Paper 1

5/25/2018 Paper 1

1/66

Figure 16thCOREXKnow-how Exchange Meeting

February 25 - 27, 2003, Toranagallu

Presentation: A036_14Pub00 COREX Adoption_Wieder.ppt Date: February 2003

Considerations for COREXAdoption

Development

FINEX

Operation Philosophies

COREX

Presentation - Kurt Wieder

OPERATION COMPARISON AND DEVELOPMENT
http://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A037_14Pub00%20COREX%20Development_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A038_14Pub00%20FINEX_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A038_14Pub00%20FINEX_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A040_14Pub00%20Operation_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A040_14Pub00%20Operation_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A038_14Pub00%20FINEX_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A038_14Pub00%20FINEX_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A037_14Pub00%20COREX%20Development_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A037_14Pub00%20COREX%20Development_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_6/A036_14Pub00%20COREX%20Adoption_Wieder.ppt

5/25/2018 Paper 1

2/66




Considerations

forCOREXAdoption

5/25/2018 Paper 1

3/66




Contents

Basic Considerations

Present Status COREXTechnology

Future Targets

COREX-Considerations for Adoption

5/25/2018 Paper 1

4/66




Basic Considerations for Adoption

High raw material flexibility

0 % coke high lump ore rates utilisation of raw materials available locally

Hot metal quality comparable to BFeasy integration

Lowerhot metal production costscompared to BF route

Exportgasutilization

Environmentalbenefits

Obtain Know How


5/25/2018 Paper 1

5/66




Present Status COREXTechnology


5/25/2018 Paper 1

6/66




COREXPLANTS WORLDWIDE

SALDANHA

1 x C-2000650,000 t/a

ISCOR1 x C-1000350,000 t/a

JINDAL2 x C-2000

1,600,000 t/a

HANBO2 x C-20001,500,000 t/a

POSCO1 x C-2000

700,000 t/a

5/25/2018 Paper 1

7/66




COREX

POSCO

implemented in a large integrated steel millwith BOF 7 years in operation export gas utilization in CPP

COREX

SALDANHA

implemented in an integrated compact millwith EAF combined operation with DR plant mainly local raw materials highest lump orerate more than 3 years in operation

COREX

JINDAL

2 COREXplants implemented in an integrated steel millwith BOF high flexibilityon imported and local raw materials high productionlevel (3037 tHM/day peak production at No. 1) use of up to 15% ore fines, partial use of coal fines export gas utilization in pellet plantand CPP 3,5 years in operation

COREXoperation successful under different circumstances


COREX- total accumulated hot metal productionso far approx. 13 mill. t

5/25/2018 Paper 1

8/66




Present Status COREXTechnology (1)

Small / mediumcapacity(operational 1 mio. t/y, offered 1,4 mio.t/y)

HM qualitysatisfying up to excellent: A, T, tap mass instable

Raw material qualities!Plant availability: 93 - 95 %

Concern: refractory / stave system at char bed, shaft emptying,

wear DRI screws, tapping problems

Coals

Wide range of coals usable Limited availability of best suitable qualities (coke rate, consumption,

hot metal quality)

Utilization of undersize material important (30 - 50 %)partial use in situ, coal briquetting - use in situ, cement industry, PCI,

power plants

Consumption rather high (Cfix ~ 600 kg/tHM)


5/25/2018 Paper 1

9/66





Iron oxide

High lump ore rates possible (8085 %) Total undersize fraction can be used in situ

Cokeconsumption (0) 5 - 15 %, average too high, lower qualityrequirements

Valuable export gas- economic utilization of utmost importance

thermal utilization (steel plant, pelletizing plant, calcination plant, ......) generation of electric energy (CPP realised, CCPP gas quality suitable) production of DRI


5/25/2018 Paper 1

10/66





Slag rate high - utilization comparable to BF

High sludgerate (3550 kg/tHM) - sludge granulation

technology developed

(partial recycling, cement industry, sinter and pellet feed)

Environment

low emissions compared to BF route hardly any bonus considered yet (soft fact)

CO2emission as for BF route (gas utilization !)


