

Processing of Coal needs also Coal Wash plants with huge capital demand:

Coal wash plant in Clay County, Kentucky.

S y n o p s i s As Synopsis we can make the

Observation that

Worldwide there is a deficit of good quality coking coal for the iron and

steel industry in a yearly amount of approximately 200 MT.

There are advanced technologies to produce metallurgical coke from non-

coking coals, which however should be further developed.

New Mines for Coking Coal should be opened to cover the worldwide

demand for good quality coking coal.

Thank you for yourAttention

EURASIA – MENA Mining, Industrial Minerals and Mineable Energy Trade & Investment Summit MAY 16 TH...

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