Fine ore is preheated and reduced to dri in a four stage fluidised bed system. Finex as an environmentally sustainable ironmaking process. In the area of steelmaking, bof plant practice including pretreatment of hot metal, metallurgical features of oxygen steelmaking processes, and their control form part of the book. Therefore coke making and sintering of fine iron ore can be. The finex process is an innovative ironmaking process which has been developed by siemens vai and posco. This project seeks to demonstrate the scaleup feasibility of the process allowing for new ironmaking capacity at a significantly lower capital cost than with traditional systems.
The main benefits of the finex process include process efficiency, lower environmental impact, process simplification through removal of process steps. Finex process is a commercial proven alternative iron making process for the production of hot metal hm in addition to the blast furnace bf process route, consisting of bf, sinter plant, and coke oven. The iron nuggets are slag free and are also free from re oxidation. Furthermore, the thermodynamic behaviour of volatile elements potassium, sodium, chlorine, fluorine and zinc is described in typical atmospheres for iron making processes. Elimination of preliminary processing is claimed to make the plant for finex less. Finex can use noncoking coal and a fine ore that might otherwise serve as sinter feed. This process is based on the direct use of noncoking coal. Alternative iron making processess linkedin slideshare. Besides corex, finex is the only commercial proven alternative iron making process to the blast furnace bf route, consisting of blast furnace, sinter plant and coke oven, generating hot metal. Jan 18, 2014 finex process siemens vai and posco jointly developed the process. Pores are left behind in the dri after oxygen has been removed. Finex process is a fluidized bed based process using ore fines instead using iron ore lumps and pellets. Ironmaking and steelmaking metallurgical and materials.
A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. Most exciting iron making technology on the market today. Ironmaking capability arguably deter mines the strength. This is a process with great potential with regard to productivity and the low. Smelting reduction technology is an alternative technology to the conventional blast furnace. Posco commence construction of new steel plant that will use. Direct reduced ironis a process in which iron ore is reduced to the solid state or by gaseous reducing agent. The first involves the production of molten iron and the second is that of actual steel manufacture. In addition, use of coal as the primary fuel for iron and steel production means that iron and steel production has among the highest carbon dioxide co 2 emissions of any industry. Elimination of preliminary processing is claimed to make the. A series in which both limestone and coke were varied in the charge. The manufacturing process iron ore is converted to steel via two main steps. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. May 20, 2008 the finex smeltingreduction process based on the direct use of noncoking coal and fine ore is perhaps the most exciting iron making technology on the market today.
The finex process can directly use iron ore fines without any kind of agglomeration. Because the preliminary processing of raw materials is eliminated, the construction of the finex plant will cost 8% less to build than a. Alternative emerging ironmaking technologies for energy. Ferrous metallurgy is a process of iron coal chemical engineering at high temperature. It does not generate fines and is easy to transport. As the finex process is commercialized and processed by the steel producer posco, a. Reduction in charge requirements of hismelt ironmaking process in indian context article pdf available in american journal of engineering and applied sciences 611. Finex is the name for an iron making technology developed by former siemens vai now primetals technologies and posco. The finex smeltingreduction process, developed by siemens vai and the korean steel producer posco, is based on the direct use of noncoking coal and fine ore. In the finex process, fine iron ore is charged at the top of a cascade of fluidized bed reactors where it is heated and reduced to directreduced iron dri by means.
The facility will bring proven commercial technology currently used in asia to the north american market. Modern developments in blast furnaces, including modelling and process control are discussed along with an introduction to the alternative methods of ironmaking. Iron and steel manufacturing is one of the most energyintensive industries worldwide. The itmk3 process is similar to fasmelt except that there is no melting process and therefore the product will be in the form of pig iron nugget. Blast furnace ironmaking an overview sciencedirect topics. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. When iron is reduced from iron ore, first it could be a solid state. It is distinguished by the production of highquality liquid hot metal, on the basis of directly charged iron ore fines, and coal as the reductant and energy source. Hismelt process of ironmaking hismelt is short for high intensity smelting. Rio tinto has for many years been a trusted supplier to the worlds iron and steel industry, particularly in south east asia, where its australian mines offer costeffective raw material. Maritime iron is developing a merchant pig iron processing facility using proven leadingedge technologies to minimize its environmental footprint. Finex the ironmaking solution of the 21st century youtube. Molten iron is produced directly using iron ore fines and noncoking coal rather than processing through a sinter plant and coke ovens as traditional blast furnace route.
