You are on page 1of 104

- 1 -

1.COREX IRON MAKING





Liquid hot metal, either for production of steel or pig iron for foundry, has been
traditionally produced in the blast furnace using metallurgical coke, produced from coking
coal ,as reductant and energy supplier. This call for a need of an alternative iron making
technology also for conserving the depleting reserves of good quality coking coal, making
use of non-coking coal reserves, exploiting large price differential of imported
metallurgical coal and non-coking coal. In recent years, Smelting Reduction (SR)
processes have been under development throughout the world. The basic principle of a SR
process is to smelt the pre-reduced iron ore/sinter/pellets with non-coking coal and oxygen
in a reactor called Melter-Gasifier. Compared to the conventional Blast furnace process;
SR processes have many advantages with respect to raw materials, energy cost, investment
cost, economy of scale and environmental pollution. COREX process, which is one of the
commercially and technologically proven alternate routes of Iron making. The COREX
technology is based on the physical separation of reduction and melting process, which are
carried out in two reactors. In the Melter Gasifier (MG), reduction gas is generated and
liquid hot metal is produced .The Reduction Shaft (RS) which is located above the Melter
Gasifier, is designed for the reduction of iron oxides.


Smelting reduction is an emerging technology for making hot iron using non-
coking coal. Till today various smelting reduction processes like COREX, ROMELT,
HISMELT, AUSMELT, DIOS etc. have been developed of which COREX is the first and
so far only commercially established smelting reduction process, which is developed by
Voest Alpine Industrianlagenbau (VAI), Austria. The stable and highly successful
operation of four COREX plants (1 POSCO, Korea, 2 JVSL, India, 1 SALDANHA, South
Africa) confirms that COREX process is a proven and viable alternative to conventional
blast furnace technology.


1. INTRODUCTION:


COREX is the one of the commercially and technologically proven alternate routes
of Iron making. While even todays worlds most of the hot metal or liquid iron is produced
through the giant Blast Furnace route, very small fraction of iron is produced through the
alternate routes. COREX process gives advantage of power generation and makes integrated
steel complex totally independent of petro-based products due to availability of COREX gas
as fuel.







- 2 -
1.1 HISTORY :























Chronology of COREX development and establishment.


These are some of the strength of COREX technology over other Iron making
process:

It is a two-stage process, Reduction and Smelting. It is a clean iron making
technology, which is flexible in term of operation and usage of raw materials of less
stringent quality.

Various fines such as iron bearing fines, limestone & dolomite fines can be
directly used into the furnace. About 10-15 % of the total iron bearing material can be
replaced with direct use of Iron bearing fines.

The gas coming out as by-product is a clean gas having very high calorific value i.e. ~
2000 Kcal/Nm.
3
this can also be used in many areas like:

Power plants.

Production of DRI.

Lime Calcination plant.

Hot strip mill reheating furnace.

2005
2005
Essar Steel (Hazira) Limited, Hazira, C -_2000 x 2
Bao Steel, China C - 3000
- 3 -
Fuel gas within the Iron and Steel complex.

Advantages of Corex Process:

Easy and fast correction of hot metal and slag chemistry with in 2 3 hrs as the
process is divided into two stages.

Excellent quality hot metal. High hot metal temperature (1480 1520
o
C) offer great
advantage in the subsequent process of steel making.

Easy stop and restart of the furnace. After restart, furnace can attain its rated capacity
within a short duration i.e. 2 - 3 hrs without effecting the quality of hot metal.

It is the only commercially established alternative route of iron making an efficiency
very much comparable to the conventional route.

Environment friendly process as this technology does not require setting up the coke
oven and sinter plant. The emissions from COREX contain only insignificant amount
of NOx, SOx, dust, phenols, sulphides, ammonia etc. The million worth of saved
carbon over the years can also be sold as a part of carbon trading.


1.2 COREX FACILITIES

I Melter Gasifier
1 Tuyeres 26 Water-cooled Copper body.

2 Level indicator 5pair Source and Detector, Water-cooled Copper body.

3 Dust Burner 4 Water cooled Copper body.

4 Staves 184 Cast iron boby expect row 5 and row 6, Copper
body for row number 5 and 6.It is water Cooled.

5 Drilling machine 1 Drilling is Pneumatically Operated and seweling
by hydraulic.

6 Mud gun 1 Hydraulically Operated. Both swelling and
ramming.

7 Dust Recycling System 4 Each DRS consists-Hot Gas Cyclone, LowerDust
Bin, Disc gate, Injector, T-piece and dust burner.

8 Generator Gas Duct (GGD 4 Water-cooled four numbers of generator In-liner.

9 Coal Screw 1pair Upper coal screw and lower coal screw.

10 Coal lock hopper system 1 Consists of feeding bin, intermediate bin and
- 4 -
charging bin, two set of material flaps and seal
flaps, Pressurising and depressurizing system.

11 Coal Reffler 1 Located center of MG dome to take care coal
distribution.

12 Coal in liner 4 Located just below the refler,on which reffler is
mounted.

13 Heating Unit 1 For both coal and oxide, heated oil is circulate to
the
Lock hopper system for smooth charging
operation.

II Reduction Shaft



1
DRI screws 6 Hydraulic driven.

2 DRI down Pipes 6 It is vertical DRIconveying line, DRI discharged
from Screws is conveyed to the MG through this
line.

3 Oxide Lock hopper system 1 Consists of feeding bin, intermediate bin and
charging bin, two sets of material flaps and seal
flaps.

III Gas System
1 Cooling Gas System
2 Baumco Scrubber (B S) 1 Number just before cooling gas packing scrubber.
It facilitates to cool the high temperature gas.

3 Cooling Gas Packing Scrubber
(CGPS)
1 To cool and clean the Excess Gas produced in the
System
(Gas remained excess out of total gas produced
and the reducing gas used for reduction in the
reduction shaft).


4 Excess Gas Venturi Scrubber
(EGVS)
1 to clean excess gas, it is further cleaned and
Venturies are used for Pressure Control. It consists
of mist eliminator (EGME) , water level control
tank.
5 Cooling Gas Venturi Scrubber
(CGVS)

1 to clean the gas going the Cooling Gas
Compressor.



6 Cooling Gas Compressor 1 One working one stand-by. It is used to Boost the
- 5 -
(CGC) gas Pressure by 1 bar more than the pressure to the
inlet cooling gas pressure. This gas is added into
four-generator gas duct through temperature
control valve (TRCs) to reduce the generator gas
temperature; normally Temperature is reduced to
850 deg C from 1050 deg C. This reducing gas is
then taken in to RS for Oxide reduction.
IV Top Gas System
1 Top Gas Packing Scrubber
(TGPS)
1 To cool and clean the top gas which is coming out
from Reduction Shaft.
2 Top Gas Venture Scrubber
(TGVS)
1 To further clean the top gas and control the
Pressure. It consists of one mist eliminator and one
water level control tank.
V Export Gas System
A Low Pressure (LP) Gas Line
1 Pressure Control Valve (PRC) 1 It controls the line pressure for Low Pressure (LP)
export gas consumer; It is located in Export gas
after flare stack.
2 Solenoid Valve ( SOV) 1 It is located after PRC in LP export gas line .It is in
open or close condition depends upon consumer
requirement.
3 Goggle Valve (GV) 1 It is located after SOV in LP export gas line .It is
can be manually / automatically operated. It is used
for mechanical isolation during long shut down for
perfect sealing of process gas system from export
gas network.

4

Shut off Valve (SHV) 1 It is located after GV.It used for same for gas
isolation during plant shut down.
B High Pressure (HP) Gas
Line

1 Goggle Valve (GV) 1 It is located in HP export gas line .It is can be
Manually / automatically operated. It is used for
mechanical isolation during long shut down for
perfect isolating of process gas network from
export gas network.

2 Pressure Control Valve (PRC) 1 It controls the line pressure for high Pressure (HP)
export gas consumer; It is located after HP goggle
valve.

3 Solenoid Valve (SOV) 1 It is located after PRC in HP export gas line .It is
in open or close condition depends on consumer
requirement.



- 6 -


4 Flare Stack 1

It is having four burner (flare tip), Ignition panel
and fuel gas (NG/LPG) for pilot ignition.

5 Seal pots 5 It is for HP gas line ,in which Two number in Top
gas system ( export gas 1) one number in Excess
gas system (export gas 2) ,one in flare stack drain
and one more in HP line.

6 Flare Stack 1 It is having four burner (flare tip),Ignition panel
and fuel gas (NG/LPG) for pilot ignition.
7 Seal pots 5 It is for HP gas line ,in which Two number is for
Top gas system ( export gas 1) one for Excess gas
system (export gas 2) ,one for flare stack drain and
one more for HP line.


1.3 EQUIPMENT


MAJOR
REACTORS:
AUXILLAIRIES:

I. Reduction Shaft
[RS]
II. Melter Gasifier
[MG]

i. Coal blending station
[CBS]
ii. Coal drying plant [CDP]
iii. Raw material stock
house [RMHS]
iv. Gas cleaning system
v. Water Cleaning system
vi Cast house[C/H]
vii Pig casting machine
[PCM]
viii Cooling gas and air
compressors [CGC]





1.4 PROCESS DESCRIPTION:

COREX consists of two reactors, the reduction shaft and the melter gasifier. Figure 1
shows the COREX process schematically. The reduction shaft is placed above the melter
gasifier for easy descend of material by gravity. The functions of reduction shaft and the
melter gasifier are explained in the following

- 7 -







Figure-1: Flow sheet of COREX

process





1.5 Reduction shaft:

Iron ore, pellets and additives (i.e. limestone and dolomite) are continuously
charged into the reduction shaft via lock hopper system located on the top of the shaft. The
burden descends through the shaft by gravity. The reduction gas is injected through the
bustle located about 5 meters above the bottom of the shaft at 830
o
C temperature and over 3
bar gauge pressure. The gas moves in the counter current direction to the top of the shaft and
after the exit from the shaft it is termed as top gas. The top gas temperature is around 300
o
C.
Some amount of Coke is also added to the shaft to avoid clustering of the burden inside the
shaft due to sticking of ore/ pellets and to maintain adequate permeability in the burden.
Following are the primary reactions taking place inside the shaft.


Reduction of iron oxide by CO and H
2
and transforming the iron oxides to metallic iron.

Fe
2
O
3
Fe3O4

FeO Fe

Calcination of limestone and dolomite
CaCO
3
= CaO + CO2

(endothermic)
CaMg (CO
3
)
2
= CaO. MgO + 2 CO
2
(endothermic)

BU
- 8 -
Carbon deposition reaction and formation of Fe
3
C

2 CO CO
2
+ C (exothermic)
3 Fe + 2CO Fe
3
C + CO2

(exothermic)


After a residence time of about 6 hrs. Inside the shaft, the iron bearing material gets
reduced and achieves the metallization to the extent of about 80 - 90 %, and is termed as
DRI. Subsequently, 6 discharge screws convey the DRI from the reduction shaft to the
melter gasifier.

The reduction gas is nearly fully de-sulphurized in the shaft due to the presence of the
burnt lime and dolomite according to the following reactions.

CaO + H2S = CaS + H2O
MgO + H2S = MgS + H2O

A low content of the hydrogen sulphide of the top gas is important with respect to the
further usage of the COREX gas.

The metallization degree of the DRI and the calcination of the additives are strongly
dependent on the following parameters.

Amount and quality of the reduction gas flow.
Temperature of the reduction gas.
Reducibility of the iron carrier.
Grain size of the solids charged.
Reduction gas distribution in the shaft.
Retention time in the shaft.
Plant Pressure and Pressure drop in the shaft.

The specific reduction gas flow is maintained at about 1000 - 1200Nm
3
/ton of
iron carrier charged to the shaft.

1.6 Melter gasifier:

The melter gasifier can largely be divided into three reaction zones as the following.

Gaseous free board zone (Upper part or dome)
Char bed (Middle part above oxygen tuyeres)
Hearth zone (Lower part below oxygen tuyeres)

Due to continuous gas flow through the char bed, there also exists a semi-
fluidized bed in the transition area between the char bed and the free board zone.

The hot DRI at around 750-800
o
C along with the calcined limestone, dolomite is
continuously fed inside the melter gasifier through DRI down pipes. The DRI charging
pipes are uniformly distributed along the circumference near the top of the melter gasifier
so as to ensure proper distribution of material over the char bed. Additionally non-coking
- 9 -
coal, quartzite and required quantity of coke are continuously charged by means of lock
hopper system and coal screws. Like reduction shaft the melter gasifier also operates at
an elevated pressure in excess of 3-bar gauge.

Oxygen plays a vital role in COREX process for generation of heat and reduction
gases. It is injected through the tuyeres, which reacts with carbon present in the char will
generate CO and H2 and Heat. This hot gas ascends upward through the char bed. The
sensible heat of the hot gases is transferred to the char bed, which is utilized for melting
iron and slag and other metallurgical reactions. The hot metal and slag are collected in
the hearth.

The efficiency of the furnace depends largely on the distribution of this gas in the
char bed and utilization of the sensible heat of the gas. The dome temperature is
maintained between 1030 and 1070
o
C which assures cracking of all the volatile matter
released from the coal. The gas generated inside the melter gasifier contains fine dust
particles, which are separated in hot gas cyclones.

The dust collected in the cyclones is recycled back to the melter gasifier through
the dust burners, where the dust is burnt with additional oxygen injected through the
burners. There are four such dust burners located around the circumference of the melter
gasifier above the char bed.

The gas generated inside the melter gasifier is cooled to the reduction gas
temperature (~830
o
C) through the addition of cooling gas. A major part of this gas is
subsequently fed to the reduction shaft. The excess gas is used to control the plant
pressure. This excess gas and the reduction shaft top gas are mixed prior to the take over
point. Thereafter this gas is termed as COREX export gas.

Following are the reactions taking place inside the melter gasifier.

Drying of coal (100
o
C).
Devolatilisation of coal (200 to 950
o
C) and liberation of methane and higher
hydrocarbons.
Decomposition of volatile matter.

Due to the higher temperature prevailing in the melter gasifier free board zone, the
hydrocarbons are cracked into hydrogen and elementary carbon.

C
n
H
m
= nC + (m/2) H
2
It is desirable that all higher hydrocarbons are cracked in the free board zone so as
to assure generation of a good quality reduction gas. Maintaining a dome temperature
between 1030 and 1070
o
C confirms the same.

Further reactions in the freeboard zone are outlined as the following.

CO
2
+ C = 2 CO Boudouard reaction

H
2
O + C = CO + H
2
Water gas reaction

- 10 -
CO + H
2
O = CO
2
+ H
2
Shift reaction

Decomposition of unburnt limestone and dolomite.
Residual reduction of iron oxide.
Direct reduction of FeO in the DRI takes place by carbon in the char bed.
Burning of coal char by oxygen.

Burning of the coal char takes place near the tuyeres. The maximum temperature
inside the melter gasifier exists in front of the tuyeres. The following carbon gasification
reaction takes place in the tuyere area.

2C + O2 = 2CO

2CO + O2

= 2CO2

C + CO2 = 2CO

Later, Melting and formation of hot metal and slag.

The typical analysis of COREX

hot metal and other by-products is shown in Table 1.



The typical analysis of the various gases produced in COREX is shown in Table 2. In
order to achieve higher degree of metallization and sufficient carbonization of the DRI, the
contents of CO
2
and H
2
O in the reduction gas should be below 5%.






Table-2 Typical analysis of COREX

gases

ANALYSIS TOP GAS REDUCTION GAS EXPORT GAS
CO % 43 - 46 65 - 70 45 - 47
H
2
% 18 -20 20 - 25 19 - 21
CO
2
% 30 35 3 - 8 30 33
CH
4
% 1 - 2 1 - 2 1 - 2


ANALYSIS
(%)

C


Si


S


P


Ti


CaO


MgO


SiO
2



Al
2
O
3



FeO


Fe
2
O
3



TiO
2


HOT
METAL

4.5

0.6

0.04

0.15

0.06


SLAG

0.80

0.26

34.5

13.0

31.7

17.0

0.50


SLUDGE

35.6

0.81

0.25

7.94

3.20

9.18

4.38
30.61
0.29
- 11 -

The efficiency of the COREX primarily depends on the following.

Size and chemical analysis of the raw materials; specially the coal.
Reduction gas quality & shaft condition for good rmetallization of the DRI.
Optimum distribution of oxygen between the tuyeres and dust burners.
Permeability of the char bed.
System pressure.
Melting rate.


COREX export gas is suitable for a wide range of applications as stated above.

Tapping of hot metal and slag takes place approximately 8 to 10 times per day with
a tapping capacity of approximately 300 thm/tap. The tap hole is opened by a pneumatic
drilling machine. For closing of the tap hole hydraulically operated clay gun is provided.
After opening the tap hole, hot metal and slag discharges into the main iron trough, where
slag is separated from hot metal by means of a skimmer.
Hot metal flows from the main iron trough through the iron runner and a tilting
runner into open ladles positioned on ladle transfer cars below the cast house platform.
The slag proceeds from the main iron trough through a runner system to slag granulation
plant or slag dry pits, in case the slag granulation plant is not available. To operate the tap
hole opening and closing machines a central hydraulic system is installed.


1.7 PROCESS CONTROL:

Raw material quality charged to the furnace is controlled at the screening station to
ensure
required size as a first stage of control.
Sample checking for input raw materials as per quality plan.
Weigh bins/feeders are connected to DCS in control room to weigh raw materials
accurately charged to the furnace. The load cells of the weigh feeders are calibrated as
per the frequency in the calibration plan.
Coal and Oxide feed rate varied to control the process parameters and hot metal quality.
Controlled oxygen flow to the tuyere and dust burner.
Thermocouples for In-burden Temperature measurement inside the reduction shaft.
Delta-p inside the reduction shaft to ensure proper permeability of the burden.
Reduction gas temperature going into the reduction shaft
Controlling of specific top gas to ensure proper metallization of the burden.
Dome temperatures inside the melter gasifier to control the composition of the generated
gas. Control of Char bed level to ensure proper hot metal & slag quality.
Adjustment of slag quantity and basicity B2 (CaO/SiO2) to control the Slag Alumina,
Viscosity and sulphur distribution.
Plant pressure control.
Maintaining proper tap-to-tap time for ensuring proper drainage of the hearth.


