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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Corex Process for Production of Iron

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 irpn 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 raw material uses since a wide variety of iron ores and coals can be used, vi good operational flexibility with respect to production capacity, production stops and raw material changes.

Retrieved October 27, Nevertheless, it helped to overcome the critical demonstration stage for this smelting reduction technology.

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.

Views Read Edit View history. In the two-stage operation of the process DRI produced from prrocess shaft furnace is charged into a melter-gasifier for smelting.

Because of many peripheral requirements, the total cost of a Corex project can be relatively high. In Siemens first completed a life cycle assessment for pig iron production, looking at both conventional production in a blast furnace and the more environmentally friendly COREX and FINEX processes.

Iron ore lump ore, pellets, or a mixture thereof is charged into the reduction shaft, where it is reduced to direct reduced iron DRI by the reduction gas in counter flow. The emission levels with the Corex process are much lower than the BF route of production which consists of blast furnace, sinter plant and the coke ovens.

The plant rated capacity is ranging fromtons per year totons per year. 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.


The process has three stages. Sulphides discharge is around 0. The air emissions are also lower than the conventional BF units. The metallization degree of the DRI and the calcination of the additives are strongly dependent on four parameters namely i amount and quality of the reduction gas, ii temperature of the reduction gas, iii reducibility mqking the iron bearing burden, and iv average particle size and the distribution of the solids charged.

The commissioning was in This first generation reactor which is called melter-gasifier had a hearth diameter of 5. 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 most innovative pdocess of corrx Corex process is the separation of the iron reduction and smelting operations into two separate reactors, namely reduction shaft and melter-gasifier.

Phenols discharge is around 0. However, nearly all of the sulphur in the non-coking coal kaking the slag and hot metal.

So, the phosphorous content of ore and coal should be as low as possible. Use of high purity oxygen in the Corex process generates of nitrogen free top gas. Further due to the in-situ coking of the coal in the melter-gasifier, a large portion of sulphur is captured in the slag, dramatically decreasing emissions of gaseous SO2 or H2S.

Typical analysis of hot metal from procfss Corex process consists of carbon — 4. Corex process captures most of the pollutants in an inert state in the slag and the released hydrocarbons are destroyed in the dome of the melter-gasifier. Your email address will not be published. Reducing gas for the shaft furnace is produced by partial combustion of coal irn oxygen in the fluidized bed maknig the melter-gasifier. The outputs can be used either by integrated mills or EAF electric arc furnace mills.

Smelting reduction processes come in two basic varieties, two-stage or single-stage. The rest of the hot gas is then cooled and sent into the reduction shaft resulting in maing Corex export gas which is used to control pressure in the plant.


Corex Process | Industrial Efficiency Technology & Measures

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. Languages Deutsch Italiano Edit makign. 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, this particular problem can be mitigated by using the export gas in electricity production. After the commercial success of C module, Corex process developer started offering also higher capacity modules namely i C Limitations of the Corex process include i optimized distribution of coal and DRI is needed in the melter-gasifier to avoid peripheral flow of hot gases, ii absence prcoess post combustion results into the loss of the chemical energy in the export gases resulting into high consumption of coal, iii many of the equipments such as cooling gas compressor are maintenance oriented, iv transfer of hot DRI and recycling of the hot gas are hazardous especially during their maintenance periods, vi melter-gasifier is subjected to high occurrence of pressure peaks on account irno use of raw coal with poor char bed conditions resulting into jamming of dust recycling systems as well as gas cleaning systems, vii sensitiveness of the process inputs quality parameters such as granulometry, percentage of fines in the inputs, decrepitation, and degradation behaviour of coal, iron ore and pellets at high temperature.

Corex process distinguishes itself from the blast furnace route by i direct use of non-coking coal as reducing agent and energy source, ii Iron ore can be directly and feasibly charged to the process in form of lump ore, and pellets, and iii use of pure oxygen instead of nitrogen rich hot blast.

Furthermore, it has also been found that Corex plants require large amounts of oxygen which can be expensive.

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