The blast furnace has been the dominant technology for iron production for centuries. Molten iron is produced directly using iron ore fines and noncoking coal rather than processing through sintering and coke making. A series in which the amount of coke in the charge was varied, other components remaining constant. The process has been developed to treat iron ore fines with minimum pretreatment, making the process more flexible in terms of the quality of iron ore it can treat. Finex is the name for an iron making technology developed by siemens vai and posco. The key technologies of finex are fluidized bed reduction of ore fines, hot dri fines compaction to hcihot compacted iron. Iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities. Posco signs mou with uttam steel and power limited uspl to set up a 3 mtpa integrated steel plant at satarda, india. Posco commence construction of new steel plant that will. An itmk3 plant can be placed either at the iron mine site or near steel making facilities.
Aug 18, 2004 the finex process is an innovative, next generation iron making technology. The finex process a commercially proven alternative iron making process to the conventional blast furnace route the milestones of the finex process in december 1992, posco and primetals technologies signed a cooperation agreement for the joint development of the finex process. Ironmaking and steelmaking direct reduction, scrap processing, melting, refining and recovery plants. The finex process, developed by siemens vai and posco is an innovative methodology in which molten iron is produced directly using iron ore fines and noncoking coal. This is a process with great potential with regard to productivity and the low cost production of hot metal. Reduction in charge requirements of hismelt ironmaking. The coke is of course the source of reduction of iron ore by providing carbon to iron ore and when it burns, and it also generates a lot of heat. Jul 02, 20 hismelt process of ironmaking hismelt is short for high intensity smelting. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium bc iron was being produced from iron ores from at least greece to india, and. New iron making processes have been extensively explored with a view to saving resources and energy, as well as reducing environmental pollution. It eliminates sinterpellets plant and coke oven battery. It has a wide range of properties that are largely determined by its chemical composition carbon and other alloying elements.
The major difference between the corex and finex processes is that the finex process can directly use sinter feed iron ore up to 0. The iron nugget is an excellent raw material for eaf or bof steel making. Finex can replace the blast furnace technology, the dominant steelmaking process for 100 yrs competitiveness over bf finex innovation case study 6 the worlds first commercialized new ironmaking process 1 finex completed in may 2003 annual production of the demo plant. In the corex process, a combination of lump ore, pellets, and sinter is prereduced to about 90% metallization sponge iron in the reduction shaft furnace by a gas containing co and h 2 supplied from the melter gasifier, which is the main reactor of the corex plant. Development of innovative alternative iron making process technologies to use low grade, low cost resources and to reduce the level of air pollution new, lowcost process technologies to secure virgin iron for eaf continuing development of highgrade, highmargin steel products for bf mills to differentiate their markets from eaf mills. Finex process flow sheet finex produces hot metal with comparable quality to the conventional blastfurnace route i. An itmk3 plant can be placed either at the iron mine site or near steelmaking facilities. Sublancebased bof process control hot metal desulphurization.
The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic iron nickel. The iron nugget is an excellent raw material for eaf or bof steelmaking. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon most important impurity are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel. Finex process siemens vai and posco jointly developed the process. The finex process for making steel is better for the environment and lower cost the finex process uses less expensive powerstation coal and fine iron ore which is available all over the world approximately 80 % of iron deposits in the world. Products ironmaking and steelmaking direct reduction.
Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. Request pdf finex as an environmentally sustainable ironmaking process finex is an alternative ironmaking process to the blast. Ironmaking 101 from ore to iron with blast furnaces. The process produces highgrade iron nuggets with better meltability than pig iron during the steel making stage. The manufacturing process consists of many procedures and consumes plenty of resources and energy. Co 2 abatement in the iron and steel industry 5 steel is basically an alloy consisting of iron, 0. A falling stream of iron ore particles is directly converted to metal in just seconds using low cost natural gas. Step 1 the production of molten iron the primary concentrate is mixed with limestone and coal and heated. Five groups of experiments were made on the electricfurnace production of pig steel, arranged as below.
The primary reduction of the iron oxide feed stocks takes place in the reduction shaft furnace. So heat energy required for ironmaking process is supplied by this coke and this is a source for carbon of hot metal. Finex process for liquid iron production ispatguru. Discover the technology that is making steel production. An interesting representative of such processes is the blast furnace iron making process 1 2 3, which uses multisensors such as two manual measurements and two infrared acquisitions to. The process duration varies with the injection rate, hot metal chemistry, and desired final sulfur content, and is in the range of 5 to 30 minutes. Steelmaking is the process of producing steel from iron ore andor scrap. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. The finex process is jointly developed by posco, korea and primetals technologies, austria. In 1992, posco and vai, austria signed an agreement to work together for a joint development of the finex process. Dec 02, 2009 ii absence of post combustion means that much chemical energy is lost in the exit gases and consequently the coal consumption in corex is much higher than in any other iron making process. Finex is a fluidizedbed smelting reduction process, and is considered to be a. The finex process is an innovative, next generation iron making technology.
In the finex process, fine iron ore is charged at the top of a cascade of fluidizedbed reactors where it is heated and reduced to directreduced iron dri by means of a reduction gas derived from the gasification of the coal that flows in the countercurrent direction to the ore. Thermochemical modelling of the finex process to determine. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. The process reduces iron ore using a reforming gas made from natural gas. Elimination of preliminary processing is claimed to make. The manufacture of steel nz institute of chemistry. To develop computational and mathematical abilities to be applied for process design and control. Based on the direct use of noncoking coal and fine ore. The finex process of iron making features, merits and. Finex steel process better for environment and lower cost. The finex process combines coking plant, sinter plant and blast furnace into a single iron making unit. The finex is the latest addition and an optimized fineore smelting reduction sr iron making process based on the direct use of the coal and iron ore fines. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace.
In 2006, direct industrial energy and process co2 emissions amount to 7. Finex can replace the blast furnace technology, the dominant steel making process for 100 yrs competitiveness over bf finex innovation case study 6 the worlds first commercialized new iron making process 1 finex completed in may 2003 annual production of the demo plant. However, many of them were not so successful yet, but probably the only commercially successful process is finex. Finex is an innovative ironmaking process jointly developed by primetals technologies and the korean steel producer posco for the production of hotmetal based on the direct use of fine ore. Manufacturing process engineering came from the technological development and profound change of the steel industry. Posco has been operating the worlds first commercial finex plant, with 1.
Pdf calculating the value of iron ores in ironmaking and. Directreduced iron process dri nippon steel engineering. Emerging energyefficiency and carbon dioxide emissions. It is a direct smelting process for making liquid iron straight from the iron ore. Molten iron is produced directly using iron ore fines and noncoking coal rather than traditional blast furnace methods through sintering and reduction with coke. Pdf corex process in ironmaking elvis marca catachura. Fluidizedbed technology for the t production of iron. The dri is used mainly as the raw material for electric arc furnaces eafs, as a clean iron source substitute for scrap iron.
Pdf reduction in charge requirements of hismelt ironmaking. Abstractfinex is an alternative ironmaking process to the blast furnace route. Several types of alternative iron making process have been investigated and developed, in order not to emit this kind of gases and to compete with available low quality ores. These pores, if filled with water, for example, can cause the iron to reoxidize with.
The sponge iron is delivered as hot from the reduction shaft furnace by screw. Consolidation of the iron and steel branches manifested itself in a significant increase of mergers and takeovers. Ferrous metallurgy is the metallurgy of iron and alloys. A novel flash ironmaking process department of energy. Environmentfriendly corex, finex and midrex ironmaking. Magnetic separation is used to remove some of the undesirable minerals or gangue in the crushed ore.
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