1.8 RAW MATERIALS
- 12 -

Table 3: Physico-chemical properties of Iron bearing material

Parameter Analysis
Chemical Analysis
Fe - Total 64 -65 %
SiO
2
+ Al
2
O
3

< 5.4
Al
2
O
3

< 5.2
P < 0.10 %
S < 0.03 %
Cold Tumbling Test
Tumbler index (+6.3 mm) > 95 %
Abrasion Index (-0.5 mm) < 5 %
Static Reduction Test [Under load]
Reducibility (dR/dt)
40
> 0.4 % O2/min
Metallisation Degree > 90 %
Disintegration Index (-6.3 mm) Pellets < 10 %, Ore < 20 %
Abrasion Index (-0.5 mm) Pellets < 3 %, Ore < 5 %




Table 4: Physico-chemical properties of COREX coal

Parameter Analysis
Chemical Analysis
Fixed carbon % > 58 %
Volatile matter % 26-32
Ash % < 12 %
Sulphur % < 0.60
Phosphorous < 0.06
Chlorine < 0.04
Calorific value Kcal/Kg > 7000
Ash analysis
SiO2 < 60
Al2O3 < 30
Na2O + K2O < 1.5
Thermal Stability
+ 10 mm % > 80
- 2 mm % < 3
CRI % < 35
CSR % > 40
Free Swelling Index 1 -3

- 13 -



Table 4: Typical analysis of Additives


ANALYSIS LIMESTONE DOLOMITE QUARTZ
CaO % 46.79 27.98 0.14
MgO % 3.83 19.84 -
SiO2 % 5.20 6.81 97.88
Al2O3 % 1.16 0.53 0.90
Fe2O3 % 0.96 0.49 0.62
P2O5 % 0.04 0.01 0.01
SO3 % 0.01 0.01 0.01




1.9 BLAST FURNACE:

The blast furnace is the first step in producing iron from iron oxides. Blast furnace
equipment is in continuous evolution. In Blast furnace coke is used for heat generation,
production of reduction gases and to maintain adequate bed permeability. Blast furnaces
will survive into the 2000 millennium because the larger, efficient furnaces can produce
hot metal at costs competitive with other iron making technologies.


SIMILARITIES BETWEEN BLAST FURNACE AND COREX PROCESS:


1.Both the process is used for the production of hot metal (liquid pig iron).
2.Except fuel and oxygen, similar raw materials could be used in both the processes.
3.Overall reactions taking place in both the routes are quite similar, except those of coal
devolatization and cracking etc.
4.The function of the hearth and concept of tapping of hot metal and slag, cast house design,
slag & hot metal handling practices are identical in both Blast furnace and Corex.
5. Hot metal composition is same in both processes. However, Corex HM temperature is
relatively higher and sulphur in the HM is lower compared to BF.










- 14 -
1.9 DIFFERENCES BETWEEN BLAST FURNACE AND COREX.

SL. NO BLAST FURNACE COREX
1 Blast furnace is single tall process vessel
where from top to bottom the following
sequential activities take place. Elimination
of both combined and un-combined water
from the raw materials, calcination of fluxes,
formation of sponge iron, sub sequentially
melting of iron and gangue material
forming liquid slag and finally
accumulation of liquid slag and metal in the hearth
for intermittent tapping of liquid.
Corex is two stage reacting vessel. Upper one
is called as reduction shaft where solid stage
metallisation takes place with the reaction of
reducing gas generated in lower vessel called
Melter Gasifier. Sponge iron (DRI) & coal is
fed to melter gasifier from top and oxygen is
blown through the tuyeres. Burning of carbon
with oxygen generates the heat required for
melting of the sponge iron and slag.
Additionally the gas generated during
combustion of carbon is utilized for reduction
purposes in the reduction shaft.
2 Uses Hot blast (pre heated air) at tuyeres. Uses 99.9% pure oxygen.
3 Uses Coke as primary reductant and gas
generation source with hot blast.
Non-Coking coal is used as reductant and the
source of gas along with oxygen.
4 Iron bearing material is used in the form of
Sinters normally, in addition of some % of
lump ore. Presently some %age of pellet
has also been introduced into the burden.
Pellets, Sinters, Lump ores can be used as
source of iron bearing material. However, use of sinter
in Corex does not provide any additional
benefit.
5 Due to the need of coke oven and sinter
plant this route is not environmental friendly when
compared to COREX.
Highly environmental friendly due to absence
of coke oven and sinter plants. The pellet used
in Corex is environmental friendly process.
6 Coke is costlier and the world reserve of
coking coal is depleting very fast.
Non coking coal is cheaper and reserve is plenty.
7 Process is less flexible and needs more
response time for the changes.
Highly flexible and very lesser time for
correcting the hot metal and slag chemistry.
8 Low calorific value off gas is generated
(about 800-1000 Kcal/Nm3) which cannot
be used unless enriched with higher
calorific value gas.
Medium calorific value off gas is generated
(about 2000 Kcal/Nm3), which can be used
for power generation, fuel gas for internal
purpose, DRI plant, fertilizer manufacturing
process etc.
9 BF can not be operated with any fines
(undersized raw material).
Significant amount of various fines can be fed
to Corex, which provides a cost saving and
pollution control as well.




- 15 -

2.RAW MATERIALS FOR COREX



2.1 Introduction

The production for Hot metal is the basis for steel making and is traditionally performed
via the route of Coke Oven Plant and Blast Furnace. An economically operated Blast Furnace
requires typically Sinter as an Iron Carrier and a basic amount of Coke.
The COREX process provides an alternative production route for the Hot Metal with
reasonable advantages compared to the Blast Furnace. Besides the economical impact due to the
possible use of a wide variety of raw materials and the environmental benefit the process
flexibility offers an enormous advantage in operating a metallurgical process.
2.2 The basic raw material required for COREX operation are classified under the
following major heads.
a. Ferrous Material (Iron Bearing)
Lump Ore
Pellets
Sinter

b. Carbonaceous Material
Coal
Coke

c. Additives
Dolomite
Limestone
Quartz

2.3 Specifications for Raw Materials
Criteria for Ferrous Material


- 16 -




Additional Criteria for Ferrous Materials












Criteria for COREX Coals



Lump Ore:
Fe
tot
Grain Size
60 % min.
6 - 32 mm
Pellets:
Fe
tot
Grain Size
60 % min.
6 - 20 mm


65 % min.
10 - 30 mm
65 % min.
8 - 16 mm

Tolerable: Preferred:
Criteria Guideline Value: Remark:


Chemical Analysis:
SiO
2
+ Al
2
O
3
max. 6 % slag operation
S max. 0.01 % S in hot metal


Static Reduction Test:
Reducibility min. 0.35 % O/min
Metallisation min. 87 % end of test
DI
-6.3
max. 15-25 % disintegration index after drum
AI
-0.5
max. 5-8 % abrasion index after drum
- 17 -





Additional Criteria for COREX Coals









2.4 Raw Materials used in different COREX Units


Coals for
Blending
Max. 12 %

0 - 50 mm
Tolerabl
Max. 12 %
max. 5 %
0 - 50 mm
> 50 % + 15 mm
< 10 % - 2 mm
< 5 % - 1 mm
Preferred
< 8 %
< 5 %
< 0.5
8 - 40 mm
d
50
: 20 - 30 mm
< 5 % - 8 mm
before dryer
after dryer
Grain
Coal or Coal-
Blends
Proximate Analysis [dry]
Fixed Carbon
Volatiles
Ash
Fixed Carbon/Ash
min. 50 %
max. 30 %
max15 %
min. 2.7
min. 55 %
max. 30 %
max. 12 %
min. 3
55 - 65 %
25 - 27 %
5 - 10 %
> 5
Moisture

Sulfur [dry]
Criteria: Guideline value: Remark:

Chlorine max. 0.04 % corrosion
Swelling Index up to 6

Thermo-mechanical Stability
+ 10 mm min. 70 % after pyrolysis
- 2 mm max. 5 %
+ 10 mm min. 25 % after NSC drum 600 rev.
- 2 mm max. 22 %
Reactivity of Char
RI max. 50 % CO
2
, 1100 C, 60 min
RSI
>5
min. 40 % + 5 mm after NSC drum


Mechanical Strength of Coal
+ 10 mm min. 70 % after Micum drum 100 rev.
- 2 mm max. 16 %
- 18 -
Coals used in POSCO Steel






Coals used in SALDANHA Steel
















South
(%)
(%)
(%)
9
6
5
0.5
Mount
1
6
5
3
0.4
Thorley Blackwater
(PCI)
Bays
Water
Coalex
1
4
5
6
0.5
Ash [dry]
C
fix
[dry]
S
total
Volatiles [dry]
(%)
2
6
3
1
3
0
Optimum
1
1
5
7
0.7
3
2
7
3
8
5
5
0.4
Ensham
8
2
7
6
5
0.4
South

Africa Australia
United
1
2
3
3
5
5
0.4
Van Dijksdrift
(%)
(%)
(%)
14
0.6
Grootegeluk
12
63
0.
8
Delmas
Ash [dry]
C [dry]
fix
S
total
Volatiles [dry]
(%) 25 25
17
57
0.9
26
61
South Africa
Optimum
1
2
5
6
0.7
3
2
- 19 -



Coals used in Jindal Steel



South Africa Australia China

D
o
u
g
l
a
s

O
p
t
i
m
u
m

G
r
o
o
t
e
g
e
l
u
k

G
u
n
n
e
d
a
h

S
B
W

S
h
e
l
l

E
n
s
h
a
m

M
e
t
r
o
p
o
l
i
t
a
n

C
e
n
t
e
n
n
i
a
l

I
l
l
a
w
a
r
a

D
a
t
o
n
g

S
h
a
n
x
i

Ash (Dry) (%) 14 12 12 11 10 12 9 11 13 10 9 9
Volatiles
(Dry) (%) 28 32 27 33 26 33 29 20 27 22 31 30
C
fix
(Dry) (%) 58 56 61 56 64 55 62 69 60 68 60 61
S
total
(%) 0.9 0.7 0.7 0.7 0.4 0.5 0.4 0.3 0.4 0.4 0.6 0.9



Ores/Pellets used in POSCO










Ores/Pellets used in JINDAL

Algarrobo CVRD
Pellets
Fe
SiO
2
Al
2
O
3
CaO
MgO
K
2
O
P
2
O
5
SO
3
(%) 65.2 65.8
(%) 2.1 2.5
(%) 0.5 0.6
(%) 2.6 2.5
(%) 0.4 0.1
(%) < 0.02 < 0.02
(%)
0.06 0.06
(%)
Mt. Newman
Lump Ore
64.3
3.0
1.0
1.3
0.1
< 0.02
0.12
< 0.02 0.02 0.01
Pellets
Peru
Pellets
65.5
3.6
0.5
0.5
0.8
0.1
0.02
0.02
Sishen
Lump Ore
66.6
3.1
1.0
0.1
0.1
0.12
< 0.1
0.02
LKAB IHG
65.6
2.1
1.5
0.1
0.0
0.02
0.01
66.3
2.0
0.3
0.3
1.6
0.04
0.06
< 0.01
0.09
Lump Ore Pellets
Sweden South Africa Brazil Chile Peru Australia India
GIIC
Pellets
66.0
1.9
0.6
1.5
0.6
0.02
0.07
0.01
Bahrain
- 20 -




Ores/Pellets used in SALDANHA










2.5 Overview and Operation Management of COREX Material Handling Section
Fe
SiO
2
Al
2
O
3
CaO
MgO
K
2
O
P
2
O
5
SO
3
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
Ramu Minerals
Lump Ore
66.2
1.5
1.1
0.2
0.1
0.00
0.07
0.01
Kariganur
Lump Ore
67.4
0.8
0.6
0.1
0.0
0.01
0.17
0.01
Mandovi
Pellets
64.7
3.1
1.9
1.1
0.1
0.02
0.09
0.01
Kudhremukh
65.1
4.1
0.5
1.0
0.1
0.01
0.01
0.00
Pellets
GIIC
Pellets
66.0
1.9
0.6
1.5
0.6
0.02
0.07
0.01
Essar
Pellets
66.1
2.6
1.4
0.8
0.1
0.02
0.07
0.01
NMDC
Lump Ore
65.4
1.3
2.2
0.1
0.1
0.02
0.10
0.02
JVSL
64.7
3.2
2.0
1.5
0.2
0.02
0.07
0.01
Pellets
India Bahrain
VMPL
Lump Ore
66.1
1.6
1.7
0.1
0.0
0.01
0.01
0.01
CVRD
DR-Grade Pellets
Fe
SiO
2
Al
2
O
3
CaO
MgO
K
2
O
P
2
O
5
SO
3
(%)
66.6
(%)
(%)
(%)
(%)
1.9
0.9
1.3
0.5
(%)
< 0.05
(%)
0.07
(%)
0.13
Sishen
Lump Ore
66.6
3.1
1.0
0.1
0.1
0.12
< 0.10
0.02
Brazil South Africa
- 21 -














Silo04
900m3
To CDP
Screened coal
Tripper Car Conv.
Silo03
900m3
Silo02
900m3
Silo01
900m3
From
Jetty
Fines
to
Yard
Screened
coal
To
stacking
Re
cl
ai
m
ed
co
Stacker Re-
claimer
ESSAR
- 22 -





Wet coal bunker

Wet coal bunker


Dedusting Bag
filter
Dus
t
silo
ID
Mixing air
Combustion air
Fuel
LPG
Pilot
Compress
ed
Perforated plate Dryer
Off
Pneumatic
Dosing
Divertor
From
Wet
Hot
Cl
ea
n
Dry Coal Conveyor
Dry Coal Conveyor
Tanke
Dry
Coal Bin
Dry
Coal Bin
Wei
gh
bin
Vibro
Wei
gh
bin
Charging
Dry Coal
From
Batching
Skip Charging
Intermediate
Feeding
Reduction
Divertor
Dry Coal
Loc Hopper
D DR RY Y C CO OA AL L H HA AN ND DL LI IN NG G
- 23 -















225
B04
250m3
225 B03
250m3
225 B02
250 m3

225 B01
250m3



265
B01
260m3
















225



225

225


From
RMHS
137F1

225






255
B02
150m3





235
B01
900m3

265B02 to 265B07
To Reduction Shaft

255




255
B01
150m
3

235

235

From mines
Fines to
bunker
To stacking
Re
cla
im
ed
m
at
eri
als
Stacker Re-claimer
MANUAL
TO COREX STOCK HOUSE
OSP
From Jetty
ESSAR
- 24 -


Theoretical Calculation for Consumption of Raw Materials

Operating
condition
Melting Rate (Full
Capacity) 106 TPH 870048 Tons/Year
Coke Rate 15 %
Furnace Operating
Period 342 Days

RAW MATERIAL RQUIREMENT
FOR
MAKING OF ONE TON OF HOT METAL

Material Specification
Bulk
Density Quantity
(in T/M3) in Tons in M3
To Reduction
Shaft
Pellet + Ore 65 % Fe 2.1 1.50 0.70
Dolomite + Lime
Stone 350 Kgs/THM 1.45 0.35 0.23
Coke to RS 100 Kgs/THM 0.65 0.1 0.15
Total 1.99 1.09

To Melter
Gassifier
Coal 0.90 0.85 1.12
Coke 0.65 0.05 0.08
Flux (Quartz) 1.5 0.025 0.01
Total 0.925 1.21

225
B03
250m
3

225
B02
250m3


225
B01
250m3

255
B02
265
B07

265 B01
260m3



235 B02
800m3



235 B01
8000m3


From
CDP
From
RMHS
TOP VIEW

225
B04
250m
3
255
B03
255
B04
255
B01
265
B06
265
B03
265
B02
265
B04
265
B05
- 25 -

3 COAL DRYING PLANT

3.1General
In Coal Drying Plant, the moisture of Coal is reduced to below 5 %. Wet coal is fed to
the Vibrating dryer and the hot gas is passed through the coal bed from the bottom. The
vibrating dryer is a perforated trough that vibrates with some amplitude and as a result
the coal moves forward. Due to passing of hot gas through the bed the heat exchange
takes place and the moisture in the coal is driven out.

3.2 Coal Drying Plant consists of the following major equipments

1. Wet Coal Bunkers.
2. Belt Weigh Feeder.
3. Coal Dryer.
4. Hot Air Generator with burner assembly.
5. Hot Gas Dedusting System.
6. Dry Coal Transport System.
7. Dedusting Dust Conveying System.
Hot Gas Generator System comprises the following
Combustion Chamber
Mixing Chamber
Flame Detector
Mixing Air Fan
Combustion Air Fan
Hot Gas Ducts

Hot Gas Dedusting System Comprises the following
Bag House
Off Gas Duct
Explosion Vent
Hot Gas Fan
Clean Gas Stack




- 26 -


3.3 SYSTEM FLOW








Bag Filter
Dust
Silo
ID
Fan
Pneumatic
Conveying line
Clean
Air Stack
Tanker
Explosion
Duct
Vent Filter
HOT GAS DEDUSTING
DP
m bar
Screw Conveyor
Rotary Air Valve
Feed Bin
Pressure
Vessel
Valves
Screw Conveyor
Rotary Air Valve
IGV
Purge
Valve
- 27 -









Mixing Air Fan
Combustion Air Fan
Fuel Gas
LPG Main
Pilot LPG
Perforated Plate Dryer
Hot gas
Wet Coal
Hot Gas Duct
Hot Gas Chamber
HOT AIR GENERATOR
C
M
3
/h
M
3
/h
Off Gas
C
M
3
/h
- 28 -

































Perforated Plate Dryer
Hot gas
Dry Coal Conveyor Mod-01

Wet Coal Bunker
Hot Gas Duct
Rod Gate
Belt Weigh Feeder
Off Gas
Swivel
Conveyor
VIBRATING DRYER
Hot Gas Chamber
Bunker
C
- 29 -

3.4 OPERATING INSTRUCTIONS

Dedusting System
Check pre-condition for the Dedusting Group Start-up.
Keep all the drive controls in Remote mode and set it to Auto
Start the Dedusting Group in Auto Mode

After the start condition is initiated

Pneumatic conveying sequence starts
After a delay the Rotary Air Valves starts
With some delay the Screw Conveyor Starts.
The Bag Filter cleaning sequence starts.
Then the Hot Gas Fan Starts
After the fan is run for 10 secs the inlet damper control is set to E1 mode with control
loop of Dryer hood pressure set to 0.005 Bar.