5/25/2018 Paper 1

11/66





Campaign life(2)5 years

defined by damages to stave system in char bed zone upgrade installed: Reline POSCO/SALDANHA,

Upgrade JINDAL Mod. 2

Expected campaign life approx. 10 years

Operation costsare competitive

Higher investment compared to BF stand alone (European basis)

COREX C-2000 / C-3000 175 / 225 million EURO

(ASU, gas utilization, coal briquetting, infrastructure excluded)BF 1 / 1,4 million t/a 150 / 190 million EURO

(coking plant, sinter plant, infrastructure excluded)


5/25/2018 Paper 1

12/66




0

20

40

60

80

100

120

140

160

180

200

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16Annual hot metal production [million tons]

Hotmetalopera

tioncosts[$/tHM]

COREXC-2000

SALDANHA

Southafrica

ISCORSouth Africa

Vanderbijlpark

POSCO

South Korea

Pohang

Tata Iron & Steel

India

Jamshedpur

COREX C-2000POSCO

South Korea

2 x COREXC-2000

JINDAL

India

Blast furnace data are based on year 2000

POSCO

South Korea

Kwangyang

CST

Brazil

Vitoria

Bethlehem steelUSA

Burns harbor

CORUSNetherlands

IJmuiden

KOBE steelJapan

Kagogawa

Baosteel

China

Shanghai

COREX - Economy

Comparison of Hot Metal Operation Costs Blast Furnace vs. COREX

Blast furnace data are based on year 2000

5/25/2018 Paper 1

13/66





Project realization time: 32 months

No Risk:

COREX = Proven Technology


5/25/2018 Paper 1

14/66




Future Targets


5/25/2018 Paper 1

15/66




Future Targets (1)

Upscalingof COREXand DR plant C 3000 / DR: 1,4 / 1,1 mio. t/y already offered C 4000 / DR: 1,8 / ? mio. t/y under investigation

Average availability: 95 %

(elimate shaft cleaning, screw- / down pipe blockages, ...)

Campaign life 15 yearsWider spectrum of usable raw materials

Quality Fines charging


5/25/2018 Paper 1

16/66




Future Targets (2)

Utilization of recycle- / wastematerial

Average coke rate 5 %

Improvedoperation

Lower consumption figures (coal, oxygen, ...) Improved stability Lower sludge rate

Exportgasutilization

Injection in BF CCPP Increase of DR plant capacity


5/25/2018 Paper 1

17/66




Future Targets (3)

Decrease of CO2emissions

Reduced investment

Successful development of hot metal production with oxide fines

based on COREX: FINEX

Result:

Significantly Lower Operation and Production Costs than BF


5/25/2018 Paper 1

18/66




COREX

Development

5/25/2018 Paper 1

19/66




Projects: Fit for Use / Design to Cost

Exportgas Utilization

Utilization of Recycle- / Waste MaterialUpscaling

FINEX

COREXDevelopment

5/25/2018 Paper 1

20/66




COREXDevelopment

COREXDevelopment of Technology

ProcessPlant

Pilot Plant

8 t/hKehl

(1980)Test Results

OptimisationEngineeringBench Scale

Laboratory

C-100040 t/hISCOR

Commercial Plant

(1987)

C 2000 + DR1

stGeneration

POSCO,JINDAL

HANBO,SALDANHA

Commercial Plants

80100 t/h 100110 t/h

C 2000 + DR2ndGeneration

80 -125 t/h 100 -125t/hAvailable for Market

C 3000 + DR145 -170 t/h 125 -140 t/h

Available for Market

+++

5/25/2018 Paper 1

21/66




Development Projects:

Fit for Use

and

Design to Cost

COREXDevelopment

5/25/2018 Paper 1

22/66




Fit for Use (FfU) and Design to Cost (DtC) (1)

General Goals:Improved Operation and Reduced Investment

Analyse system for unnecessary allowancesand weaknesses Adapt and optimize overall design to meet requirements on

basis of operation experience

Start with general concepts, progress down to details Allow upgrades !

