The corex Process

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The Corex- Process Since the eighties Voest Alpine developed the coal reduction process. The Corex- Process is an alternative to the conventional hot metal production because hot metal is produced without coke. Since 1981 lump ore, pellets and sinter have been successfully tested. The most important advantages are: • Only coal instead of coke is used • Lump ore, pellets may be used The Process: The raw materials are iron ore, coal and additives. These three components are charged via a lock system. The coal gets through a screw convey from a storage bin (number 3 in the picture) into the melter gasifier. 1 In the upper part of the melter gasifier the coal is completely dried and gasified with the reducing gas which has a temperature of 1100° C. The reduction proceeds rapidly, thus enhancing the conversion from coal to coke which is gasified and with oxygen blown in. The gas flows in the cylindrical part of the melter gasifier and because of this a stable fluidered bed occurs. Upstream of the tuyeres oxygen reacts with carbon to a form of CO2 which is then converted to CO by using coke. The temperature of the fluidered bed is between 1600 and 1700° C. After leaving the melter gasifier the hot raw gas is mixed with cooling gas to reach a temperature of 900°C. After this the gas is cleaned in the reduction shaft. 4 Part of the pre- cleaned gas goes into a Venture 5 scrubber to obtain cooling gas. The fine particles, which are separated from the gas, are recycled into the melter gasifier. In the reduction shaft 2 the iron ore is reduced to sponge iron. The hot sponge iron goes then from the reduction shaft via screw conveyers and drops by gravity into the melter gasifier. In the fluidered bed the fall of the material is strongly decelerated. In the melter gasifier the sponge iron is heated up and melted to form a hot metal and a slag bath

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