Burner Group

Check Pre-Condition for Burner Group Start-up.
Keep all the drive controls in Remote mode and set it to Auto.
Ensure the level of Wet Coal Bunker to be at High Limit.
Start the Burner Group in Auto Mode

After the start condition is initiated

The combustion air fan and the mixing air fan are started.
A fuel gas is selected and other fuel gas lines are closed tightly.
The purging mode is started when fuel gas is available and the air fans are running
and
the burner is in a rest status.
Combustion Air Flow is set to a set point of 2000m3/h and MAF Damper is opened
30%.
The purging mode is ON when both valves have almost reached the set points.
The purging time is 10 minutes.
When this time is elapsed the purging mode is reset and the ignition mode is started.
Combustion Air Flow is then set to a set point of 1000m3/h and MAF Damper is
- 30 -
closed.
When these conditions are reached, the ignition valves are opened.
With opened valves the ignition transformer is energized.
During the ignition supervision time (60 sec) if the pilot burner flame detector is not
healthy, the ignition mode is reset and after all valves has reached their home position
the Burner Group starts again with the purging mode.
When the ignition valves are open and the Flame detector is healthy for at least 10 sec
the ignition burner is confirmed to beON and then bleed valves closes.
After the valves are closed the Combustion Air Flow Controller is set to a set point
of
2000m3/h and MAF Damper to an output of 30%. Also Fuel Gas (COREX
Gas/CNG)
valve is set to 25% dependent if Export gas or CNG used.

DRY COAL TRANSPORT
Check pre-condition for the Dry Coal Transport Group Start-up.
Keep all the drive controls in Remote mode and set it to Auto
Start the Dry Coal Transport Group in Auto Mode
After the start condition is initiated

At first the Stock House Top conveyor 149F11 starts.
Next to this, the conveyor 149F01 (and 149F02 in case module-01 group is started)
starts along with fines conveyor 149F03.
For the Dry Coal Bins 235B01 and 235B02 Diverter Gate position is ensured.
The Dry Coal Screen starts on receiving the run feedback of 149F01.
Then after a delay of few seconds the conveyor 147F01 starts.

DRYER
Check Pre-Condition for Dryer Group Start-up.
Before start-up of Burner Group itself, keep all the drive controls in Remote mode
and
set it to Auto
Start the Dryer Group in Auto Mode
After the start condition is initiated
The Swivel conveyor starts (the position of swivel conveyor to be predetermined to
set the destination of Dry Coal).
After a delay, the Vibrating Dryer Starts.
Soon after that the Belt Weigh Feeder starts with a set feeding rate of 10 TPH.

- 31 -
After achieving the desired parameter and stabilizing the system the feed rate to be
increased to achieve the maximum output.

4. SKIP CHARGING

4.1. General
The Skip System is used to hoist the raw material up to the top of the COREX tower.
The skip systems in principal consists of the skip bucket, which is running up and down
along the skip bridge and the winch system with rope guidance as well as supervision
system for the control of the skip system.

The skip system has to control the speed at top and bottom very accurately for safety. For
the purpose of it each end positions are provided with different limit switches, which
enable to control the speed of skip in steps.
The winch system of both skip hoists are provided with hydraulically operated disk
brakes for emergency purposes. The skip motor is controlled by means of frequency
converters.

4.2. Skip Diagram

























DESCRIPTION OF LIMIT SWITCHES


FULL
EMPTY
FULL
EMPTY EMPTY
FULL
EMERGENCY STOP SAFETY STOP STOP
SLOW SPEED INCHING SPEED
INTERMEDIATE
BIN
CHARGING BIN
FEED BIN
REDUCTION SHAFT
SKIP CHARGING BIN
SKIP CHARGING BIN
FULL
EMPTY
OXIDE LINE COAL LINE
- 32 -





The Speed Control Diagram

Technical Data
DESCIPTION OXIDE COAL
CAPACITY OF BUCKET 12 M3 12 M3
WEIGHT OF BUCKET
EMPTY
FULL

12.0 TONS
35.5 TONS

09.0 TONS
18.9 TONS
TRAVEL DISTANCE 110.8 Mtrs 99.3 Mtrs
BRIDGE INCLIBATION 55.0 57.7
CYCLES 8 Cycles/Hr 12 Cycles/Hr
SPEED 1.04 Mtrs/Sec 1.52 Mtrs/Sec
SPEED AT INSPECTION 0.1 Mtrs/Sec 0.1 Mtrs/Sec
CYCLE TIME 325 Secs 250.8 Secs
ROPE DIAMETER 48 mm 35 mm
GEAR RATIO 48.75 24.98
MOTOR SPEED 0 750 RPM 0 750 RPM
DIA OF ROAD DRUM 1300 mm 1300 mm
V2
V1
V3
V1
V1
V2
V3
V1
UP DOWN
S - 580
S - 510
S - 511
S - 512
S - 513
S - 514
S - 515
S - 517
S - 581
S - 516
EMERGENCY STOP
SAFETY STOP
DUMP POSITION
FILLING POSITION
SAFETY STOP
EMERGENCY STOP
V1 : 100 rpm

V2 : 200 rpm

V3 : 900 rpm
- 33 -
ROPE FORCE 297.055 N 158.390 N


4.3. Skip Operation

PRECONDITIONS

The Skip bucket must be parked at the bottom positioned.
All safety systems must indicate healthy conditions and satisfies the interlock.
Select the local switch to remote.
The drive system (Frequency converter) must be operational and ready without any
fault indication.
Lock Hopper feeding bin is in empty condition.

START

Select skip hydraulic pump in sequence and give Start command to the group.
Select electric motor in sequence.
Select skip charging bin gate in Auto.
Select skip group in Auto.
Give Start command to the Skip Group.
If the Oxide skip starts automatically, it first runs with empty bucket when the
feeding
bin of lock hopper is empty. After this initial operation the skip is now in auto mode
ready for charging material accordingly.

STOP
Give stop command: The command is complete when the Coal skip is at bottom
parking position.
If Coal Skip trips, it can only be controlled by local operation from the skip winch
station.

START SKIP IN MANUAL (from LOCAL BOX)

This mode can be used when the skip is tripped due to any problem or the test is needed
after maintenance.
Switch local switch to local from remote.
Switch group switch to manual from Auto in CCR.
Push UP or DOWN button switch and adjust the speed by the potentiometer at
the Local Control Box.
Stop the skip in any position by pushing STOP button.

If the skip control is interrupted and the skip bucket stops at other places than at
the bottom, it is necessary to bring the skip bucket down to bottom parking
position from the local control box. This ensures that the system is investigated
properly for eliminating the reason of fault.


- 34 -




SLACK ROPE
This is the signal to detect the loosening of wire rope.

ROPE LENGTH
Signal to detect the deviation of distance between the the position of slow limit switch
and the input value of the cam switch.


































LOCAL - OFF - REMOTE

EMERGENCY
STOP
STOP
SAFETY
SLACK ROPE
ROPE LENGTH
STOP
SAFETY STOP
EMERGENCY
STOP
MOTOR AMPS SPEED MOTOR TEMP

DISTURB
UP
UP
OFF
STOP
DOWN
DOWN
EMERGENCY
STOP


SPEED
DOWN
C
%
%
SLOW
UP
UP
FAST
FAST
SLOW
SLOW
SLOW
DOWN
DOWN
FAST
SLOW
LOCAL CONTROL PANEL
- 35 -



5 LOCK HOPPER SYSTEM

5.1 General

The COREX plant is equipped with two Lock Hopper Systems to charge the Raw Material
into the pressurized reactor vessels of the plant. One system is used to charge Coal by means
of the Lock Hoppers and coal screws into the Melter Gasifier and the other one is used to
charge Ore and Additives into the Reduction Shaft through charging distributor.

In principle the Lock Hopper System comprises of the following items:

Feeding Bin
Upper Material Flap
Upper Seal Flap
Intermediate Bin
Pressurizing Valves
Depressurizing Valves
Lower Material Flap
Lower Seal Flap
Coal / Oxide Charging Bin
Charging Distributor (only for Oxide System).
5.2 Operation Principle:-

The system is generally operated in automatic mode. In this mode, the level
monitoring instruments of each bin is initiating the charging and discharging of material
in the bin and the low level in the Feeding Bin/Intermediate Bin is calling the new batch,
which is supplied by the skip charging system.

The other mode is on Manual basis, which means that the individual control of flaps
is performed on operators action from CCR.

Under normal circumstances the Lock Hopper system is operating on AUTO
mode and doesnt need any special supervision by the operator, since the program will
monitor any delay in the process steps and an alarm will be generated if the sequence is
interrupted.
As a precondition for the system the run feedback of the Lock Hopper Hydraulic System
is required. If the Lock Hopper hydraulic is not in operation, the AUTO signal will be
switched to manual and an alarm is generated.
In order to prevent the intrusion of Hot Gas from Melter Gasifier to the Coal Charging
system, Nitrogen is injected into the system to make a gas seal.
The charging distributor is meant to set the profile of the burden in the Reduction
shaft to achieve uniform gas distribution for effective and maximum reduction of the
oxides. Operator can activate the charging distributor only if the level of the shaft is
below LOW-LOW and the movement of that will be a very slow action, either inward or
outward.
- 36 -



Lock Hopper Operation


Manual-Mode

Can be selected by the operator if:

- Sequence is not running & Sequence is not in HOLD-mode
Sequence changes to MANUAL-mode if:
- Sequence is in HOLD-mode & End Step has finished (120s)
- Sequence is in HOLD-mode & Operator presses the RESET-button.

Auto-Mode
Can be selected by the operator if:
- Sequence is not running & Sequence is not in HOLD-mode
If the sequence is not running and from Manual- to Auto-Mode selected all valves will
be closed.

Hold-Mode
Sequence changes to HOLD-mode if:
- Valve or Pressure measurement fault
- Step alarm
- Operator presses the HOLD-button

Reset of Sequence
Sequence will be reset if:
- Sequence is in HOLD-mode & Operator presses the RESET-button
- Sequence is in HOLD-mode & End Step has finished (120s)
- Operator presses the STOP-button & End Step is running

5.3 START and STOP of Sequence

Start of Sequence
Sequence is started if:
- Sequence is in AUTO-mode & Operator presses the START-button

Stop of Sequence
Sequence is stopped if:
- Operator presses the STOP-button
- COREX-Process trips

In case the sequence is stopped following steps are finished and/or interrupted. Then the
sequence jumps to the End-Step, Stops and is Reset.
- Step 1 / Preconditions: interrupted
- Step 2 / Depressurize: finished
- 37 -
- Step 3 / Down charge 1 and Step 4 / Close Flaps 1: finished
- Step 5 / Prepressurize: interrupted
- Step 6 / Pressurize: interrupted
- Step 7 / Addl. Depressurize: interrupted
- Step 8 / Waiting: interrupted
- Step 9 / Down charge 2 and Step 10 / Close Flaps 2: finished
- Step 11 / Close All Valves: finished
- Step 12 / End Step: finished


Effects of Sequence-Reset

- All Depressurizing valves are closed
- All Pressurizing valves are closed
- Material and sealing flaps remain in their present position.

Effects of Sequence-Hold

- All Depressurizing valves remain in their present position
- All Pressurizing valves are closed
- Material and sealing flaps remain in their present position

Effects of COREX-Process Trip

- If the COREX-Process trips the sequence wil be stopped and the intermediate bin
depressurized, regardless whether the valves are in Manual or Auto.
- Step 1 / Preconditions
- Step 2 / Depressurize
- Step 3 / Down charge 1 and Step 4 / Close Flaps 1
- Step 5 / Prepressurize
- Step 6 / Pressurize
- Step 7 / Addl. Depressurize
- Step 8 / Waiting
- Step 9 / Down charge 2 and Step 10 / Close Flaps 2
- Step 11 / Close All Valves
- Step 12 / End Step







- 38 -

6. General Conception of Process Control

6.1 COREX Operation Control

The basic operation control is the control of gas flow rate and permeability for
reduction in the shaft furnace and the oxygen flow rate control and the heat energy
control for melting iron in- the melter gasifier. COREX process should be controlled
as following diagram of the operation management for maintaining proper reduction
rate and hot metal temperature & quality.





































Top Gas
Temp
Reduction Gas
Flow & Temp
Reductio
n Shaft
Quality of Lump
Ore / Pellets

Melter
Gasifie
Export Gas
Oxygen
Flow Rate
Hot metal &
Slag Quality
Quality of
coal & coke
Shaft Press
Drop
RS Inburden
Temp

Metalisation

Melting Rate

Dome Temp
Gas
Generation &
Quality
- 39 -




6.2 Melting Rate

Melting rate




Oxygen rate HM Quality Metallization



Coal feed rate RM Quality (coal) Shaft operation



DRI feed rate Slag Chemistry Material distribution



RM quality Fixed bed level Gas distribution



Total gas generation DRI metallization Descending rate



Dome temperature Melting rate quality & reduction gas flow


Plant pressure control

Melting rate

Melting rate is rate of melting or quantity of HM produced per hour. In case
of corex mainly it is controlled by tuyeres oxygen flow followed by DRI & Coal
feeding. But it is affected by many parameters like metallization, RM quality,
slag volume and other parameters.


COREX operation control should satisfy the basic precondition for maintaining
proper hot metal temperature of molten iron & slag and making iron with good
quality. Each character of operation control shows as following table.

- 40 -

Purpose Indication Influence Control method
1.
Reductio
n control
-Hot metal
temperatur
e and
quality
-Analysis of DRI
- In burden Temp
- Top gas
component
-Reduction gas
Flow rate and
temp
-Descending
rate
-Top gas control
valve
DRI screw rpm
Reduction gas
temp
2.
Melting
rate
control
-Hot metal
temp
Production
-Ore batch
DRI screw speed
-Reduction rate
-Hot metal
temp
-Dome temp
-Oxygen rate
-DRI screw rpm

3.Shaft
permeabil
ity
control
-Reduction
gas rate
-Uniform
gas profile
-Pressure drop in
shaft
-Size
distribution
-Ore
decrepitating
-Shaft temp
-Reduction gas
flow rate
-Descending rate
-Input Raw
material
4. Fixed
bed
control
-Hot metal
temp &
quality
Level in MG -Coal quality &
quantity
-HM Temp
-HM/ Slag
drainage.
-Dome temp
-Coal screw rpm
-Oxygen rate
-Dome temp
-System pressure
5. Dome
temp
control
-Prevent
tar
generation
-Dome temp
-Gas component
-Coal quality &
quantity
-Oxygen rate
-Gas velocity
& analysis.
-Coal and DRI
screw
-Dust burner
oxygen
-System pressure
6.Sysrtem
pressure
control
-Dome
temp
-HM temp
System pressure -Oxygen rate
-Coal quality
-Amount of gas
generation
-Excess gas
control valve
-Oxygen rate
-Coal rate
7.HM
temp
control
-HM
quality
-Liquidity
of iron &
slag
-HM temp
-Race way
brightness
-Oxygen rate
-Reduction rate
-Fixed bed
-Oxygen rate
-Melting rate
-Coke rate
8. HM
quality
control
-HM
quality
-Analysis of iron
and slag
-Fixed bed
level
-HM temp
-Additive rate
-Fixed bed level
-HM temp
- 41 -
-Reduction rate
-RM quality

6.3 Melting rate vs. oxygen consumption.
Oxygen consumption rate (sp oxygen) is normally inversely proportional to
the melting rate. Generally as the latter increases the former become lower due
to relatively reduced heat loss for emission in initial stage of restarting melting
rate usually low.
It is not advisable to run the corex with low melting rate for the prolonged
period because fuel consumption rate will increase and shaft going to be
unstable due to higher retention time of burden. Then the quality of HM getting
effected.
Similarly very high melting rate also lead to quality as well as the other
problems like DRS jamming, gas cleaning, lower Metalisation etc,. In higher
melting rate quantity and quality of the reduction gas and also retention time of
burden in shaft is a big constraint leads to lower HM temperature and more coke
requirement. So it is necessary to optimize the melting rate within boundary
considering all process parameters, raw material and system availability.


800

700


500
O2 consumption
Nm/hr



20 40 60 80 100 110
Melting rate (T/hr)
6.4 Dome Temperature Control
Dome temperature to be maintained 1000 C to 1050 C depends on the coal
volatile matter for proper devolatization and of coal CH4 % in cooling gas. Both
low dome and very high dome temp not advisable. Low dome may lead to tar
formation and chocking of ducts gap and bend jam etc, very high temperature also
Heat loss for emission- low
Metalisation- high
Heat exchange of burden- good
Heat loss for emission-high
Metalization-low
Heat exchange of burden-poor
- 42 -
will lead to coal decrepetation & refractory damage. In case the dome
temperature is reached approximately 950 deg C, the generation of Metal and
reduction gas is occurred
MR vs. Dome temperature:
As the melting rate increase dome temperature & hot metal temp will go down
because of non-metallized & un-calcinated material flow from shaft. So it is
important to watch dome temperature before increasing the melting rate.


Free energy
(kcal/mol)
-40

-20

0

20

40



1000 C Temperature

2. Indication factors
Decision factors of dome temperature control are temperature
measurements (TR0 1440-1442) and the composition of the cooling gas. If
the dome temperature is too low, the percentage of CO2 and CH4 of the
cooling gas are increased. On the contrary, if the dome is too high, the
percentage of CO of the cooling gas is increased and the quality of cooling
gas is gone badly. So it is important to maintain the normal dome
temperature.

3. Affection factors
The factors that affect the dome temperature are the feeding rate of
DRI, the reduction rate in the reduction shaft, calcinations of additives the
o2 amount of dust burner, the feeding rate of coal, the level of the fixed bed,
total gas generation and the system pressure etc, the dome temperature is
decreased as the following cases; the feeding rate of DRI is fast, the
reduction of DRI is low, the calcinations of additives are low, and the
feeding rate of coal is low. On the contrary, the dome temperature is
increased as the following cases; the o2 amount dust burner is increased and
the coal size is small.

4. The theory of the dome temperature control
If the system pressure is increased the gas flow of melter gasifier is
CO+ 3H2- CH4 + H20
2CO + 2H2 CH4 + CO2
C + 2H2 CH4
- 43 -
gone to the wall side, the velocity of the gas is decreased, the heat exchange
is improved thee dome temperature is decreased, and the temperature of the
hot metal is increased.

6.5MR vs. RS operation
Shaft condition to be checked before increasing MR. Availability of
reduction gas and quality of reduction gas is important. In the higher MR
more gas required to maintain same metallization with decreased retention
time. Also observe shaft AP in burden temperature and gas utilization

6.6 MR vs. other parameters
While starting the plant it is better to increase the tuyere O2 as quick as
possible. After dome reaches 950 C start coal feeding and also DRI
feeding. Along with DRI screw speed increases, increase the reduction gas
to shaft and also coal input proportionately. Depends on s/d duration try to
stabilize the process as quick as possible.