COREXDevelopment

5/25/2018 Paper 1

23/66




FfU / DtC - COREX

Results

COREXC-20002ndGeneration Design

Optimized / upgraded equipment Increased capacity C-2000125 t/h Reduced weight

Reduced total investment(- 20 % !)

COREXC-20002ndGeneration = Basis for Upscaling

COREXDevelopment

5/25/2018 Paper 1

24/66




FfU/DtC COREXTower Equipment Modifications

COREXDevelopment

COREXTower

Mass Flow BinsSimplified Coal Line (1 Coal Screw)

Optimized Duct Dimensions

Optimized Lining Thickness

Scrubber with internal Demister

Redesign Cast Houses

Double Pocket Lift

etc.

Melter Gasifier )

Reduction Shaft ) refer separate slides

Dust Recycling )

5/25/2018 Paper 1

25/66




FfU / DtC COREXExamples for Equipment Modifications (2)

Material Handling

coal blending in stock house

coal screening in 3 fractions and drying of mean fraction only (1 drier)

dosing belt conveyors instead of vibro feeders

mass flow bins

double pocket lift for combined coal / ore feeding

etc.

Compact Lay Out

General reduction of structrual steel and civils (pipe bridges, ...)

Miscellaneous Water systems, electric, instrumentation, ......)

COREXDevelopment

5/25/2018 Paper 1

26/66




Main Focus for Development

Targets Plant Area / Equipment

Raw material flexibility, less coke gasifier,(shaft, briquetting)Lower consumption gasifierHigher availability gasifier,shaft, dust recyclingLonger campaign life gasifier

Utilisation recycle/waste material briquetting, injection, etc.Utilisation of export gas DR plant, CCPP, BF injectionReduced investment overallUpscaling COREX, DR plant

COREXDevelopment

5/25/2018 Paper 1

27/66




Melter Gasifier

Reduction Shaft Dust Recycling

COREXDevelopment

5/25/2018 Paper 1

28/66




Melter Gasifier - Comparison of Design Generations

COREX Development

FirstGeneration

SecondGeneration

Dust Burner LeveL

Freeboard Zone

Char Bed

Hearth

Tuyere Belt

Main Modifications:

Coal Distribution1

1

DRI Distribution2

2

Smaller Freeboard Zone

3

3

Addional Oxygen Burners

4

4

Fines/Waste Injection

5

5

Higher Char Bed

6

6

Upgraded Stave System

Cast Iron Stave State-of-the-Art Refractory Supports

Copper Staves lower Char Bed7

7

Bosh Angle 11 228 824 longer Tuyeres9 9

Increased Hearth Diameter10

10

Spray- /Chamber Cooling Hearth

11

11Longer Tap Hole

1212

Deeper Sump

13

13

5/25/2018 Paper 1

29/66




Melter GasifierValuation of Modifications

COREXDevelopment

EquipmentRaw Material

FlexibilityLower

ConsumptionLessCoke

CampaignLife

Coal distribution ++ + ++ +

DRI distribution + + + +

Bosh angle + ++ ++

Char bed height +ox en burners

+ +

Sump + tap length ++

5/25/2018 Paper 1

30/66




COREXDevelopment

Melter Gasifier - Dynamic DRI Distribution

Tiltable Distribution Flap

5/25/2018 Paper 1

31/66




COREXDevelopment

Melter Gasifier - Dynamic Coal Distribution

Collecting Chute1

1

Tiltable Rotating Chute3

3

Drive Unit4

4

Leverage for Chute Adjustment2

2

2

COREX D l t

5/25/2018 Paper 1

32/66




COREX DevelopmentMelter Gasifier Profile - Bosh Angle

1st

GenerationDesign

2ndGenerationDesign

Hot Face of

Staves in Conflict

with Rules:

12 x 5 ft

22 aw shit

Hot Face of

Staves under

Consideraton of

Rules:

12 x 5 ft

22 aw shit

12 ft12 ft22

5 ft 5 ft

22

Area of

critical

Attack

COREX D l t

5/25/2018 Paper 1

33/66




Reduction Shaft

COREXDevelopment

1

Improved Material Distribution

Rotating Feeding Bin

Mass Flow

min. 12 Distributor Legs

12

One Top Gas Duct2

3

Upper Shaft Inclination3

4 Gas Inlet(2ndBustle, Areal Gas Load,...)4

5

Lower Shaft

ADM + ADW

Shorter Screws

5

COREX Development

5/25/2018 Paper 1

34/66




COREX - Development

Dust Recycling - Basic Flow Sheet

Closed

Dust Line

Open

Dust Line

Hot Gas Cyclone

Shut-off Valve

COREX Disc Gate

Lock Bin

Burner

Melter

Gasifier

T-Piece

O2

N2

Lock Bin +

Screen (fine)

Shut-off Valve

COREX Disc Gate

Dust Control Valve

Cyclone Bin +

Screen (coarse)

OptimizedHot Gas Cyclone

Shut-off Valve

Automatic Valve

Burner

Melter

Gasifier

T-Piece-ParticleSeparation

O2

N2, CG

Lock Bin +

Screen (fine)

optional

Shut-off Valve

Automatic Valve

Cyclone Bin +

Screen (coarse)

5/25/2018 Paper 1

35/66




COREXDevelopment

Export Gas Utilization

COREX D l

5/25/2018 Paper 1

36/66




Export Gas UtilizationMain Focus

Fit for Use Project for DR Plant

Export Gas Injection into BF

Industrial Scale R & D Project at BF 5/6 voestalpine Stahl Linz

Export Gas Utilization in Combined Cycle Power Plant (CCPP)

COREXDevelopment

COREX D l t

5/25/2018 Paper 1

37/66




Fit for Use Project for DR Plant

COREX - Development

High PressureBuffer

ExportGas

Compressor

COREXExport Gas

Gas Heater

Gas Cleaning

ReductionShaft

DRI

ReductionShaftMelter

Gasifier

Gas Cleaning

DR

Export Gas

DR Recycle Gas I

DR PlantCOREX Plant

Hot Metaland Slag

O2

Coal

Additives/Ore/Pellets

Ore/Pellets

Top GasCO2Removal

DR Recycle Gas II

COREX D l t

5/25/2018 Paper 1

38/66




FfUDR plant

Measures

Optimized VPSA System/ compressor station Higher adsorbption pressure

Simplified vacuum system (less / smaller vacuum pumps)

2-stage centrifugal compressors

Elimination of High Pressure Buffer System

Additional GasRecycle Systemfor utilization of combined exportgas

Optimized Gas Heater

Preheating of combustion air with heater flue gas

Heat exchanger pipes in ALLOY 690 (first two bundles)

Material pretests to maximize crossover temperature planned

Simplified Product Gas System

COREXDevelopment

COREX D l t

5/25/2018 Paper 1

39/66




FfUDR plant

Results

Higher production100 t/h 125 t/hSame reduction shaft diameter as at SALDANHA Steel

Optimized / upgraded equipment (heater, ...)

Simplified gas system

Lower specific investment(- 20 %)

COREXDevelopment

COREX Use of Export Gas

5/25/2018 Paper 1

40/66




Concepts for Export Gas Addition to Blast Furnace

COREX - Use of Export Gas

May 2000\COR_ALLG\MR\04Export Gas\A006EF_04_1HOCH02.ppt

COREXPlant Gas Treatment Blast Furnace

COREX Export Gas

PSA

Flue Gas

O2

800C

400C

Hot Blast

Tail

Gas(CO2,etc.)

