Corex process

Process Description
In the Corex Process all metallurgical work is carried out in two separate process reactors The reduction shaft and The melter gasifier.

Process Description
Viewing the process from the coal-route perspective, non-metallurgical coal is directly charged into the melter gasifier via a lock-hopper system. Due to the high temperatures predominating in the dome of the melter gasifier (in excess of 1000 C), a portion of the hydrocarbons released from the coal during devolatilization are immediately dissociated to carbon monoxide and hydrogen. Undesirable by-products such as tars and phenols, etc. are destroyed and therefore cannot be released to the atmosphere. Combustion with oxygen injected into the melter gasifier results in the generation of a highly efficient reduction gas.

Process Description
The reduction gas exiting from the melter gasifier consists mainly of CO and H2 laden with fine coal, ash and iron dust. This dust is largely removed from the gas stream in a hotgas cyclone and is then recycled to the process. Through the addition of a cooling gas, the reduction-gas temperature is adjusted to its optimum working range. After leaving the hot-gas cyclone, the reduction gas is then blown into the reduction shaft via a bustle, reducing the iron ores in counter flow.

Process Description
The top gas is subsequently cooled and cleaned in a scrubber, after which it is available as a highly valuable export gas with a net calorific value of approximately 7,5008000 kJ/m (STP). This gas is suitable for use for a wide range of applications.

Flow Diagram of Corex Process

Main Plant Sections of Corex Plant

Process Economy
Coking and sintering plants are not required for the Corex Process, substantial cost savings in the range of up to 20% as proven under actual operating conditions.

Environmental Aspects
Corex plant emissions contain only insignificant amounts of NOx, SO2, Dust, Phenols, Sulphides and Aammonium. Waste-water emissions from the Corex Process are far lower than those in the conventional blast-furnace route.

Use of Export Gas

After the cleaning and cooling of the top gas which exits the reduction shaft, can be used in: Electrical power generation Production of DRI (direct-reduced iron) For heating purposes throughout the iron and steel works.

Typical Plant Performance

Unit Melting Capacity Coal Consumption t HM/hr kg/t HM Using Lump ore 45 1080 Using Pellets 53 1000

Emissions Dust SO2 Nox g/t HM g/t HM g/t HM 39-139 26-333 21-33 39-139 26-333 21-33

Issues before Plant Erection

Ore Quality Coal Quality Coal availability Plant redesign with the above parameters

Corex Plant, Saldanha Steel, RSA

Corex Plant, Boasteel, China