6.7 Plant pressure and tuyere velocity

Both parameters are inter- related and important in the quality control and
also total MG gas distribution profile as well as refractory life in long run. So
it is important to maintain the constant plant pressure and tuyere velocity. Try
to operate with 3.5 bar plant pressure and approximately 190-200 m/s of
velocity by opening and closing tuyeres with MR
1. Purpose
1) Gas distribution and tuyere oxygen velocity control in the melter gasifier
2) To prevent the formation of fluidized bed
3) To improve the efficiency of heat exchange in the melter gasifier

2. Affecting Factors
1) Quality of coal
2) Amount of charged coal and DRI
3) Amount of generation gas
4) Dome temperature
5) Gas permeability within the fixed bed, etc.
3. Actual operations
1) Control the system pressure by oxygen & tuyere Velocity
Maintain 190 -200m/sec during the normal operation.
2) If system pressure decreased, the dome temperature will be increased
But the hot metal temperature is decreased.
3) In case of the formation of fluid bed is increased and the hot metal
temperature is decreased, increase the system pressure.
4) If volatile matters of coal is increased and coal size is small,
the fluctuation of system pressure is increased.
5) If the amount of coal to the melter gasifier is increased, generator gas
- 44 -
amount is increased because of the combustion of volatiles. System
pressure is increased. Control of coal screw speed is needed according to
the amount of oxygen within the melter gasifier


Relations to other parameters
1. Amount of O2 to the tuyere- system pressure


Tuyere O2
Nm/hr





System pressure (bar)0

2. Dome temperature system pressure


3. Hot metal temperature- system pressure





- 45 -
The control of system pressure is a main factor to control the hot metal
temperature. The fluctuation of system pressure makes hot metal
temperature decrease

6.8 CG analysis

Especially CG CO2 content plays a major role in DRI metallization.
Both high and very low CO2 content is not good. So it is better to control
CO2 in the range of 5-8%
Tools like iron ore fines, specific O2 to tuyeres, dust burners O2 and
melting rate can be used for controlling the analysis.


6.9MR vs. DRI screw operations

During normal plant start DRI screw can be started from 0.8 rpm.
It is to be increased steps along with reduction gas and specific tuyere
O2. Normally screw discharge is 165 lit/rev. Calculate every day screw
discharge, because day-to-day lot of parameters discharge rate can vary
day to day. Monitor screw pressure and down pipe temperature and shaft
AP to ensure shaft condition.

6.10 Char bed level control

1. Basic concept
Fixed bed is a burden that is mixed up with DRI, additive and char. -With
going downward it is heated up by counter flow gas. If DRI heated up for
enough time, quality of hot metal becomes better. So its level has, to be
kept high as possible. In actual operation it is always sustained at the level
that is belw1m of dust burner. But it is not advisable to, control dome
temperature and other operation factor by controlling fixed bed level.

2. Fixed bed level control
1) Casting and level
As cast progress fixed bed level tends to go slow down. If slag and metal is
drained out successfully, usually down of fixed bed level is about 1 m. So in
advance of cast DRI & coal screw rpm need to be increased to maintain fixed
bed level.
2) Flow rate of oxygen through tuyere and level
Down speed of fixed bed is determined by flow rate of oxygen through
tuyere. That is, if flow rate of oxygen increase fixed bed level is going fast
down due to increasing consumption rate of char and melting rate of DRI
simultaneously. So both coal and DRI

screw speed have to be adjusted
according to flow rate of Oxygen to keep fixed bed level.
3) System pressure and level Increase of system pressure contribute
passing gas to delaying in burden. This serve as merit that quality of hot
metal can improve. But if system pressure is very high, because
- 46 -
penetration distance of oxygen is too short to form central flow, burden
becomes unstable.

4) Quality of hot metal and level Rising of fixed bed level make contact
time between material and gas longer. Accordingly both hot metal
temperature and [Si] content is higher.

3. Fixed bed level control in actual operation
1. Level control in normal and abnormal operation
Item Normal
Maximum level LRO 1602 -100 %
Minimum level
LRO-1602 0 %

In advance of plant stop increasing fixed bed level is to compensate level down
during restarting, that coal screw cannot permit to start
2.Leveller position and volume




TAP HOLE


2. If the dome temperature is too high and the hot metal temp is not so low,
increase the melting rate. But, the HM temp is low; increase the coal screw
speed considering the fixed bed level.

Leveler
position
Volume
m
Vertical
height (m)
Dust burner-
LRO 1602
109 1.2
LRO 1602-
LRO 1603
105 0.95
LRO 1603-
LRO 1604
50 0.6
LRO 1604-
LRO 1605
100 1.3
LRO 1605-
LRO 1606
105 1.8
LRO 1606-
TUYERE
LEVEL
113 2.56
LRO 1602-
Tuyere
501 12.9
D/B

LRO 1602

LRO 1604



LRO 1606


TUYERE
- 47 -
3. The purpose of the O2 injection of dust burner is to control the dome
temperature and to burn the dust inside the melter gasifier. In case the )2
amount of the dust burner is low, the following phenomenon will be
occurred.

- The amount of dust circulating in MG is increased
- Fine particles of dust is increased
- The height of fluidized bed is increased
- The efficiency of hot cyclone is decreased
- The dust loading in reduction shaft is increased
- Some trouble in the gas cleaning line is occurred
The following table shows the affecting factors of the dome temperature.

Factor Dome
temp
Factor Dome
temp
Feeding rate
of DRI
Increase Decrease Feeding
rate of
coal
Increase Decreas
e
Metalisation Low Decrease Coal
size
Small Increase
Calcination Low Decrease System
pressure
High Decrease
Dust burner O2 Decrease Decrease Fixed
bed
level
High Decrease



Fixed bed & Taping: I

Burden material load of melter gasifier in COREX is lighter than that of blast
furnace
because of the COREX furnace separated by reduction shaft and melter gasifier,
and also the behavior of molten iron in the melter gasifier is different from the
blast furnace. Molten iron of the blast furnace moves through the void of the coke
deadman in the hearth due to high burden load, but COREX molten iron moves in
the free space below the char dead man.
The shape of coke deadrnan and the existence of free space effect the
corrosion of the brick in hearth and bottom. According to tapping time, COREX
char bed moves up and down because the char bed floats on slag and melten iron.
Total burden weight of char bed can be calculated by the weight subtracted
floating force by gas from char bed weight itself, and char bed can be floated with
the balance of total burden weight of char bed and the buoyancy of slag & molten
iron.

- 48 -

(Precondition to float char bed on slag & iron)
1) Total burden weight Buoyancy: Deadman penetrated by slag and iron
2) Total burden weight = Buoyancy: Begin to float deadman on slag and iron
3) Total burden weight (Buoyancy: floating deadman on slag and iron
" Burden weight = char bed weight floating force by gas (AP)
" Total burden weight = burden weight + deadman weight
Slag buoyancy + molten iron buoyancy

2. Slag & iron behavior and tapping time
COREX char bed is floating on slag & molten iron, which cause to
move the char bed up and down as tapping time. Behavior of Slag & molten
iron is subjected to the balance of total char bed weight and the buoyancy of
slag & molten iron. Fig 10-2 shows the behavior of char bed that comes down
until the tap hole level after finishing cast. Iron & slag is continuously
generated below the char bed before cast, and the char bed moves up because
of slag buoyancy. When iron & slag start to drain, iron drains out at first as
interface of slag and metal moves up to the level higher than the tap hole level.
With Draining slag and metal, char bed moves down again. Usually char drains
out from the taphole when char bed reached on the tap hole level, and then the tap
hole should be closed. So char deadman is always penetrated by some of slag and
char bed is always floating on slag and molten iron. It is very important to control
slag, level because the characteristic of tapping effects the corrosion of the brick
in hearth and bottom and tuyere melting as the slag level reached tuyere level.



Tuyere
Char
bed


Char +
slag


Slag

Metal
Char bed


Char+ slag

Slag



Metal


Char bed



Char + slag

Slag


Metal
Char bed




Char + slag



Slag

Metal
Finish cast Begin cast Separate slag Finish cast



- 49 -


6.11 Reduction shaft Operation

The reduction rate in the shaft mainly depends on reduction gas flow and
quality. Also other things like gas distribution, pressure drop, material
descending condition etc,.

Factors affecting the reduction rate.
The ore reduction rate in the shaft should be more than 90%. Basically
reduction rate depends on reduction gas flow rate. Reduction rate increases
if reduction gas flow rate increase, and reduction rate decreases if
reduction gas flow rate decrease. But gas distribution should be even for
reduction because reduction rate could be influenced by shaft condition like
pressure drop, gas flow and material descending condition.

- Reduction gas flow rate
- Reduction gas temperature
- Material descending velocity
- Material traveling time
- Gas distribution
- Indication factor of reduction rate
- Analysis of DRI Sample
- Gas utilization
- Shaft wall temperature & vertical temperature

Flow rate control of reduction gas

Reduction gas flow is controlled by top gas control valve for ore
reduction. In case of using pellet, reduction gas flow rate should be injected
less than using lump ore because the reduction velocity of pellet is higher
than that of lump ore, and reduction flow rate is different from each pellet
and ore brand. Gas utilization decrease due to uneven gas distribution and
high dust loading which result to reduce reduction rate of same reduction
flow. Reduction gas flow should be properly maintained in the shaft
considering ore and pellet characteristic because dust content per unit
volume become high and void age decrease if reduction as flow become
excessive. To keep more than 90% reduction rate in the shaft, top gas flow
should be calculated Viand maintained for each material. Melting rate will be
increased in case of high temperature of hot=metal if top gas flow is excessive
compared with charging ore. But melting rate will be decreased in case of low.
Temperature of hot metal or top gas flow will be increased if top gas flow is
insufficient compared with charging ore.
Brig 2-1
shows the weight loss of
pellet is higher than that of lump ore during reduction, which means than
reduction rate of pellet is better than lump ore. So using lump ore needs
- 50 -
more much reduction gas to be injected to shaft than using pellet.


Reduction gas temperature control

Reduction gas is controlled by cooling gas injected to generator gas in
liner according to bustle temperature, and the temperature keeps 790-
.8500C for ore reduction. The temperature of reduction gas injecting the
shaft with 800C increase up to 880C in the shaft because of ore
reduction, and at this temperature ore reduction occur actively. If
reduction gas temperature is extremely high, material temperature increase
above 830C, which makes pellets, be clustered due to growing metal fiber
material. Clustered pellets cause to make material bridge above DRI
screw, stop revolving the screws and deteriorate gas profile. So it is very
important to keep the reduction gas temperature suitable. Especially for
using pellets, it is necessary that reduction gas flow should be low and
reduction gas temperature. keeps lower than ore.

Descending velocity and retention time of material in shaft
Descending velocity is proportioned, to retention time. In case of 90 ton/hr
of melting rate, the traveling time of material is about 8 hours in the shaft. The
longer retention time is, the better ore reduction become. Reduction rate
becomes high due to high retention time, but dust content becomes
increased and pressure drop goes up, which may cause to make uneven gas
distribution, slip and hanging. Therefore descending velocity should keep
as high as possible to shaft condition because it makes material void age
increased. Descending velocity can be adjusted by DRI screw rpm and hot
metal temperature.

Reduction rate and hot metal temperature
Reduction rate can be known by analysis of DRI sample, gas
utilization and theoretical calculation. If reduction rate drop, hot metal
temperature will be down. So reduction rate should be controlled
previously to prevent hot metal temperature decreasing abruptly.
Generally, hot metal temperature drops after 3 hours when
reduction rate decrease, and so oxygen rate or coke rate should be increased
before the temperature drops. Prior to dropping reduction rate, shaft condition
shows a phenomenon; vertical. Temperature, gas utilization and wall
temperature below bustle decrease. Most abrupt: drop of hot metal temperature
occurred in case of bad shaft condition. Specially using mixture of pellet and
ore, reduction rate dropped abruptly because of high pressure drop, slip and
hanging due to segregation of pellet
and ore.




- 51 -



Gas distribution
It is of the most important thing to distribute reduction. gas uniform
through burden to accomplish stable operation of shaft furnace as well as
melter gasifier. From this, pellet can be reduced well to and additive be
calcinated. To achieve even gas flow, minimum size, size distribution and
reductive degradation properties of pellet has been controlled. can be judged
how gas distribution is going by pressure drop, temperature variation,
abnormal descending of burden and utilization of reduction gas .

Gas distribution control

Small particle regulation and size distribution control:
Because larger particle guarantee gas to flow well through burden, input of
small particle has to be regulated. The smaller particle is, the worse
permeability is even if size distribution of particle is harrow and shape is regular.
Generally resistance to gas flow increase greatly as particle size decrease below
13 mm.. Also permeability is effected by the range of particle sizes. By
keeping the range of particle sizes to a minimurn
permeability increase.

Degradation control of particle:
Iron ore and pallet are inclined to degrade during heating and reducing.
Specially pellet tends to swell at its maximum around 850 C to degradate
early; Small particle generated from degradation is accumulated into pore and
block the way of gas. If dust is accumulated in particular parts, dust stack is
accelerated and gas flow is deviated. It can be caught in observing vertical or
horizontal temperature deviation and pressure drop of burden in shaft furnace.
To avoid this problem, select iron ore or pellet that cam endure degradation
from heating and reduction. Also samples have to taken to be analyzed
periodically.

Dust control of reduction gas:
COREX reducing gas contains considerable dust generated from coal
pyrolysis and pellet reduction. Most of them is captured and eliminated in hot
cyclone but some is in flowed into shaft furnace and accumulated. In case that
hot cyclone system is run in abnormal operation and input of dust into shaft
furnace become to increase, condition of shaft furnace such as gas distribution,
deviation of temperature and so on should be checked from time to time. If
abnormal operation may prolong,, it has better be run after being resolving the
problem.


- 52 -
Gas distribution control in actual operation:

It can be judged whether gas distribution is uniform or no uniform by total
pressure drop of burden. Total pressure drop of burden become to increase
steadily with the gas velocity on condition that other operation factor is fixed.
The following figure show relationship between bounds of pressure drop and
top gas flow rate in normal operation. Also Gas distribution has been
controlled monitoring the differential pressure across the shaft. When pressure
drop exceed critical value, slip and hanging appear. It happens when material
is sticky and degraded, dead man grows up, bustle port is blocked and gas flow
is deviated severely.


6.12 Hot metal temperature control.

The purposes of hot metal temperature control are first, to ensure proper
behavior of melts (slag & hot metal) inside melter and during tapping to
achieve dry operation of melter gasifier. Second, to obtain target hot metal
quality which influences down-stream process. Especially, silicon content and
sulfur content in hot metal are strongly influenced by hot metal temperature.

The key point of hot metal temperature control is to keep target hot
metal temperature stably using several control measures. The most
influencing factor is metallization degree, which is directly related to the
shaft performance. Every indicating and controlling parameter has their
own response time according to the melting rate.


Main affecting factors Metallization (or reduction)/ degree of DRI:

Iron oxide is reduced by two step reduction path. The first step is
indirect reduction by gas I solid reaction which is exothermic and mainly
occurs in reduction shaft. The second step is direct reduction by liquid I
solid reaction which is highly endothermic and occurs during / after
melting of DRI. Therefore, the target of COREX Operation should be
maximizing indirect reduction in the reduction shaft and minimizing
direct reduction in the melter gasifier. If low metallized DRl is fed to
melter gasifier, then heat level is decreased and fixed bed is deteriated
(char consumption increase, fixed bed level decrease, char particle size
decrease, gas & liquid permeability decrease) due to highly endothermic
nature of direct reduction, in real operation, metallization degree itself is not
referred by operator because analysis results can not cope with control
actions. However, factors which affect Metalisation degree, for example top
gas flow rate, top gas composition, cooling gas composition, in-burden
temperature, horizontal gas temperature distribution, shaft temperature shaft
delta pressure, are continuously evaluated to counter measure low
metallization.
- 53 -

.6.13 Melting rate and oxygen flow to tuyere
The only heat source to MG is combustion of oxygen at tuyeres front and
dust burners. Oxygen flow to tuyere is increased but specific O2 flow is
decreased, as melting rate is increased. HM temp is promptly controlled by O2
flow.
3.Response time
A) Indicating parameter


































Factor Response
time
1
st
affecting
factor
1 In burden temperature 7-8 Metalisation
2 Down pipe temperature 4-6 Melting rate
3 Slip and hanging 6-10 Penetration of
gas
4 C/G CO2 CH4 4-6 Dome
temperature
5 CO of top gas 8-10 Distribution of
gas
6 Basicity 2-3 Change the
retention time
7 Brightness of tuyere 2-3 Change hot
metal temp
8 Dome temp 3-4 CG Analysis
9 Fixed bed level 3-4 -
HM temp (comparison
with last tap)
0-1 Change HM
temp
- 54 -
B) Controlled Parameter.

Factor Response
time in
hrs
Check place
1 Amount of tuyere
O2
2-3 FRC8001
2 DRI feed rate 4-5 DRI screw rpm
3 Coke ratio 4-5 Weighing time
4 Feeding rate of coal 4-5 Coal screw pin
5 Amount of reduction
gas
7-8 FRC 2001
6 Specification of coal 4-5 Mixing bin (sampling)
7 Specification of
pellet
12-15 Raw material handling
8 Velocity of tuyere
O2
2-4 Monitor
9 System pressure 2-4 PRC 2003


6.14 Quality control of hot metal

HM quality means maintaining HM temperature and chemical composition
(mainly C, Si, S,P etc,) as per the required standard.
Carbon & Silicon have generally co-relation with HM temperature and
retention time. So they can be controlled by proper HM temperature (i.e. also
coke rate) ,certain height of fixed bed and melting rate
Sulphur can be controlled by slag volume & basicity based on input raw
material composition. Very high acidic or basic slag are not advisable. It is
better to maintain Basicity (CaO/SiO2) in the range of 1.10.
Si content in HM normally increase dramatically after restarting the furnace
after shutdown due to longer retention time.
P and Mn content of HM can be only controlled by input raw materials. 98%of
the total P2O5 gas to hot metal.









- 55 -
7. Process Gas Systems

























Total gas generated in Melter Gasifier (MG) is having four outlets for carrying the gas which are
called Generator Gas ducts (GGD).

These Generator Gas ducts (GGD) are connected to a hot gas cyclone (HGC) for cleaning the
dust carried along with the gas. The dust settled in the cyclone is further taken to a Dust bin which is
located below the Cyclone and is injected in to the Melter Gasifier through a Dust Burner with
Nitrogen as Injecting media and Burnt with Oxygen. The process of this dust separation in HGC
and burning in the MG again is called Dust recycling system which makes the Corex process
environment friendly.