Refined

COREX

Gas

Heater

Compressor

COREX Use of Export Gas

5/25/2018 Paper 1

41/66




Combination of COREXand a Combined Cycle Power Plant

Gas Turbine Steam Turbine

Reduction

Shaft

Melter

GasifierHot Metal

Slag

Export Gas

Filter

G

Combined CyclePower PlantCOREX

Plant

Buffer

G

COREX - Use of Export Gas

COREX Development

5/25/2018 Paper 1

42/66




Utilization of Recycle- / Waste Material

COREXDevelopment

COREX - PROCESS

5/25/2018 Paper 1

43/66




COREX PROCESSWaste and Recycling Materials; Charging Possibilities

shredded

granular

Tires

Plastics

EAF or LD

Drop Out

Fine Iron

granulated

granulated

briquetted

briquetted

briquetted Sludge

Dusts

Mill Scale

lumpy

Fine Ore

LD Slag

Drillings

briquetted

*) treated de-S slag

Fine Coal

Kish*)

(briquetted)

COREX Development

5/25/2018 Paper 1

44/66




Use of Recycle and Waste Materials

Reduction Shaft

Steel plant recycle materials (oxide briquetts)Significant higher Zn load acceptable

CX: 5000 gr/THM BF: 200 gr/tHMLabor tests and basket tests at DR shaft SALDANHA successful

Melter Gasifier

Coal line- Ore / coal undersize material

- External wastes: plastic, tires, etc.

- Sludge granules

Injection of fines into freeboard zone via burners- (TG dust, metallic / oxidic / carbonaceous materials, etc.)

COREXDevelopment

COREX - PROCESS

5/25/2018 Paper 1

45/66




COREX PROCESSWaste and Recycling Materials; Criteria

Chemical ComponentsZn: up to 5000 g/tHM

Cl: up to 500 g/tHM*)

Melter Gasifier

Max. 150 kg/tHMundersize material (< approx. 8 mm)Mean size min. 1 mm

Reduction Shaft

Iron carrier replacement by max. 30% briquettes

Lumpy and stable material free of hydrocarbons

*)further increase with special equipment and measures possible

General

5/25/2018 Paper 1

46/66




Comparison Zn/Alkali Accumulation Blast Furnace vs. COREX

General

Blast Furnace COREX

Zns

Zng

Zns Zng

80% 20%

Cooling Gas

Export Gas

ZnO

Topgas

COREXProcess

5/25/2018 Paper 1

47/66




0.8

5

0.3

Melter GasifierDome

0.7

0.2 2Coal

Input

Ore

Input Top Gas

Dust

Recycling

Reduction

Shaft

Sankey Diagram for Zn in the COREXProcess

nFactor

COREXDevelopment

5/25/2018 Paper 1

48/66




COREXUpscaling

COREX Development

COREX

5/25/2018 Paper 1

49/66




COREX Up - scaling of COREX

\

3.5 m

2 m

5.5 m

5 m

7.3 m

7 m

8.8 m

8.3 m

C-1000 C-2000Pilot Plant C-3000

6 - 8 t/h 145 - 170 t/h80 - 125 t/h40 - 50 t/h

60,000 t/a300,000 -

400,000 t/a

600,000 -

1,000,000 t/a

1,200,000 -

1,400,000 t/a

Hot Metal Production Capacities

5/25/2018 Paper 1

50/66




0,0

1,5

3,0

4,5

6,0

7,5

9,0

10,5

12,0

13,5

15,0

16,5

0 50 100 150 200 250 300 350 400 450 500

Hot Metal Rate [t/h]

Hearth

Diameter[m]

p

C-2000 (1.0 Mio t/a)

C-3000 (1.4 Mio t/a)

Vision C-4000 (2.0 Mio t/a)

Blast Furnace(worldwide)

COREX

COREXDevelopment

5/25/2018 Paper 1

51/66




FINEX

COREX Development

FINEX

5/25/2018 Paper 1

52/66




Prereduction Reactor

Fine Ore, Additives

Melter Gasifier

Lump Coal

Preheating Reactor

Hot Metal and Slag

Basic Process Flow Sheet

R1

R2

R3

Export Gas

O2

Oxygen

Reduction ReactorDRI/Add.

