Corex Process for Production of Iron. During the late twentieth century, several new initiatives have been taken for the development of the. COREX PROCESS in IRONMAKING Report Submitted by: Aditya Kumar Singh ( ), Bachelor in Technology, Metallurgy & Materials. A brief technical review about what is COREX process of iron making, some merits and demerits of COREX technology.

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As far as coal is concerned, the non-coking coals having too high volatile matter VM or too low fixed carbon FC cannot be used in corex process of iron making.

Reducing gas for the shaft furnace is produced by partial combustion of coal with oxygen in the fluidized bed of the melter-gasifier. The heat and mass balance calculation for an ironmaking process plays an important role during the operation of Corex process.

Phenols discharge is around 0. Advantages of the Corex process include i reduction in the specific investment cost compared with conventional blast furnace route of production, ii lower production cost, iii better environmental performance because of lower emissions and discharges, iv higher calorific value of export gas makes it suitable for use in a wide range of applications, v flexible with regards to the cofex material uses since a procdss variety of iron ores and coals can be used, vi good operational flexibility with respect to production capacity, production stops and raw material changes.

Meanwhile, carbon monoxide and hydrogen gas from the original gasification of the coal exit the gasifier while other byproducts are captured in the metallic slag.

Corex Process for Production of Iron |

Also the export gas can make the process highly inefficient. Presently, the majority of steel production is through the blast furnace which has to rely on ever decreasing amounts of coking coal. irkn

The corresponding typical specific consumption figures with the recycling of export gas in per ton of hot metal are around kg for dry non-coking coal, kg for additives and cum for oxygen. Due to this increased gas utilization which is based on gas recycling, gas production in the melter gasifier can be significantly lowered, which is directly reflected in lower fuel and oxygen consumption.


However, nearly all of the sulphur in the non-coking coal enters the slag and hot metal. Retrieved November 3, The second stage of the process consists of melting and carburizing of hot DRI by the coal and oxygen which is added in the meter-gasifier.

It takes only half an hour to stop the plant and only four hours to restart it. The export fuel gas is also being known as Corex gas. During the late twentieth century, several new initiatives have been taken for the development of the smelting reduction technology which can become alternative route for the production of liquid iron hot metal since the conventional blast furnace BF ironmaking depends on metallurgical coal, which is required for producing BF coke needed for the production of hot metal in the blast furnace.

The gasified coal is then fed into a shaft furnace to remove oxygen from iron ore lumps, pellets or sinter and finally, this direct reduced iron DRI is fed to the smelting reactor. The high dome temperature exceeds 1, deg C which results into complete cracking of the hydrocarbons released by the non-coking coal and avoids the formation of tar.

The most innovative feature of the Corex process is the separation of the iron reduction and smelting operations into two separate reactors, namely reduction shaft and melter-gasifier.

The gas at the temperature range of 1, deg C to 1, deg C makin the melter-gasifier is cooled to the reduction gas temperature deg C to deg C by the addition of cooling gas. This raises export gas utilization to a higher level and improves the overall economics of the process besides making it more environmentally friendly. Views Read Edit View history. The Corex Process is a smelting reduction process created by Siemens VAI as a more environmentally friendly alternative to the blast furnace.


Proceas being reduced, the DRI is redirected to the char bed where the iron and slag are melted and then directed to the hearth zone. The gas is cleaned in a hot cyclone to recycle entrained fines. Compared with the traditional iron making process via the blast furnace route, the COREX process differs since non coking coal can be directly used for ore reduction and melting work, eliminating the need for coking plants.

The melter-gasifier can largely be divided into three reaction zones namely i gaseous free board zone upper part or domeii char bed zone middle part above oxygen tuyeresand iii hearth zone lower part below oxygen tuyeres. Typical specific consumption figures in per ton of hot metal are around kg for dry non-coking coal, kg for additives and cum for oxygen. So, the phosphorous content of ore and coal should be as low as possible. The hot metal temperature is around deg C to deg C.

Retrieved from ” https: This first generation reactor which is called melter-gasifier had a hearth diameter of 5. The general mkaing of this first generation process was limited and a lot of technical problems had to be solved.

Corex Process for Production of Iron

The export gas generated in Corex technology can be used as a fuel gas in the downstream facilities to generate electricity or for the production of direct reduced iron in a region that has almost no resources of natural gas.

Posted by Satyendra on Feb 22, in Technical 0 comments. Specific melting capacity is higher than that in Blast Furnace; productivity around 3.

Unlike the conventional Blast furnace route for production of hot metal, it can accept high alkali containing ores without any build up inside the reactor.

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