The Major composition of gas generated in MG:

%
CO : 65-70
CO
2
: 05-08
H
2
: 20-25
CH
4
: 1 - 2

The generated gas from MG is coming out at around 1050 Deg C and which is controlled to a
range of 850 Deg C for Reducing and Calcination of Additives. Control of this temperature is done
by adding the cooling gas in to the GGD through Temperature control valves which is called cooling
Gas addition.
Gas
Holder
PDC 2212
H/C
Ore
Coal
Melter
Gasifier
Shaft
Excess gas line
C/G Compressor
Top Gas
Line
FRC2001
SOV2940
Export
gas
PRC2210
Sludge
PDC-2207
PDC-2208
Sludge Sludge
Sludge
Sludge
PRC2203
- 56 -

The clean gas that is coming from the cyclone is taken through Bustle of the Reduction shaft
for reducing the Iron Oxide and Calcination of the Additives that are charged in Reduction Shaft,
which is called Reducing Gas.


As shown in the schematic, the clean gas of from the outlet of HGC is taken in to the
Reduction shaft bustle, through a Top gas flow control valve FRC2001. The amount of flow through
the RS is depending upon the conditions and movement of Reduction shaft, which is generally 1050-
1120 m3/hr/ ton of oxide charge.

The gas that is coming out from the RS is called Top gas that is at around 280 -300 deg c and
the major composition of the gas is follows



Top gas composition:

%
CO : 40-45
CO
2
: 30-35
H
2
: 15-20
CH
4
: 1-1.5

The top gas is further passing through a packing scrubber for cooling and cleaning the gas.

As shown, the gas which not passing through RS is taken via a packing scrubber which is called
Cooling gas Packing scrubber which is having two outlets i.e. Excess Gas scrubber and Cooling Gas
venturi scrubber.

Excess gas scrubber is controlling Plant pressure through its two hydraulic actuators DN 400 &
DN 800. Plant pressure is controlled always to maintain fixed velocity at the exit of the tuyeres.

Top gas and excess gas after gas cleaning are connected to a gas network for the gas
consumers. Gas network is controlled by the level in the gasholder and unused gas is flared as shown
through a pressure control valve PRC 2210.

The cooling gas venturi is connected to a Compressor which can boost the pressure by about 1 bar
for cooling gas addition to GGD.










- 57 -



HOT GAS CYCLONE
N
2
INJECTOR
LOWER DUSTBIN
DISC GATE
DUST BURNER
MG
O2 TO TUYERS
RS
GENATOR GAS DUCT
COOLING GAS ADDITION



The hot generator gas, leaving the Melter gasifier is connected to a the refractory lined hot gas
cyclone where in the dust particles settle down due to loss in momentum before entering the
reduction furnace.

The dedusting takes place in the upper part of the hot gas cyclone where the vortex tube is installed.
In the lower part of the hot gas cyclone the dust is collected. To prevent the back stream of collected
dust to the upper part a displacement cone (Chinese cap) is installed between upper and lower part of
the hot gas cyclone.

The hot dust is transferred via the refractory lined lower dustbin to the dust burner, which is installed
in the Melter gasifier.
Purge plugs are installed in the cones of hot gas cyclone and lower dust bins for fluidization
purposes.

The hot dust, collected in lower dustbins is transported by means of nitrogen to the dust burners and
burnt in the Melter gasifier using oxygen.
The combustion takes place in front of the dust burners.

Both HGC and LDB are provided with Nucleonic level sources for measuring the level in individual
vessels

7.1 DUST RECYCLING
SYSTEM
- 58 -
Grids are installed in the lower part of the hot gas cyclone and in the lower dustbin to safeguard the
adjacent built in equipment against coarse particles.

Dust shut-off valves are installed below hot gas cyclones and below the lower dustbins.
During normal operation of the COREX plant they are in open position and only used for
maintenance purposes to block the dust flow.

Knife Edge gate valve (KGV) is installed at the emergency discharge nozzles of the hot gas
cyclones, the Lower dustbins, and below the T-piece of the dust recycling line.

During normal operation of COREX- plant they are in closed position and only used to empty the
dust recycling systems for maintenance purposes
The dust burner is continuously cooled with water which is circulating from critical cooling water
system (Closed Loop) and normal flow of circulation is 30m3/hr for each burner at 9 bar pressure.

Nitrogen injection flow through the dust burner is normally in range of 250 -350m3/hr and oxygen
flow through the burner can be varied from 500 -4500 m3/hr which is tool to control the Dome
temperature.



Dust Analysis:
C approx 60 %
S approx 1 %
Fe approx 20 %
Gangue approx 19 %


























- 59 -
7.3 Gas cleaning systems:

REDUCTION
SHAFT
TGPS
TGVS
TGME
TOP GAS DUCT
TOP GAS
FLOW CONTROLLER
WATER SEAL TANK
CLARIFIER
CLARIFIER
TOP GAS SYSTEM
TOP GAS
PACKING
SCRUBBER
TOP GAS
VENTURI
SCRUBBER
TOP GAS
MIST
ELIMINAOR



The gas leaving the Reduction shaft that is called Top gas dust laden gas with temperature in range
of 280-300 deg C normally. So this Gas requires both cleaning and cooling for which it passes
through a top gas-packing scrubber.

First the incoming gas to the scrubber is quenched in pre scrubber and then further it is cleaned in
top gas wooden packing scrubber consisting of Adjustable venturi scrubber, mist eliminator, water
separator, water level control tank as shown in the above graphic.

The differential pressure across the venturi scrubber is set and controlled through the shown
Adjustable venturi scrubber.

The top gas pre scrubber, packing scrubber and venturi scrubber are continuously circulated with
process water as described in Process water systems





DP
2
- 60 -



7.3 COOLING GAS SYSTEM




CGPS
CLARIFIER
CGVS
CGME
EXVS
EXME
EXCESS GAS
WATER SEAL TANK
CLARIFIER
COOLING GAS
COOLING GAS COMPRESSOR
CGPS CONE
PRC2210
FLARE
STACK
FRC2001
PRC2222
SOV2940
GV
SHV
Cooling Gas Addition to GGD
EXPORT
GAS
BAUMCO SCRUBBER
PACKING SCRUBBER
VENTURI
MIST ELIMINATOR
TOP GAS

The gas which is not taken to the RS is directed to the Cooling packing scrubber which is
first quenched in Pre scrubber and enters the packing scrubber. The differential across the packing
scrubber is controlled through Baumco scrubber Cooling packing scrubber has two outlets as shown
i.e. excess gas and cooling gas in which the differential pressure is controlled through its respective
adjustable venturi.


The Cooling packing gas pre scrubber, packing scrubber, Excess & Cooling venturi scrubber are
continuously circulated with process water as described in Process water systems
- 61 -




Cooling gas compressor is a Lobe type positive displacement compressor which is used to control
the temperature of the Gas leaving the MG to a range of 850 deg c.

The inlet to the compressor is connected from cooling gas venturi and the compressor can boost the
pressure by about 0.9 bars.

There are two compressors provided for each module among which one is stand by and one is
running. Each compressor is provided with separate lubrication system for both Gearbox and
Compressor.

Stand by compressor is always kept running with its slow speed drive so that there is no dust
accumulation on the lobes.

Pre conditions for Compressor start:
- Both compressor and Gear box lubrication systems are running in order
PDC2213
TDC2419
Inlet Valve Discharge valve
Silencer
Compressor
HIC
T2
DT=T2-T1
T1
CG addition to GGD
From CG PS
7.4 Cooling Gas compressor

- 62 -
- All the drives and position of valves are healthy
- Process cooling water system is running in order
- Machine cooling water system (non critical ) should be running in order
- Inlet pressure to the compressor should not be Low low



Control of the Compressor:

During the start of the compressor to avoid the excess load on the compressor, one Control valve
(HIC) is provided which bypasses the discharge back to the inlet f the compressor and it closes after
opening the normal discharge valve.

The discharge of the compressor is cooling the gas coming out from MG, which is temperature
controlled and hence cooling gas flow to GGD is not constant. But the compressor being fixed
displacement type, it is required to control the Pressure differential across the Compressor and a
control valve is provided (PDC2213) which diverts the discharge back to cooling gas venturi.

Temperature differential control (TDC2419):

It is desired to avoid any condensate water that could hamper the compressor and hence a control
valve is provided to maintain the differential temperature of the gas entering the compressor. The
temperature measurement is just after cooling gas venturi and before entering the inlet silencer of the
compressor. Normal temperature differential between these two points is 5 deg C. Part of the gas
from the discharge of the compressor is used through TDC2419 for this control.

Vibration control:

Vibration of the compressor is online monitored in both axial and radial directions which should be
-8 mm / sec. These vibrations could be because of two reasons basically. One is due to the
unbalanced lobes due to accumulation of dust and second one is due to any loosened Foundation
bolts etc.
The vibrations due to the first reason i.e. unbalanced lobes can be controlled with the given ethanol
injection on to the lobes which brings down the vibrations significantly. Normally each start and
stop of the compressor is accompanied by the ethanol injection and it can be injected in between
when ever the vibration goes high.


Cooling gas addition to GGD:

As described in introduction of the gas systems, the gas leaving the MG is at around 1050 deg C
which needs to be controlled to a range of 850 deg c and this is done by adding cool gas through a
temperature control valve in each generator gas line (TRC 2411- 2414). The pre conditions for the
addition is running of cooling gas compressor and discharge pressure of the compressor is more than
the plant pressure at least by 0.1 bar.
Failure of the cooling gas addition due to any reason makes nitrogen valve to open till the gas
addition resumes. The scheme of addition to GGD is shown here for one line, which is similar to the
other three lines.
- 63 -











































MG
N
2

N
2

Cooling gas addition
SOV TRC
Generator gas Duct
- 64 -

8. PLANT START AND STOP PROCEDURES

8.1 PLANT STRT:

1. Check the preconditions: Before start, confirm the below mentioned items
a. Check the dedusting systems including pneumatic dust transporting systems
b. Check the charging systems of raw materials
c. Check the coal drying facilities
d. Check the conditions of all water treatment system
e. Check the gas analyzer of C/G &T/G
f. Check the all hydraulic pumps for lock hopper, scrubbers, skips etc,.
g. Check the depressurizing and equalizing systems of lock hoppers
h. Check if the tap holes and facilities of the cast house are ready for tapping
i. Check the preconditions of cooling gas compressor (hydraulic pumps should be
operated in advance)
j. Check the impulse lines of instrument system at the site and output signal for each
automatic valve in monitor
k. Check the supply pressure of O2 and N2 (including N2 for instrument) for
main: 110.5kg/cm
l. Check if the labyrinth part of each DRI & coal screw is supplied with a certain
amount of nitrogen through each FIO line
m. Do the poking works to each tuyere

2. Plant leakage test
a. Open all tower shut down hand valves labyrinth N2 for screws etc,.
b. Ignite the burners for the flare stack
c. Announce the start of nitrogen system to )2 plant
d. Set the differential pressure valve for each gas scrubber for cleaning gas
generating from the MG
e. Set the system pressure by using of PRC 2211 and close the FRC-2001
f. Open all hand valves for supplying O2 and close all branch valves of N2 tuyeres
g. Set 6000 Nm/hr for FRC-3020 to check the poked condition of tuyeres
h. After checking N2 flow of each tuyere, reduce N2 flow to 3600 NM/hr in order
to perform the leak test of plant.
i. Do the leak check over each maintenance parts when the system pressure is reached
to 1 kg/cm

3. Plant purge & Start CGC.
a. Pressurize and depressurize the system repeatly until the O2 density of C/G is
decreased below 0.5%.
b.
Start the C/G compressor.




- 65 -
4. OXYGEN START:

1. Check the interlocking for O2 start
b. Select O2 / N2 group switch on CRT and set it ON
If the plant is started successfully.
O2 flow The rate of tuyere is set to 22000 Nm3/hr
System pressure is set to 1.2 kg/cm3
The controller for system pressure is changed to PRC-2202 from PRC-2211
Check the set value of FRC 3020 is 6300NM3/hr with open SOV-3920
Check that SOV-8906 is closed
Check that the out put value of FRC-8001 is 20% as a preset value.
Check the sequence that the SOV 8901 is opened when the N2 flow of FRC 3020 is
reached at 5000nm3/hr and 1 second later SOV8900 is opened
Check the sequence that SOV3920 is closed when the FRC 8001 reached at
8000nm3/hr, and manual output of FRC3020 is forced to100%.
10 seconds later, check the set point of FRC 8001 is set to 22000nm3/hr.
c. Check the combustion status of char in front of tuyere and the O2 flow rate of each
tuyere on the CRT.
d. Check that the densities of CO & H2 in cooling gas is increasing and gas
combustion status of the flare stack
e. Check the supplying condition of cooling gas to gas inliners and down pipes.
f. Increase the O2 amount as 1000nm3/5 minute up to 26000 nm3/hr in
steps.
g. Start dust burner
h. Start an upper coal screw and set the speed of it to 4 rpm.
i. Start DRI screws after starting coal screw.

j. Take the gas in the reduction shaft for reduction work
k. Take the gas in the gas holder


5. adjust the system parameters and production rate
a. Adjust the speed of melting rate according to the time of shut down and plant
conditions
b. Decide the amount of quartz by the material charging calculation according to
melting rate
c. Adjust the set point values for controlling the bustle temperatures and down pipes.
d. First tapping
-Do the first tapping when the total charging amount of ore is accumulated
approximately 200 ton.





- 66 -
8.2 PLANT STOP PROCEDURE:

3 Hours before stop:
Inform to all relative departments. (O2 plant, Power plant, Energy Center, all gas
consumers, LRS, SMP & PPC etc.)
Fixed Bed (LRO 1602) should be kept in full level. Increase the speed of the coal screw
gradually 3 hours earlier before the stop of the plant.(depends on level).
Increase coke rate & reduce ore fines depends on shutdown duration.

2 Hours before stop:
Decrease the melting rate Decrease the DRI screw speed in step of 0.1 rpm/10 minutes up
to 1.0 rpm and reduce the top gas flow rate according to ore changing amount. While
reducing the top gas flow reduce SP to TGVS (PDC2208 also)
Decrease the O2 amount in step 1000 Nm/10 min and make O2 amount 29000 Nm/hr for
FRC 8001 1/2 hour before the stop of the plant, accordingly reduce coal screw speed also.

1 Hours before stop:
Open last tapping before stop.
Empty all dust recycling lines (Hot cyclone, Lower dust bin).
Decrease the Bustle Temperature -Decrease the set point of TRC2411-2414 by 10/15 min
to 800 deg.
Adjust melting rate and each process parameters - Decrease the DRI screw rpm by 0.1 up
to 0.8 rpm - Decrease the O2 amount by 1000 Nm/ 10 min and 15 min before the stop of the
plant, let the amount of O2 be 26000 Nm/hr for tuyere side.
Reduce the speed of the coal screw in order to decrease tar formation (In this case, careful
operation is needed to prevent the level loss of fixed bed)
10 minutes before stop:
coal & ore feeding and intermediate bins are empty.
The plant is ready for stop The total gas flow through the reduction shaft should be
reduced up to 30000Nm/hr in steps.
Adjust the amount of O2 flow for each dust burner according to the dome temperature.
Reduce the speed of the coal screw up to 4.0 rpm.
- 67 -
Confirm quality of hot metal, HM temp & tuyere condition.
Stop the Plant Stop by Selecting the O2/N2 Group on CRT and initiate the stop signal of the
plant. The stop command closes the oxygen to tuyeres & dust burners- 22000 Nm3/hr nitrogen
enters in to tuyeres
Also Depressurizing valves for coal and ore lock hoppers opens.
System pressure: Auto SP to1.2 Bar.
Coal and all DRI screws: stop.
15 minutes after the plant stop:
-N2 flow rate via FRC3020 is changed to 12,000Nm/h from 22,000Nm/hr (in integral
steps of 1000 m3/min).
30 minutes after the plant stop:
Decrease the system pressure up to 0.7 kg/cm.
FRC3020: 120005, 000 Nm/hr (in integral steps of 500 m3/min).
Purge the plant with 0.4 to 0.7 Bar pressure. Adjust all venturi scrubber SP.
45 minutes after the plant stop:
Decrease the system pressure up to 0.2 bar. If the sum of the inflammable gas wouldnt go down
below 10%, repeat the pressurizing & depressurizing.
Stop cooling gas compressor.
Give clearance for opening alternate bolts in the system.
Close all shutdown valves except +19 meter ramping nitrogen.
60 minutes after the plant stop:
Close N2 all shut off valves for dust recycling systems on the CRT
Keep minimum nitrogen to tuyere (~ 300 Nm3/hr)
Depressurize so that the system pressure may be zero.
Open the following valves fully to maintain the draft (negative press) toward the flare stack
valves, Baumco, DN 800 & DN 400 line SOVs & cones.

- 68 -
75 minutes after the plant stop:

After getting small draft close ramping nitrogen slowly & close hand valve also.
Close LP shut off valve in PB-3.

Announce the completion of the plant purge after getting negative pressure & all shut
down valves closed. Start giving clearance to maintenance jobs as per schedule.


9. REFRACTORY FOR COREX

Steel industry is the major consuming industry of refractories in any country. It is well
known that 70-75% of the total refractories produced in any country are consumed by the Iron and
Steel industry. It is therefore, essential that the refractory industry should respond and also meet
the requirement of the changing demands of Steel industry particularly in terms of quality and
then quantity. So, the development and growth of both Steel and Refractory industries are
somewhat inter dependent.

The quality of refractories produced in the country, the installation and maintenance
techniques and operating practices of the various units of Indian Steel industry needs to be
upgraded to improve the refractory practice in our country. This paper deals with the various
refractory practices for different units for steel making like Corex, Blast Furnace, LD converter,
Secondary Metallurgic units like LHF, Continuous Casting.

COREX: Present day Steel industrys demand to produce steel at lower cost and through
environmental friendly process. Worlds industrially Proven Smelting Reduction Process COREX
allows flexible, cost efficient and environment friendly production of Hot Metal.

Corex technology is based on physical separation of Reduction and melting Process, which are
carried out in two main reactors. There are:

1. Melter Gasifier
2. Reduction Shaft

Beside above units, there are other areas where refractories are used like DRI Conveying System,
Gas Circulation and Dust Recycling and Cast House where sufficient quantity of refractories are
used. Here we will give main units description and the quality of refractories used

1. Reduction Shaft: Here in the reduction, the main activities occur are
(a) Reduction of Iron Carriers
(b) Calcination of Limestone or Dolomite

Here mostly 45% dense Al
2
O
3
bricks are used which are procured indigenously. In the Bustle
area special shape in silicon carbide burled bricks are used. The main aspect for using these brick
is its stability. Dome portion refractory is done by gunning with 55-60 Al
2
O
3
mass.