Fines

FINEXProcess - Development Targets

5/25/2018 Paper 1

53/66




Development Targets

FINEX: Commercial feasible process for production of hot metal with

direct use of fine ore and non coking coal

Premisses for process development Direct use of sinter feed ore -8 mm

Direct use of non coking coal, quality comparable to COREX coals

Benchmarks for feasibility Consumption figures:

Coal 1070 kg/tHM

Oxygen 630 m/tHM

Fine ore 1500 kg/tHM

Availability 90 % Product: same quality as BF and COREX hot metal

Operating costs 100 EUR/tHMInvestment costs 245 mio. EUR for F3000

(for location Central Europe)

FINEX

5/25/2018 Paper 1

54/66




Development of FINEXTechnology (1)

FINEX

= Joint Development of VAI / POSCO / RIST

Hot Lab Scale Tests

Cold Bench Scale Tests - 4 t/h (fluid bed) 1993

Hot Bench Scale Tests - 15 t/d (fluid bed) 19951998

Pilot Plant Campaigns - 6 t/h (fluid bed) 19992002

Demo Plant F-2000 - 85 t/h (fluid bed + smelting)

Go Decision June 2000 Start Up May 2003

FINEXF-2000 Demonstration Plant

5/25/2018 Paper 1

55/66




Dryer

Fine Ore &

Fine Additives

DRI Fines Hot Compacting

and Transport

R1

R4

CoalBriquetting

Heat Recovery (optional)

2 x

Backup Gas

GeneratorO2

Light Oil

Coal Fines

H2O

O2

O2

O2

O2

O2

Plant Concept - DRI Fines Hot Compacting

R3

R2Lump

Coal

Export

Gas

Hot MetalSlag

COREX and FINEXDemo Plant

5/25/2018 Paper 1

56/66




FINEX

Demo Plant

COREX

C-2000

FINEX

5/25/2018 Paper 1

57/66





Important Development Steps

Fluidized bed reduction Demo Plant Hot DRI fines handling

1st step: Hot briquetting Demo Plant

2ndstep: Pneumatic conveying / fines charging (?)

Melter Gasifier operation1st step: DRI briquettes, coal briquettes Demo Plant

2ndstep: DRI fines (?)

FINEX

5/25/2018 Paper 1

58/66





Status = FINEX

Demonstration Plant POSCO Pohang Commissioning May 2003

Achieve stable industrial production 2004/5 Major challanges - Operation practice

- Availability

- Sticking behaviour of metallic fines

- (Melter gasifier operation with HCI)

Vision = FINEXCommercial Plant 1 mio.t/yDirect HotFines Charging Precondition for development: Successful Demo Plant operation Add. major challanges: - Pneumatic transport of hot DRI-fines

- Melter gasifier operation with 100 %

DRI-fines

FINEXCommercial Plant

5/25/2018 Paper 1

59/66




Dryer(optional)

Fine Ore &

Fine Additives

R 1

R 2

R 3 Coal

Briquetting

Backup Gas

GeneratorO2

Fuel

Coal Fines

H2O

O2

O2

O2

O2

O2

Pneumatic Conveyer

and Material Splitter

Heat Recovery (optional)

Lump

Coal

Feed Gas

R4 (optional)

Plant Concept - Direct Charging of DRI FinesExport Gas

Hot Metal

Slag

COREXversus FINEX

5/25/2018 Paper 1

60/66




Economic Evaluation

COREX

C-2000

FINEX

F-2000HCI

FINEXVisionF-2000

Direct Charg.

Investment Millon EUR 175 270 230 *)

HM Operation Cost EUR/tHM(excl. Capital Charges)

105 - 3 % - 8 % *)

HM Production Cost EUR/tHM(incl. Capital Charges)

115 + 3 % - 4 % *)

*) Target figures

Basis: EuropeExport Gas credit: 5,6 EUR / GJ

FINEX Demo Plant: Adapted COREXunit plus FINEXreactor building, HCI, etc.Vision F-2000: First commercial FINEX plant, direct hot fines charging, etc.