9.1 Melter Gasifier (MG): Here the following function takes place:
- 69 -

- Drying and volatisation of coal
- Generation of reduction gases
- Final reduction of Iron carriers
- Melting of DRI (sponge Iron) and
- Generation of liquid Hot Metal & slag

This is the only unit where refractories are exposed to various severe thermal shocks. To take care
of these conditions, the following quality of bricks is selected in different zone in the MG.

1. Hearth Bottom: This is similar to BF lining. Bottom most area is of two layer and graphite
blocks. Above this, three layers of carbon blocks and above it mullte bricks are used on two
Courses. Outer most side of the Hearth wall up to tuyere zone are Micro Porous carbon blocks.
The use of micro pore carbon blocks will limit the attack of alkali, Zn, CO and iron penetration.
By adding metallic silicon and pure Al
2
O
3
to the carbon mix as additives, will give reduced pore
size to the bricks. A carbon ramming mass is provided between water-cooled staves and carbon
blocks.


To safe guard the hearth pad, ceramic cup lining is recently is introduced in furnaces like Blast
Furnaces as well as corex hearths.


Requirement of the Ceramic Cup brick:
- High resistance to corrosion and corrosion by Iron and Slag
- Dimensional stability (PLC at 1000
0
C should be zero)
- Resistance to Alkali vapors and CO corrosion
- Ability to accommodate thermo-mechanical stress
Hence, high quality SIALON bonded corundum bricks of special shape are used at the inner
walls. Special inter locking pattern arrangement is done to take care of complete stability for
lining.

- Tuyere zone refractories: In this area of furnace, oxidation from leaking tuyeres and
abrasion from swirling coal and coke at the edge of the raceway are the principal attack
mechanism. Temperatures are highest in this part of the furnace. Hence high conductive
refractories with excellent thermal shock resistance like sialon bond corundum bricks are used in
the area.


- Char bed Zone: This has generally proved to be the critical area of the furnace other than the
hearth. It is at the top of the cohesive zone where liquids are beginning to form. Temperatures are
high, reduction reactions are still occurring and slag formation is just begins here. High thermal
conductivity nitride silicon carbide bricks are best suited for this zone. Silicon carbide-ramming
mass is used to fill the gap between water-cooled staves and refractory.

- Calming Zone: Temperature in this zone is lowest but the burden materials are abrasive. In
addition carbon monoxide will tend to attack the refractories. High Alumina corundum base
SIALON bonded bricks are preferred in this zone. The working layer in backed up by insulation
layer.
- 70 -

- Dome Area: This area is called gaseous free board zone also. Due to the continuous gas flow,
the transition area between free board zone and char bed zone is fluidized.
Gunning twin layers does entire lining of dome zone. The first is insulation and the working
lining is done by 60% Al2O3 gunning mass. Proper metallic and ceramic anchors are welded in
site to have the stability to the gunning material, which is to be done in panels of 1.5 Mt x 1 Mt.

A protection lining is given all through the side wall starting from ceramic cup to calming zone to
avoid initial thermal shocks to the main working lining.



9.2 Cast House:

The refractories used in the cast house are primarily high Alumina or alumina-silcate based,
since the basicity of slag is around the neutral region (varies from 0.95-1.1). In the cast house
trough, the refractory has to offer multiple aspects of resistance. First, the refractory has to be
strong to resist the weight of molten iron and slag; secondly, it has to resist the effect of
continuous flow of iron and slag and above all the erosive / corrosive action of the slag and
slag/iron. In cast house troughs, most wear takes place at the iron/slag interface followed by the
slag area. The lining below the iron level is the least affected zone. In the sag area, the refractory
is exposed to the chemical and mechanical effect of the molten slag. Since the choice of refractory
is compatible with the slag chemistry, the erosion is not severe in the slag zone alone. The most
refractory wear is visible in the slag/iron interface. There are multiple reasons for the refractory
wear in this region. First, the slag being in contact with the molten iron is at its highest
temperature. Secondly, at the interface there is a partial oxidation of the iron into FeO, which is
highly corrosive. Thirdly, the refractory erodes both from chemical attack by the slag at the
slag/metal interface along with the mechanical erosion from the continuous flow of slag and
slag/iron along the lining; thus exposing new surface of the refractories.

The refractory composition in this area has to satisfy the above criteria. The composition of
refractories in the trough is based on Alumina as base material to provide resistance to high
temperature, silicon carbide addition to provide the corrosive / erosion resistance and some
amount of carbon (as graphite) to provide non-wetting characteristics. Since the development of
low and ultra-low cement castables (LCC and ULCC), LCC and ULCC have been preferred as the
cast house refractories, which replaced the earlier use of resin or pitch-bonded ramming mixes.
The major advantage of ULCC is its ability to be repaired by recasting the lining at regular
intervals until the lining becomes weak due to the oxidation of the carbon in the unaffected area of
the lining. Since the development of sol-gel based castables in the early 90s, the use of monolithic
refractories has taken a new direction. The change in the bonding system from high Alumina
cement to colloidal silica provide not only a number of significant advantages, but also a newer
application method, namely by pumping.

There are several advantages of sol-gel-based castables / pumpables over low-cement
castables which are as follows:
(a) By nature the gel-bond castable has self-flow characteristics, it is easier to cast either by
gravity or by a pump.
(b) Due to the absence of minor ingredients in the mix (such as deffloculants and dispersants), the
mixing time is shorter resulting in less time for casting
- 71 -
(c) The high temperature bond from sol-gel bonding being mullite, the refractoriness of the gel-
bond castables is much higher than of LCC, which forms less refractory compounds such as,
anorthite/gehlenite
(d) Due to the nature of the bonding, the sol-gel bonded castable has much superior thermal shock
resistance resulting in less cracks in linings
(e) Since the sol-gel bonding provides a coating on the carbon particles, the gel-bond castables
also provide better oxidation resistance
(f) The hot strength of sol-gel bonded castables are much higher (hot modulus of rupture @
1500
0
C) than that of LCC or ULCC
(g) Due to less oxidation of the carbonaceous materials and better thermal shock resistance, the
lining life of sol-gel base castables are longer than that of LCC or ULCC

Tables 1 and 2 show the chemical and physical properties of LCC and sol-gel based castables used
in Corex cast house troughs. It may be noted that at 14000C the LCC forms a glassy phase
primarily consisting of anorthite and gehlenite. This provides a better compressive strength.
Whereas in the sol-gel bonding, the high temperature phase is mullite which provides better MOR
and not high CCS.

Table I: Chemical compositions of ULCC and gel-bond castables for blast furnace trough

Compositio
n (%)
ULCC Gel-bonded
Al
2
O
3

SiO
2

TiO
2

Fe
2
O
3

SiC
CaO
68 - 70
8 - 9
1.5 - 2.0
0.4 - 0.6
19 - 21
0.4 - 0.5
72 73
7.4 7.8
1.4 1.6
1.0 1.2
17.0 18.0
--


Table II: A physical property of blast furnace trough castable/pumpable mixes


Properties ULCC Gel-bonded
Bulk density
(kg.m
3
)/porosity (%)
after heating at
110
0
C
815
0
C
1400
0
C


2805/15.6
2740/19.7
2740/18.5


2915/14.3
2835/17.2
2805/18.4
Cold crushing strength
(MPa) after heating at
110
0
C
815
0
C
1400
0
C


8.9
11.7
48.2


21.8
53.1
43.3
Cold modulus of
rupture (MPa) after
heating at


2.1


4.0
- 72 -
110
0
C
815
0
C
1400
0
C
2.4
11.7
8.3
9.6
HMOR (MPa) at
1400
0
C (in N
2
atm)
2.2 3.8




10 SUPPORTING SYSTEM FOR FAILURE

10.1 POWER FAILURE

THE ACTION GUIDE LINES IN POWER FAILURE:

1.Confirm the power failure of the plant.

2. Confirm the O2 cutoff and N2 injection to tuyeres (N2: 22000 Nm/h)

3.Confirm the following valves are operated to power failure positions
- All venturies full open.
- All valves in excess gas line open.
- Flare valve open.
- Plant pressure auto SP 1.2 Bar & ensure pressure is coming down.
- All shutoff valves in gas system for coal dryers: close
- All LRC valves of scrubber water system close.
- All water flow control valves for scrubbers close.

- Confirm whether the HIC valves for MCW and stave cooling water system are open
fully and adjust these valves in few steps depends on levels of head tanks and the temperature
of the return water.
- Confirm the emergency generator is running, if not, make it start in manual and make the
loads start in regular order.

- The following emergency pumps (hard wired pumps> have to be run quickly:
1) Inlet cone pumps (2).
2) Gland water pump (1).
3) Stave pump (1).
4) MCW critical pump (1).
5) MCW non-critical pump (1).
6) Start both clarifier rakes from field.
7) Start + 0 meter & venturi Hydraulic pumps.
8) Ensure power for tilting runner.

4. If the tapping is in progress, this shall be kept under N2 pressure of plant.

5. If the level of a scrubber is coming down continuously, nevertheless LRC valve is closed; the
hand valves should be closed to prevent gas leakage.

6. Confirm FRC2001 is closed after 10 mins to prevent air suction in reduction shaft.
- 73 -

7. Switch from the emergency power to regular power after recovering the power failure.

8. Announce the message that regular power will be on for people to escape from danger places.

9. In process of back of regular power, the power failure will happened once more; therefore
careful action is needed against it.


10.2 O2 AND N2 FAILURE:

COREX plant is quickly stopped as the supply of oxygen or nitrogen is interrupted by the trouble
of this supply system. In that case certain flow of nitrogen is fed in to the melter gasifier via the
tuyeres to establish raceways in it and prevent flowing backward of slag into the tuyeres within 3
seconds after plant trip. Preparing for a failure of the O2 main compressor N2 and O2 back up
systems is installed. But if the N2 back up system does not work, nevertheless the O2 plant is
tripped, which cause COREX plant to a big troubles.

Requirement

Remarks
NORMAL MAX Emergency
Pressure
Kg/cm3
Rate
Nm3/hr/THM
Oxygen 55000 60000 - 8.5 500-530
Nitrogen
14000 18000
32000
X 30 min
Down
insteps
11 95 - 120


10.3 Operations according to O2 and N2 failure cases

a). The power failure at Corex.
COREX plant will be stopped, but N2 will be supplied by oxygen plant for purging the COREX
plant.
b). The power failure of Oxygen plant.
It is possible to operate the COREX plant for 2-4 hours with t the back-up systems of oxygen
plant.
c). The compressor trouble of oxygen plant
Possible to operate the COREX by nitrogen and oxygen supplied from L.P and H.P back-up
system.





- 74 -

11. REDUCTION SHAFT EMPTYING

11.1 REDUCTION SHAFT EMPTYING STOP PROCEDURE


Adjust coke rate to ensure Hot-metal temperature in the range of 1480 C to
1520 C.
Aim for Slag Basicity around 1.05, with Al
2
O
3
content 14% max.
Operate the plant with 100 % Essar DR pellets.
Operate the plant with good Coal blend.

12: 00 hrs before oxygen stop:
Change ore batch to 30 % HBI/DRI & 70% - pellet.

Charge the coke to RS at 20 % by volume in the oxide feed to the shaft along with
HBI from 12:00 hrs before oxygen stop.

10:00 hrs before oxygen stop :

Change ore batch to 70 % HBI/DRI & 30% - pellet.

Charge the coke to RS at 25 % by volume in the oxide feed to the shaft along with
HBI from 10:00 hrs before oxygen stop.

08: 00 hrs before oxygen stop:
Start Temp charging to RS, Set top temp to 400 deg.
Increase nitrogen (by opening the hand valve more in the field) to the lock hopper
and charging distributor to maintain the safe temperature (below 200 C) for the
seals.
Change ore batch to 100 - % HBI/DRI.
Start reducing the top gas considering top temp.
Adjust the melting rate to 70 TPH.
Stop gas to the reduction shaft by closing FRC 2001 before 6 hours of oxygen stop & then
stop charging to the shaft.
Adjust slag basicity.
Start reducing bustle gas temp set points to 780 deg in steps.


04:00 hrs before oxygen stop:
Increase the coke rate to 35 % in steps.
Consider discharge volume of DRI screw as 10 - 15 liters higher side before starting
emptying. If one of the DRI screws stops discharging, increase the speed of the other DRI
screws to maintain the required melting rate.
Gradually cut down on the addition of the iron ore fines to zero.
Keep coal charging on higher side maintain high char bed level before stopping.



- 75 -

2: 00 hrs before oxygen stop:

Once two of the six DRI screws stop discharging HBI from shaft, Charge
few (2 3 batches) of 10 m3 batch of HBI to break / clean the natural dead man
in the shaft.
Stop charging to the coal charging bin at the beginning of the last tap, to keep the
coal charging bin empty.
Empty dust recycling system bins by pushing the dust to the melter gasifier.
Prepare the plant on time to fill up LRO 1602 to 100 % prior to the last tap.
Adjust the last tap according to hot metal quantity of the pre ultimate tap and
number of charges put in to the shaft to clean the natural dead man in the shaft.
Plan the last tap in a such a way that the last tap should be at least 150 tons of hot
metal. When only one the five DRI screws are discharging (during charging
Period of destroying the dead man in the shaft), add few more batches if required
to have a minimum of 150 tons of hot metal in the last tap before oxygen stop


1:00 hrs before Oxygen stop:

Open the tap when at least 2 or 3 screws stops discharging.
Dry the furnace to the maximum possible extent. Reduce plant pressure at the
end to 1.2 bar for better drainage.
Approximately 15 - 20 minutes of the end of the last tap, stop upper coal screw
and maintain plant in operation in order to devolatize the coal and to avoid
degassing of the coal after oxygen stop. Reduce oxygen to the dust burner if
required.


- 00:00 hrs Stop oxygen and purge the plant.

NOTE:
After oxygen stop, normal ramping / purging starts. After completion of the purging sequence,
proceed with cooling of the plant. Open FRC 2001 to cool the shaft. Keep plant pressure at 1.2 bar
and cooling gas compressor in operation for 90 minutes. Start decreasing the set point on bustle gas
temperature in steps of 20 deg. C for every 10 minutes. Open slightly FRC 2001 to cool reduction
shaft in such a way to maintain the temperature of the seals below 200 deg. C (TIO7491). [Ref
detailed Ramping & purging procedure].

Stop cooling gas compressor and start depressurizing the plant and prepare the plant for shut down
jobs.

Stop nitrogen to the consumers (by closing the hand valves in the field) in steps as per the list
enclosed. As per shutdown schedule take up the maintenance jobs.





- 76 -

11.2 REDUCTION SHAFT EMPTYING START PROCEDURE

Before the start of oxygen, fill up the shaft up to 2 mtr below the normal level to allow proper
headroom for inspection of Charging distributor feed legs as per filling recipes.

Charge 20 tons of coke (size 13 40 mm) and limestone mix to the shaft before
charging the DRI and pellet mix.
Fill up coal charging bin with the coke rate that will be decided based on the actual
shutdown time. However, as a guideline it will be same as during stop of the plant.

Pressure test is completed and tuyeres are poked and plant is ready for start. [To tart pressure test ref normal
start procedure].
Before starting pressure test start DRI screws with 0.3rpm.
Start blowing of oxygen with 26 tuyeres with 22000 Ncum / hr and increase in
steps of 1000 Ncum / hr every 10 minutes.
Keep tuyere velocity around 190 m / sec.
Check the tuyeres.

Dome temperature > 700 deg. C

Start dust burner system with 500 Ncum / hr of oxygen through each dust burner.
Increase the oxygen in steps to reach dome temperature to 900 deg. C within 30
minutes.
Start coal screws after discharging entire quantity of coke to MG from shaft and dome temp
is above 950 deg.

Adjust bustle gas temperature around 820 deg. C.
Open top gas flap FRC 2001 and adjust specific top gas flow at 800 Ncum / t
DRI. Increase in steps top gas flow to 1200 N cum / t DRI.

1 hr after feeding DRI to melter gasifier:

Increase melting rate to 40 tons / hour and keep specific oxygen to the tuyeres at 700
Nm3/thm.
Open nitrogen to inliners and to down pipes.

Approximately after 31/2 hours:

Perform first tap, 3.5 hours after blowing of oxygen.
Decrease coke rate and keep around 25 % considering the hot metal temperature.
Start Changing DRI Pellet as per reciepe.
Achieve melting rate of 70 TPH before tap.
Increase melting rate to 80 TPH in steps if the tap is good.
Change the coal batch considering the tap analysis.
Increase pellet mix in steps as per the annexure. (Consider the tap analysis before reducing the
DRI percentage in the oxide line)
Adjust the specific top gas flow considering inburden temperatures of shaft.
Increase melting rate in steps as per the annexure.
- 77 -
Decrease coke rate and keep around 20 % considering the hot metal temperature.



12. The Irregularities in Corex process & remedial actions

The irregularities in blast furnace operation may arise either of the followings

Due to faulty mechanical devices like valve, coolers.
Due to faulty Mechanical operation like tapping, charging.
Due to abnormal process occurring inside the furnace with respect to phsico-
Chemical changes in the charge.

12.1 .Shaft Hanging.

If uniform descent of the burden in the furnace is interrupted either by wedging or bridging of the
stock or by scaffolding, it is known as hanging. It is in fact caused by different alternative reasons:
-

Bridging of Ore / Pellets / DRI particles in the vicinity of coke particles which disturb the smooth
ascend of the burden and uniform flow of gas across the reduction shaft. The material discharge
from shaft to melter gasifier is not uniform, means each batch discharge will take different time.

The following are the observation can be observed during shaft hanging.

Each batch discharge time will not be the same. Some charge/batch will discharge
faster and some will take more time.

In burden temperature will not remain uniform some cross sectional area will
show more and some area shown less.

The differential pressure across the shaft and between the screw to bustle will
show more than the normal.

The DRI screw discharge pressure will show more than the normal.

The amount of gas can pushed in to the RS will come down, and top gas
temperature will also varies drastically.

Metalisation and calcinations percentage will drop drastically in the shaft,
followed by increase in the thermal load on the melter gasifier.







- 78 -


Remedies.

Remove the Iron Ore [soft ore] from the oxide batch and reduce the gas flow to
the shaft.
Reduce the melting rate add some percentage of coke to over come the cold spell
and drainage problem.
Increase the coke volume in the shaft and observe for the uniform distribution of
gas.
Closely monitor the DRI screw pressure, Purge the screws which are taking more
discharge pressure with nitrogen to keep screws in operation, otherwise there may
be the possibility of stoppage of the Screws with high discharge pressure.

12.2 Slipping

Slipping is defined as sudden sinking of the stock caused by collapse of the hanging, welding, scaffold,
etc. In short it is the aftermath of these irregularities. In severe cases slipping causes chilling of the
hearth. The best remedy is to allow the furnace to slip on its own by Adjustment of the gas flow and
pressure.

12.3 Channeling

Preferential flow of ascending gases through certain areas of the burden, because of their relatively
much Better permeability is known as channeling since this passages appears as channels. This
basically arises because of improper distribution and wide size range of the charge in the furnace.

Use of a more uniformly sized burden and proper distribution of charge can minimize this.
Channeling Otherwise reduces the effective cross section of the furnace for gas-solid interaction and
thereby decreases the productivity directly.

12.4 Chilled hearth

This is very serious disorder since it affects the drainage of hot metal and slag adversely. The
temperature of hot metal and slag will go down. It affects the poor slag drainage due to low
temperature in turn it affects the production rate.

It may due to the following reasons

The change in the input raw material quality.
Poor slag drainage in the last tap.
Delay in tap opening due to some other problem.
Water leakages from tuyere area.
Low metallisized burden hit to the tuyere.
Dislodging of the skull from its position, falling in to tuyere area.
Wrong mix up in the burden charge, eg: - Ore charged in place of coke.



- 79 -
Remedies.
Charge more coke to keep furnace in hot condition.
Reduce the melting rate by reducing the oxygen through the tuyere.
Check the burden mix and change in the raw material quality.
Take more raw material samples for chemical and physical analysis.
Check the performance of the shaft. Improve the condition of the shaft,
metallization and In burden temperature.
Prepare the cast house as fast as possible, check the tuyeres brightness
Continuously.
Take out the fine material from coal charge, iron ore fines.
Try to take all the slag in to the SGP. Keep slag dry pits empty for worst situation.

12.5. Generator Gas Duct (GGD Jamming: -

The melter gasifier is having four gas outlet [ ducts] there are chances of chocking of
these ducts below the cooling gas addition point. This is across the cross section of generator gas
duct.

This may observed in any one of the GGDs or more than one number at any given point of time. But
most of the time GGD blockages occur at same location in the generator gas duct. This may be due to
the high volatile matter in the coal or may be due to the low dome temperature operation. The
jamming starts at slower rate at the neck position of the generator gas duct, but it will grow at faster
rate as it gets more surface area for settling and develops in to the larger size across the cross section
of the duct and finally block the gas passage.

Followings are the consequences of GGD jamming.

Gas load on other generator gas ducts will increase and in tern more cooling gas as to
be added to the duct in other ducts.
Localize temperature on each duct may increases than the normal temperature, if
cooling gas addition is not sufficient / proper.
Chance for gas channeling, it will drop the metallisation and affect the In-burden
temperature.
Differential pressure of shaft will rise.
Screw discharge pressure will go high.

Remedies

Reduce the Melting rate [production rate] to have a better control over furnace
operation. Reduce the plant pressure by 0.5 bar [3.5 bar to 3 bar].
Check the local shell temperature on the cooling gas addition duct.
Check the total cooling gas addition to the each generator gas duct and load on the
CGC, accordingly adjust the process parameter.
Increase the nitrogen flow to the each dust burner injector to have positive dust flow
towards furnace [say 200 Nm3/hr to 400 Nm3/hr].
Change the charging mix, adjust the coal blend for better operational parameter
control and to improve the furnace condition.
In worst condition like two GGD block, Plant has to be put down for GGD Cleaning,
otherwise it will further Detroit the shaft condition.
- 80 -



12.6 .Red spot on MG shell.

Over the period of operation Melter Gasifier refractory will get eroded and MG shell will get exposed
to the furnace gas, resulting in hot spots on the MG shell. It may be localized one or it may spread
through out the circumference or some parts on the circumference of the MG shell, it depends on
inside stave refractory conditions.
It is observed that after 3 years of operation, in the stave row number 5 and in the row number 6
inside refractory will have more prone to get eroded, so furnace shell for the row number 5 and row
number 6 are more suspect able for hot spots. By maintaining certain operation parameters it is
possible to form the skull over stave walls, but it is always chance that this skull get re melted due to
peripheral flow of gases due to drop in char bed permeability will once again results for hot spots..

Recommendations:

Close the tuyeres, which are laying below the shell showing high temperature, and also reduce the
melting rate by reducing the oxygen through the tuyeres. Maintain the maximum possible velocity
through the tuyeres. Close monitoring of stave water temperature is required (delta t).

Control of fines in the input raw material to the melter gasifier.
Maintain the top char bed about 80%.
Proper slag drainage to maintain dry hearth.
Furnace to be run hotter for better drainage.
Stable operation of furnace.
Ramping up of the melting rate shall be at a slow pace.

If shell temperature reaches to red hotness temperature, it may require stopping the plant if not
controlled by reducing the oxygen trough the tuyeres. Mist cooling and nitrogen cooling arrangement
is required to cool the shell.

12.7 Tuyere burning.

The burning of tuyeres can occur due to following reason

High fusion point viscous slag, which is formed above the tuyeres level

Dislodging of the skull from its position and Falling in to the char bed will splash the slag on to
the tuyeres, resulted in burning of number of tuyeres together.

Change over from Oxygen to the tuyeres to Nitrogen should be smooth; otherwise furnace inside
slag may enter in to the tuyeres and will damage the tuyeres.
Improper hot metal and Slag drainages of the furnace.

The usual remedies are.

Make fluid / less viscous slag. Adjust the basicity of slag.
Improving the quality of the raw material.
- 81 -
Use low alkali burden and making same thin and acidic slag if the alkali content is high in
the burden.
Eliminating channeling or preferential flow.
Ensuring smooth change over of nitrogen from oxygen.
Ensure good drainage of hot metal and slag


12.8 Water level abnormalities in the scrubbers:

Each scrubber is provided with three continuous level measurements that are bubbler type
instruments. The average of these three is taken for the control of the scrubber level control that is
controlled by a two-range split control valve. The control valve is consisting of one ball valve (DN
250) and one Butterfly valve (DN400), which operate with pneumatic actuators.

The scrubbers are usually set for its control at about 50% level and any failure to maintain this level
may cause the failure of water seal in the scrubbers and gas pass can pass through the water
discharge lines of the scrubbers which is highly dangerous.

Causes for abnormalities of scrubber level:

The level abnormality can be either on higher side or lower side.

The abnormalities can be due to errors in measurement or malfunctioning of the control valves

Case1: possible errors in Measurements
- Check whether all three are equal in range. If any one is abnormal, take it to maintenance
mode and get it flushed / purged by instrumentation
Case 2: possible malfunctioning of the control valve

- Check the outputs for the individual valves and their position feed back
- If there is any abnormality with the position of the valve, check the position in the field for its
air, valve positioner etc. if every thing looks normal, then the valve is assumed to be struck
and in such case the control of the level can be shifted to the single valve by closing the
manual valve in the line of the struck control valve. This operation requires special co
ordination from field and control room to ensure that the isolation is trouble free.

Low low level in the scrubbers:

This can cause the gas to rush in the clarifier and pump house, which is highly dangerous, and in this
case all the people must be made alert and area should be evacuated. Only the trained people with
suitable safety apparatus are allowed to co ordinate from the field and all efforts must be put to bring
the level in the scrubbers to normal at the earliest.






- 82 -



12.9 Jamming of Dust Recycling System:

The effective recycling of dust back into the system and burning in the MG has huge impact not only
on the process of Corex, but also on the surroundings, environment and people working. So it should
be desired to see that the all four lines are running effectively. With any one line down we may be
able to continue till an opportunity shutdown, but will have a bearing on all as specified above.


Effect of down dust line on the process:

- Increased dust load in reducing gas effecting the performance of Reduction shaft
- Increased coke and fuel rates resulting high cost of production
- Increased sludge load and sludge disposal problems


In normal operation, the dust settled in HGC is down charged in to the Lower dust Bin and then
injected into the burner and burnt with oxygen. So it is important to see that the process of this dust
injection is smooth and continuous without building any dead levels either in HGC or Dust bin.
Normally dust can be discharged in open mode i.e. keeping the disc gate continuously open. But if
any abnormality is found in the line like high temperature of the dust, high skin temperatures or any
sluggishness in the dust discharge, the system can be operated in batch mode i.e. operate the Disc
gate according to the level in dust bin.

The indications for the flow of dust are the differential pressure across the dust burner and
temperature in the dust line, T-piece and the levels in the HGC and dust bin etc. so any sluggishness
in the dust line can be identified from the above indications and some basic steps may be followed to
prevent the total jamming of the dust lines.

Steps to avoid the Jamming of lines:


Case I : Dust discharge from HGC to Dust bin is sluggish

Indications:
1. Level rise in HGC
2. Drop in dust temperature
3. No differential pressure across the Horizontal portion
4. No level in Dust bins

Remedies:
- Check the position of the hydraulic disc gates and Manual shut off valves
- Try nitrogen fluidizing



- 83 -

Case 2: Dust discharge from Dust bin is sluggish


Indications:
1. Level rise in Dust bin
2. Drop in dust temperature
3. No differential pressure across the Horizontal portion
4. Subsequent level rise in HGC


Remedies:
- Check the position of the shut off valve
- Try in batch mode
- Try nitrogen fluidizing

If the jamming is not because of any big or foreign particles like refractory bricks etc, the dust line
may be through for its normal operation. But if the jamming is because of any physical obstructions,
then it requires a shutdown to revive the dust line



Case 3: Blockage in Horizontal line


Indications:
1. Pressure rise in Dust bin and possible failure of Nitrogen injection due to Inter lock
with Pressure in Dust bin
2. Drop in dust temperature
3. Max. differential pressure across the Horizontal portion
4. Subsequent level rise in HGC and Dust bin.

Remedies:
1. stop Oxygen to the dust burner and Nitrogen injection
2. close manual shut off valve below the Dust bin
3. Open the knife gate valve in the coarse particle discharge line at +21m.
4. Flush the horizontal potion two three times with given nitrogen valves

If the line could not be revived from its horizontal line blockage, then nitrogen injector will have to
be stopped and Block valve is to be kept closed keeping the nitrogen SOV in front of the Burner
open. In this case oxygen to the burner may be given at less than the normal flow and the line will
have to be cleared in an opportunity shut down.






- 84 -
12.10 Stoppage of DRI screw:

Corex process has experienced many times the stoppage of DRI screws which will have a bearing on
the performance of the Reduction shaft and as a whole on the process.

The screws are run by Hydraulic motors and are variable speed to control the discharge of DRI feed
to MG. Hydraulic pressure of the pumps is indication of the load on the screws. In normal operating
conditions, pressure may be in range of 80 to 110 bar. Any thing above that requires a special
attention and nitrogen flow through the Screw nozzles should be increased to reduce the load on the
screw.

Various reasons for the stoppage of DRI screws:


- Blockage of DRI down pipe
- High dust load in Reducing gas
- High specific amount of Top gas
- High temperatures in the reduction shaft causing cluster formation
- Air penetration into the process during any shutdown causing fusion of the DRI
- Any foreign material like metal pieces, Refractory pieces etc.
- Bearing failure of the screw

The stoppage of any screw can be judged from the profile / Trend of the hydraulic pressure.
If the pressure rise is gradual, it could be due to blockage of DRI down pipe in which case nitrogen
purging may help to revive the screw while the plant is in operation.

If the pressure rise is very sudden, it could be due to any obstructions with foreign material or
clusters in between the screw paddles.

Revival procedures of DRI screws while the plant in operation:

- Purge the screw nozzles with Nitrogen
- Try to run the screw from field in both forward and reverse directions
- Observe the movement of the screw and if it is encouraging, stop further trials

If the screw could not be revived online, it may be tried during shutdown with all safety precaution
in place.








- 85 -


13. CAST HOUSE
13.1 General

Cast house is where tapping is carried out to take out the hot metal and slag from the furnace
using drilling machine, after draining out of estimated amount of hot metal and slag, Mud Gun
closes tap hole. The hot metal will flow through refractory lined trough (Main iron runner and
Tilting runner) in to the ladles. The slag that is lighter than hot metal will float above and get
separated near main runner skimmer & taken in to slag granulation plant trough the slag runner. In
case of heavy flow, SGP is not ready to take slag then slag is diverted in to Slag Dry Pits.

Corex is having TWO number of Cast house, one granulation Plant and Two Slag Dry pits of 600
tons (SLAG) capacity. The runner is refractory lined; it will get eroded after certain amount of hot
metal is taped. In Corex relining of main runner is usually done after 90,000 tons of hot metal
produced from the runner, this depends on how best main runner is managed is depends upon the
followings, Cast house operation, Hot metal and slag Quality, Quality of refractory, Drainage rate,
Clay quality, Proper scheduling for minor repair of running trough along with stand by cast house.

The following are the pre requisite for trouble free tapping

Constant tap hole length.
Controlled expansion in the tap hole with hot metal and slag.
Even delivery speed of hot metal stream
No turbulence in the stream at the tap hole exit.
Smooth operating and closing of the tap hole.

To achieve the above results on a regular basis continuously, it is required to have a total system
approach. It should start right from the day to day operation of the furnace, material design and
proper application technology.

The temperature and composition of the hot metal various from plant to plant. Higher temperature
and specially the Si content of the hot metal affects the performance of tap hole clay adversely

The Tapping rate determined ( Amount per unit: t/min) of iron and slag is determined by

Tap hole diameter.
Tap hole length.
The thickness of the molten iron and slag layer (level)
Plant pressure.

In order to obtain a longer tapping time the erosion of tap hole diameter due to abrasive action of
metal and slag at high temperature, to be reduced.

Material design for tap hole has undergone a radical change. Both siliceous and aluminous aggregate
are used along with various additives and binders. Phenalic resins, tar, various oils are used as binders
along with Carbides (SIC) and /or nitrides (SiN) as additives. Carbides and Nitrides imparts corrosion
and abrasive resistance properties where as it also improves sinterability of the mix.
- 86 -

Slight expansion has been recognized as desirable property. If may please be noted that SiC gets
oxidized both under oxidizing both under oxidizing and reducing atmosphere.


SiC+2FeO SiO2 + Fe + C -----------(1)
FeO+C Fe + CO (g) --------------(2)

SiC + CO SiO+2C --------------------(3).
SiO+CO Si+CO2 --------------------(4)

The last reactions are associated with volume expansion that may be beneficial for maintaining the
tap hole diameter.

Trough
The performance of trough also will depends on

Nature of the material and its characteristics.
Design and Engineering of the trough.
Operational Parameters.

The type of construction of main trough plays an important role in de-ciding the trough life and
minimizing cast house delays. Particularly important is the bottom slope which determines the flow
rate of Iron / Slag in the trough which determines the erosion rate of refractory lining. Also related
to the slope is the height of pool available at impact area of trough, which cushions impact energy
of falling stream during tapping. Presence of such a pool determines the condition of refractory
lining at the impact zone. Based on Slope, three types of main troughs can be distinguished.

a) Wet Runner/Pooling runner/Non-Drainable trough.
This trough holds molten metal for inspection of refractory lining condition. All
large capacity furnaces opt for this type of trough for faster evacuation of hot
metal.

b) Semi wet Trough
Such a trough has relatively high slope of 3 % and so wear prominent both on
bottom and side wall Refractory linings. Also, the height of pool is low at the
impact zone and so the wear at that area is also high.

c) Dry/Non pooling trough
The slope is generally more than 5% and the iron stream directly hits refractory lining. The wear in
such trough is much more in bottom and imp-act area. Such troughs are common with Blast furnace
of low volume.





- 87 -

13.2 COREX CAST HOUSE

Facilities in Cast House
NO OF CAST HOUSES : 02
NO OF TAPHOLES : 02
TAP HOLE ANGLE : 3 DEG.
MAIN IRON RUNNER ANGLE : 5 DEG.
RUNNER LINING : CASTABLE

RUNNERS
MAIN IRON TROUGH.
HOT METAL RUNNER.
TILTING RUNNER
DRAINAGE RUNNER
SLAG RUNNER
CAST HOUSE SLAG GRANULATION
CAST HOUSE DEDUSTING

Cast House Practice:

HOT METAL PRODUCTION/DAY : 2600 MT *2
NO. OF TAPPINGS /DAY : 09 10 PER MODULE
HOT METAL TEMPERATURE : 1500 20 C
HOT METAL ANALYSIS : Si 0.5 to 0.8 & S 0.04
SLAG B2 : 1.10
TAPPING PRACTICES :
- SINGLE TAPHOLE OPERATION
- TWIN TAPHOLE OPERATION

TAPPING DURATION
TAP OPEN TO CLOSE : AROUND ONE HOUR
TAP CLOSE TO OPEN : 1 Hr. TO 1 Hr. 30 Min
(DEPENDS ON THE MELTING RATE)
RUNNER LIFE : 90,000 100000 tons Through put.
REFRACTORY CONSUMPTION : 0.42 - 0.45 Kg/THM


- 88 -

13.3 Cast House Runner Refractory:

MAIN IRON RUNNER : ACCMON 16SC GEL (ACC) &
CASTON AT 390 (VIL)
HOTMETAL RUNNER : ACCMON 16SC GEL (ACC) &
CASTON AT 190(VIL)
TILTING RUNNER : ACCMON 16SC GEL (ACC) &
CASTON AT 190 (VIL)
DRAINAGE RUNNER : ACCMON 16SC GEL (ACC) &
CASTON AT 190 (VIL)
SLAG RUNNER : ACCMON 16 SC B (ACC)


.Cast House Runner Refractory:

TYPES OF REPAIRS: AJOR REPAIR DURATION 72 Hrs.
MINOR REPAIR DURATION 8 - 24 Hrs.