5/25/2018 Paper 1

61/66




COREX

Operation Philosophy and

Process Control

COREXOperationO ti Phil hi (1)

5/25/2018 Paper 1

62/66




Operation Philosophies (1)

POSCO JINDAL SALDANHA

Production rate moderate (90 t/h) maximised (110 t/h) relativ max. (85 t/h)

Raw materialPhilosophy best qualities

(min. coke rate)

max. local portion

(min. coke rate)

max. local portionmax. lump ore ratemin. coke rate

Availability coalcoke

lump orepelletadditives

own production

local

locallocal, own productionlocal

local

local

local

Fines utilization

coal, coke

oxide

coking plant, PCI,briquetting

sinter plant

CPP, part. in situ

pellet plant, in situ

cement-/brickindustry

export, (part. in situ)

Export gas utilization CPP CPP, pellet plant,heating, limecalcination plant

DR plant , heating

max./stabilizedproduction forDR plant


5/25/2018 Paper 1

63/66





POSCO JINDAL SALDANHAGeneral operation

Oxygen inputtotal (m

3/tHM) STP

to tuyeres (m3/tHM) STP

to burner (m3/tHM) STP

additional oxygen burners

570440130---

530380150

in progress

620 (95 %)450 (95 %)170 (95 %)planned

Coke rate (%)addition to

(< 5) 12 - 18gasifier

13 - 20shaft / gasifier

10 - 15shaft / gasifier

Material distributioncoalDRIshaft

in progress(adj. radius), 6 legs

staticbasic, static

(adj. radius), 6 legs

staticenhanced, (dynamic)(adj. radius), 12 legs

Steam / water additionto tuyeres

to generator gas

steam

(steam)

---

water

water

water


5/25/2018 Paper 1

64/66





POSCO JINDAL SALDANHA

Tapping pratice alternating tapping

alternating tapping alternating tappingDust line operation open line open line open line

Specialities

tuyere brightness measurement ---

longer tuyeres --- (tests)

coal briquetting --- ---

coal particle size measurement --- ---

sludge granulation / utilization --- / cement industry --- / cement industry

minimized N2consumption --- --- (CG booster)

iron granualtion --- ---

TG / EXG recycling --- ---

elevated exportgas pressure ---

fines charging

- coal --- ---

- oxide --- ()development towards FINEX

--- ---

Comparison of Operation Results (1)

COREXOperation

5/25/2018 Paper 1

65/66




Comparison of Operation Results (1)

POSCO (2002) JINDAL 1 (2002) JINDAL 2 (2002)SALDANHA (after

relining)Melting rate 80100 t/h 85110 t/h 100115 t/h 8590 t/h

Plant pressure 2,83,6 barg 3,33,6 3,43,6 3.33.5 bar g.

Spec. Fuel consumption 1000 1100 kg /tHM 1000 1100 kg /tHM 9801060 kg/tHM 1150 kgtHM

Coke rate 1020 % 10 - 20 1320 % 1015 %

Ore rate 0 % 8083 %

Spec. O2 total560 - 580 m

3/tHM

(99 % O2)520 550 m3/tHM(99 % O2)

510 - 550 m3/tHM

(99 % O2)

620 m3/tHM(95 % O2)

Spec. O2 tuyeres 430

450 m3/tHM 370

400 m3/tHM 360

400 m3/tHM 430

460 m3/tHMO2 Dust burner 28003200 each 38004200 each 38004200 each 3900 4000 each

Dome temperature 1000 1030 1050 1080 C

Reduction gas temp. 750 (- 800) C 820840 C (800)850 C 845 C

CO2 CG 68 8 11 % 7 10 % 710 %

Spec. TG Flow 1050 m3/tore 10801130 m3/tore 10601150 m

3/tore 11001150 m3/tore

Fine ore addition 0 kg/tHM 50200 kg/tHM 50200 kg/tH0 - 6. 020 kg/tHM

Grainsize of fine ore 0 6.3 mm 0 6.3 mm 612 mm

Hot metal: T 1500

1520 C 0.4

0.7 %Si 0.8 2 %

5/25/2018 Paper 1

66/66




COREXJINDAL COREXPOSCO COREXSALDANHA

The Success of COREX

Realization of

taylor-made Plant Concepts and specific Operation Philosophy

Paper 1

Documents

Transcript of Paper 1