SCHEDULE FOR MAJOR REPAIR
COOLING & CLEANING : 04 Hrs
BREAKING : 16 Hrs
TEMPLATE FIXING : 04 Hrs
CASTING : 04 Hrs
SETTING : 06 Hrs
TEMPLATE REMOVAL:01 Hrs
SKIMMER FIXING :01 Hrs
SLOW HEATING :12 Hrs
FULL HEATING : 24 Hrs



.Cast House Refractory:
TAPHOLE CLAY : UNHYDRUS TAP HOLE CLAY
CLAY CONSUMPTION : 1.35 Kg/THM
MUD GUN HOLDING TIME : 30 MIN
SUPPLIERS :VVEL, HI-TECH & UBIQUE

- 89 -

MASS COMPOSITION:

CHEMICAL
Al2O3 :55 60%
C :16 18 %
SiC + Si3N4 :15 17 %
OTHERS : REST

PHYSICAL
VM : 7 8 %
BD : 2.1 2.25 g/cc
GRAIN SIZE : 0-3.5 mm



13.4 Preparation before Tap opening.

Checking of clay gun and Drilling machine

1. Clay Gun

Check all signal lamps.
Check if any sticker material is remained in the-nozzle.
Check the oil level in the tank.
Check the temperature of oil.
Check the actuating status of motor.

2. Tap hole opener ( Drilling machine).

Check the condition of Air Pressure.
Check the status of each actuating part.
Check the chain tension.
Check the carriage movement.
Check the chain for its smooth movement.
Check all air lines for any leakage.


3. Tap hole
Check for any gas leakage around the tap hole.
Check for any sticked material is remained on the runner and to the tap
hole mouth.
Check for any water leakage is appeared around the tap hole.


- 90 -

4. Each Runner

Check the main iron trough condition.
Check the slag runner condition.
Check the for sand dressing in slag runner.
Check for any crack at the joint between tap hole and main runner.



5. Tilting Runner.

Check the bottom refractory condition in tilting runner.
Check for any crack in the refractory lining in the tilting runner.
Check for any jam remained in side the tilting runner.
Check the tilting operation of tilting runner.

6. Tapping Material and consumption

Mud gun clay: 0.3 tons /tap
Lance pipe size: 2 pipes (8 mm)/ tap
Drill rod + Bit: 1 number / tap.
Mud gun nozzle:
River bed sand:
Long shovels: as operation requirement.


13.5 Tap Opening and Closing Procedure.

1. Decide the suitable time for tap opening.

- Tap closing to tap opening time is mainly depends on melting rate.
- Tap opening time is varied from normal time of opening
of tap depends upon the followings.

Previous tap drainage status.
Quality of hot metal and slag, Temperature and Chemistry.
Melter gasifier performance.
Shut down preparation.

2. Drilling procedure

Fix the Rod having drill bit in to the Check.
Take the Tap hole opener to the tap hole face and mark the center
for tap hole, it will set the direction for tap hole which connects the hot metal.
If the center is posed correctly, Drill the tap hole up to 200 mm less than
last tap hole length.
By appearing spray and molten Braking from the tap hole ,take back the
- 91 -
Tap hole opener to parking position.
Replace ROD with iron bar and open the tap by using bar.

The measurement of Tap hole length.
Tap hole length is measured from the scale, which is position on to the tap hole opener. Each
division in the scale is equivalent to the one tenth of the meter. Maximum length can be read from
this scale is 2.7 meters.

3. Procedure for taking Hot metal temperature.

Insert tip into hot metal ("Yellow" light indicates rising temperature, "Red"
light and "buzzer" indicates dip completed).
Remove tip from hot metal.
Observe the Temperature from cast house display board.
Time is recorded from the control room.
4. Procedure for taking sample for hot metal and slag

Prepare sample mould
Clean waste material from mould surface (Ensure clean surface)
Prepare sample spoon.
Remove adhering metal or metal skull from spoon.
Position spoon over metal runner (warm up the spoon to remove
moisture).
Collect the hot metal from runner in to the dry spoon and Pour it in to the
mould.
Pour excess metal from spoon into metal runner.
Remove sample from the mould. Cool the sample and send to laboratory
for analysis.
Repeat the above for taking anther sample.

5. Plugging the tap hole.

Plugging time can be estimated by considering the melting rate, tap speed, and
tap-to-tap time, but normally final decision of tap hole plugging is done after
draining of the estimated amount of metal and slag from the furnace.
Check the erosion of tap hole and drainage status of molten metal and slag.
Especially, tap hole erosion is a critical view point to decide plugging.
Check the gas coming out from tap hole. If it more it indicates that hearth is
got emptied.
Estimate the time, of plugging with considering the amount of slag is drained
from furnace.
6. Emergency Plugging.
When the molten metal starts overflow from runner.
When Drain hole got break out.
When the operation of tilting runner got failed.
- 92 -
When the continuous tapping is impossible due to the tap hole erosion
And heavy metal and slag flow.
When the un-controlled char rush in to the runner.

Preparation for Next Tap.
Cover the main runner with rice husk to reduce the heat loss from metal runner.
Check for the erosion of sand in the slag runner and the jam in the slag runner, cleaning of the
slag runner jam and dressed with sand.
Take out the clay gun after 30 minutes back to the parking position, check the main iron
trough condition.
Empty out the clay gun barrel, Cooling the mud gun barrel, Check the clay gun nozzle and
replace it with new one if necessary, check for the reducer jam.
Cleaning the main trough and tap hole mouth, by taking out the jams
and dressing of the runner with sand.
Check the drilling machine by operating carriage and rotation. Insert the new drill rod and
prepare drilling machine for next tap.
Fill the clay gun with clay and take the tap hole impression to make proper tap hole
center.
Check for ladle placement, minimum three ladles are to be placed.



13.6 Abnormalities and remedies.

1.Tap close Failure
a. Reason for failure

Breakout in front of tap hole.
Sticked material at tap hole mouth.
Delay in pushing the mass (operating of the clay gun Ram).
Clay gun failed to operate.

b. Counter measures

Safe guard the clay gun by taking it in to parking position.
Reduce the system pressure from control room.
In case of nozzle damage replace clay gun nozzle with new one.
Place more ladles and carefully operate the Tilting Runner.

2. Erosion of tap hole
Reason for failure:
Due to bad Quality of clay.
Wrong adjustment of tap hole center.

- 93 -
Remedies:
If tapping is not under control close the Tap immediately.
Reduce system pressure for better control over the tapping.
Enhance the supervising about tilting runner operation.
When there is over flowing of molten material in main runner, plug the
tap hole Immediately.
After complete plugging, repair tap hole and remove sticking material
in main iron runner.

3.Self-Opening
Reason for failure
Improper closing of tap hole.
Bad quality of mass, its setting time should not be more than 30
minutes.

Remedies
Place one more empty ladle.
Reduce the Plant pressure and check the clay gun nozzle, if required
change with new one.
Fill the clay gun with other clay.
Close the tap, ten minutes after closing of the tap normalize the
plant pressure.
Other cast house should be kept ready for change over if
required.

4.Explosion in tape hole:
Reason:
In case of in sufficient heating up of clay in the tap hole due to less setting
time for clay before tap opening.(wet clay).
Remedies:
Before tapping, repeat movement of bar inward and backward about 3 times to vent the
gas and to open the tape hole.
In case of taping with oxygen, catch the pipe tightly as long as possible.
Safety precautions to be taken before tap opening

















- 94 -



14 Water System

14.1.Gland Water System

General Description:

The gland water system is necessary to provide the required water amount and pressure
to supply all gland points on the different process water pumps with gland water. As the
operation and the function of the gland water system is essential for the life time of the
individual pumps, the gland water system is provided with a gland water pump always
running and a standby, that will take over the operation as soon as the running pump trips.



14.2 Process Water System




The Operation of Process cooling water

1. General.

The generator gas leaving from melter gasifier cool down to 850 deg C after mixed with
cooling gas from compressor, and it is directed to Hot gas cyclone, where approximately 70
% of dust is removed from the gas. This gas constitute CO and H2, hence it is called
reducing gas, nearly 85 % of total gas is passed in to reduction shaft and rest of the gas is
- 95 -
passed through Cooling Gas packing Scrubber (CGPS) .It is further divided in to two parts,
cooling gas for and excess gas.

The gas which taken in to reduction shaft after reduction process it leaves the shaft, it
called as Top gas, it is directed into Top Gas Packing Scrubber (TGPS) and then top gas
adjustable scrubber. The gas is loaded with a lot of dust (Normally the inlet of Cooling Gas
packing scrubber: 40g/Nm3; the inlet of the Top Gas packing Scrubber: 15 g/Nm3) passes
through each scrubber; the gas is cooled and supposed to cleaned up to the 5 mg/Nm3 and
35- 40 deg C.

The process water system provides the water in the required amount, pressure and quality
for the gas cleaning systems of the COREX process. As the gas from the COREX process
(top gas, cooling gas or excess gas) is hot and dust loaded, the water serves two purposes:

Cooling and quenching of the hot gas.
Take over the dust from the gas.


For such purposes the process water is taken from the cold-water pond by means of
process water pumps to the different supply points of the gas cleaning system. Once the
water was in contact with gas, it has dissolved solid particles and is returned either to screw
classifier or the scum scrapper or partly direct to the inlet channel of the 1
st
clarifier is
guided to the hot water pond. From there the water is routed via the cooling towers to the 2
nd

clarifier .The Overflow from 2
nd
clarifier flows in to the cold water pond shall ensure that the
required process water can be provided to gas cleaning area in case of emergency situations
with the cooling towers. In this case it should be considered that the temperature increases to
a value where the proper function of the system is influenced negatively.

The level in the cold-water pond is controlled by keeping the level in the hot water pond
in a certain height, while supplying make up water to the cold-water pond.



Parts of the process water system are circulation pumps and pressure booster pumps at
the gas cleaning systems. The circulation pumps connected to the packing scrubbers ensure
that the cooling and quenching of the hot gas is performed properly, The separate booster
pumps are provided at pump house to supply the water to adjustable venture scrubbers and
for the inlet nozzles of the cooling gas scrubber on the other hand, which are located on a
higher level.

It has to be ensured that the availability of the process water system is very sensitive
.To compensate different shortcomings the water circuit will be inhibited with the traces of
chemicals that are essential for the operation of the system. The chemical dosing can only be
controlled from the local control box.

At the gas cleaning system of the COREX process, the water outlet of the scrubber is
performed in such a way that no gas is exhausted to the ambient area. For this purpose the
different vessels are provided with level control equipment. This level control equipment is
checked and controlled by two parallel working level indicators on each vessels. With these
- 96 -
controllers of the COREX plant .The gas system of the COREX plant. The gas system of the
Corex system must serve operation condition conditions from the ambient pressure to the
max. Allowable working pressure. Therefore the main water supply to the gas cleaning
system is controlled by means of the flow control valves to compensate the working curve of
the pumps with respect to change of the system pressure. This is necessary to avoid overload
on the pump motors and /or cavitations in the pumps.

2. The Specification of Gas Cleaning

DUST
DENSITY in
GAS
(g/ Nm3)
GAS (DEG C) SCRUBBER
NAME
SUPPLY
WATER
VOLUME
(m3/hr)
IN OUT IN OUT
Cooling Gas
Packing
Scrubber
1000 40 < 0.5 820 to
850

35 to 40
Cooling Gas
Adjustable
Scrubber
70 <0.3 <0.2 45 to
50

35 to 40

Excess Gas
Adjustable
Scrubber
140 <0.5 0.005 40 to
45

35 to 40

Top Gas
Packing
Scrubber
950 15 <0.5 280
to 300
35 to 40



The Pump Specification of Process Cooling Water System

PUMP NAME FLOW, PRESSURE USERS
Packing
Scrubber
Pump
1500 cum / hr, 8.7 bar Top gas &cooling gas
packing, Baumco
scrubber.
Inlet Cone
Pump
210 cum/hr, 10.2 bar

The inlets of T/G,C/G
packing Scrubber.
Booster Pump 500 cum / hr ,8 bar The inlet of each
adjustable
scrubber & the throat
part
of C/G Packing
Scrubber.
Cooling Tower
Pumps
2400 cum /hr, 4,2 bar Process Cooling
Tower


- 97 -


3. Pump operation and scrubber control

The water pumped from a Inlet cone pumps is injected at the top part of packing scrubber
is called inlet cone (dome). The water pumped from a Process cooling water (PCW) pumps
and Booster pumps is supplied to scrubbers packing, scrubber throat, to the baumco scrubber
and to all venturies.

FRC 5120 and FRC 5121 control the flow to the scrubber packing for Top gas and cooling
gas respectively.

The LRC valves, which are located at the out, control the level inside the scrubber, let (Weir
drain) of scrubber. It consists of two valves, ball valve and butterfly valve. The level is
indicated by the level indicator, it is bubbler type and it give feed back to the controller
(LRC) in term controller will control the water flow from scrubber out let and maintain the
level in the scrubber.


1. Process Cooling Water Recirculation System.

The water contains a high percentage of coarse material, it is drained from
bottom parts of packing scrubbers (Cone drain) to the screw classifier trough
Degasser.

The water is drained trough LRC valve (Weir drain) from the side of each
scrubber to the over feed box of the scrapper.

The out put from scum scrapper and screw classifier contains thick slurry is
collected separately and discharged to sludge treatment yard.

The Heavy particle settles at the bottom of clarifier, which contains, slurry is
taken out by using three numbers of sludge discharge pumps, which are located
at the bottom of the clarifier.

The water, which over flow from clarifier #1 is taken in to hot water pond.


The water from hot water pond is pumped into Process Cooling Tower to reduce
the water temperature. Nearly 25 deg can be reduced in the cooling tower. From
cooling tower water flows in to clarifier #2.


The over flow water from clarifier #2 is collected in cold water pond. The water is then
pumped in to the system by process cooling water pumps.




- 98 -

Pump House Lay Out








































Pumps Details with respect to Ponds at PUMP HOUSE
- 99 -


- 100 -


14.3 MCW AND STAVE COOLING WATER SYSTEM

1. MACHINE COOLING WATER SYSTEM

GENERAL

The closed water circuits is divided in to machine cooling water system, both Critical system
and Non-critical system and Stave cooling system. The system is provided with Overhead
tank, which assures the constant pressure head all the time in the return water line. In
emergency situation like power failure water will flow from emergency tank and protects the
equipments. Circuit also consists of filters and heat exchangers before pump suction. It
consists two pumps one working and one stand by.



SYSTEM SPECIFICATIONS

CRITICAL NON-
CRITICAL
REMARKS
TOTAL FLOW 750 CUM
/HR
500
CUM /HR

HOLDING
VOLUME
50 CUM 30 CUM Volume of Over head
tank.
SUPPLY
TEMPERATURE
36 deg C/
42 deg C
36 deg
C/
42 deg C

SUPPLY
PRESSURE
11.20 bar 11.20
bar

PUMP
CAPACITY
750 CUM
/HR
500
CUM /HR
Total pressure drop
Critical :- 0.5 bar.
Non critical:-0.5 bar.









- 101 -


Start procedure.

The group operation will be performed by the mode GROUP AUTO.

1. Preconditions.
Emergency water pond level should not be low.
Emergency water tank: level should not be low.
All recirculation pump kept ready for start.
HIC should be in closed condition.


Critical and Non Critical Water System Circuit is as shown above ,which is having two pumps one
running one stand by, attached with emergency pumps which is operated during Power failure.
Pumps will continuous to run unless there is pressure drop less than the minimum set discharge
pressure with in the interval of defined time period. The stand by pump will starts when running
pump trips.

In case of power failure the running pump trips and water starts flow from overhead tank in to the
system through by-pass line through control valve (HIC) in to the emergency pond at pump house.

The level in the overhead tank starts reducing and it is controlled by the HIC valve. At the same time
Diesel generator is started and emergency pump is taken in to operation will supply the water in to
the system circuit and also fills the water in to the overhead emergency tank.



- 102 -



14.4 Stave Cooling Water System.

1. General

The melter gasifier is provided with cooling plates, which are installed inside the melter
gasifier shell up to 23 mts. The purpose these stave cooling plates and the hearth bottom
cooling is to take off the heat that is generated in the melter gasifier.

The stave cooling plates are cooled by means of a closed water circuit, where the water is
cooled in the heat exchangers. The emergency tank is provided to take care emergency
situation, which is pressurized with Nitrogen.





Emergency Case.
In case of power failure the running pump trips and water starts flow from overhead tank in
to the system through by-pass line through control valve (HIC) in to the emergency pond at
pump house. Stave Overhead tank Depressurizing valve opens.

The level in the overhead tank starts reducing and it is controlled by the HIC valve. At the
same time Diesel generator is started and emergency pump is taken in to operation will supply
the water in to the system circuit and also fills the water in to the overhead emergency tank.



- 103 -

15 Heat Up and Start Up




15.1 Heat Up Flaps and Bottom Air Pipe Arrangements for Heat Up & Start Up





































15.2 Heat up and Start up procedures:

The process vessels i.e. Reduction Shaft, Melter gasifier, Hot gas cyclones, Dust bins and hot gas
ducts etc. are lined with refractory bricks / castable which require to be dried and heated slowly.

Purpose of Hearting up:
- Removal of moisture from refractories and castables lined in the process vessels / ducts.
- To increase the temperature inside the Melter gasifier and fixed bed temperature above the
char combustion temperature to prevent explosions


MG
Shaft
Safety Flap
Top Gas Flap
H/C
Dust bin Flaps (4 nos)
Burners for heat up (8 nos)
From Bottom air station
DRS
System
Top Gas
Scrubbe
r
- 104 -
Preconditions for Heat up:
- Successful performance acceptance test of all sections of the plant
- Completion of plant pressure test at 5.3 bar
- Process, machine cooling and stave cooling water systems in operation
- Heating up thermo couples installed.
- Bottom air pipe with thermocouples installed and covered with Converter slag
- Heat up burners(8 nos) and Tuyeres installed
- Blowers for heat up burners checked ready
- Fuel gas system for heating up ready in all aspects
- Heat up flaps installed
- Raw material preparation as per requirement
- Temporary points for cooling gas and top gas analysis shifted put in use
- Provision of lances for temperature measurement in front of tuyeres
- Both tap holes are drilled and kept open
- Gas sampling at tuyeres is installed
- Condensate points on MG and RS are open
- Bottom air station checked up for flow etc.

15.3 Salient features of Heat up:

- Heating up of Melter gasifier
- Heating up of Dust recycling System ( at around 200 deg c of Dome temperature)
- Heating up of Reduction shaft (at around 300 deg c of dome temperature)
- Charging of CRE to RS and heat
- Charging of CRE to MG and air blow through Bottom air pipe
- Dismantling of burners and installation of all tuyeres at 1000deg c of Dome temperature
- Filling of shaft with DRI / HBI
- Filling of MG with Given recipe (crushed electrodes / coke mix)
- Ensure tuyere temperature above 1000 deg c and all systems in operation
- Start oxygen through the tuyeres (Plant start)

You might also like