Coal Injection. Pulverised. in Blast Furnace. Blast furnace iron making continues. - N. M. Rao, Consultant (I&S) May 2016

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1 Pulverised Coal Injection in Blast Furnace - N. M. Rao, Consultant (I&S) Blast furnace iron making continues be the most efficient large scale industrial process for production of hot metal from iron ore. Hot metal is the liquid ferrous base for production of steel. Proportion of hot metal in the total metallic input for steel making (world average), increased from 60% in 2005 to 62.5% in Among the top ten steel producers, it is less than 50% only in case of India, US and Turkey. In India, this proportion was about 5% in (50% in ) mainly due to availability of DRI, whose proportion was 17%. In spite of lower proportion, production of blast furnace hot metal in India increased from 3.67 MT in to MT (provisional) in ; growth during the period being about 65%. However, blast furnace process suffers from the following: l It is a capital intensive process and requires setting up of Coke Ovens and Sinter Plant. It also requires more land and water. l The process requires superior quality raw materials with good consistency. l The process generates considerable quantity of greenhouse gas emissions and contributes approximately 70% of total emissions in BF-BOF route. Alternate processes of iron making like DRI and SR processes have still not reached a stage, where they can support large capacity integrated steel plants whether based on BOF or EAF. Inspite of having alternate iron making processes like DRI, Corex etc., steel companies like JSW (at both Toranagallu and Dolvi), JSPL, Essar steel, Bhushan steel, BPSL etc. have set up blast furnaces also. SAIL, RINL and Tata Steel fully depend on blast furnace for iron production. Therefore, blast furnace process has to be made more productive and economical to reduce cost of production of steel. Measures to Improve Blast Furnace Performance Important measures for improving productivity of blast furnaces and reducing coke consumption & GHG emissions are: 1. Setting up large capacity blast furnaces with improved cooling system and use of better quality refractory bricks to achieve economies of scale and higher life. 2. Adopting bell less top and conveyor charging in place of two bells & hopper and skip charging for better distribution of charge materials inside the furnace. 3. High Blast Temperature ( C) and high top pressure (2.5-3 bar) operation along with top recovery turbines.. Use of 90% or more agglomerated burden (sinter and pellets) 5. High capacity stoves with external combustion and waste heat recovery 6. Efficient stock house and cast house dedusting system 7. Cast house slag granulation 8. Process automation, mathematical modelling and expert systems for intelligent process control 9. Auxiliary fuel injection (coal, oil or 39

2 Analysis natural gas) along with oxygen enrichment of blast up to % to reduce coke consumption and GHG emissions. Use of oil has been mostly discontinued on cost considerations. Natural gas is being used in countries like USA and Russia where it is available at competitive prices. Natural gas gives better permeability compared to coal and also does not increase sulphur and ash load. However, it has a higher H/C ratio and less heat is evolved during combustion and hence endothermic effect is more compared to coal. Therefore, coal injection permits higher coke reduction compared to natural gas. Details of coal injection or PCI in respect of coal quality, process, benefits and usage pattern in some countries & major companies and Indian scenario are discussed in this paper. The PCI Process and Technical Requirements Non-coking coal of suitable quality and of 0-50 mm size is ground in grinding mills. Pulverised coal size could be either 95% -2mm ( mesh) & 20% mm (200 mesh) or 0% -2mm and 80% mm. Waste gas from blast furnace can be used for drying operation. Natural gas may also be used. An inert atmosphere must be maintained to mitigate the potential for fires and explosions. Gas and coal are separated in a cyclone and bag filter system and then sent for storage. From the storage bunker, pulverised coal is sent through a distributor for injecting through the blast furnace tuyeres. Coal preparation system represents about two-thirds of total capital cost of coal injection system. Basically the system consists of receiving hopper, raw coal bunker, air heater, pulveriser, cyclone, bag filter, reservoir tank, feed tanks, dispenser (nitrogen and air compressors) and distributor. Increase of PCI rate and simultaneous decrease of coke rate is achieved as long as pressure drop in blast furnace or carbon rate in top gas dust does not increase significantly. Hence, best possible gasification of injected pulverised coal within the tuyere and raceway of blast furnace has to be achieved. For this, following are important. l Retention time of the injected pulverised coal particles has to be maximised. Hence, speed of injected coal particles has to be reduced to the minimum. l Ingress of nitrogen into the blast furnace via pulverised coal injection system has to be minimised. To achieve this transport gas loading of pulverised coal injection has to be maximised. l Gasification of carbon needs oxygen and large surface so that reaction can take place at as many places as possible simultaneously. Therefore, oxygen level in coal cloud has to be maximised by good mixing of injected coal and the hot blast. Injected coal should have a small mean diameter to create large reaction surface. l High oxygen level next to injected coal is necessary to accelerate the speed of coal gasification. This can also be achieved by preheating of pulverised coal before injecting into tuyeres. l Oxygen content in blast up to 30 to 35% PARAMETER Proximate Analysis : Total Moisture,% Inherent Moisture, % Ash, % Volatile Matter, % Sulphur, % Phosphorous, % Calorific Value, Kcal/Kg HGI Ultimate Analysis : Carbon, % Hydrogen, % Nitrogen, % Oxygen, % Chlorine, % Flourine (ppm) Boron (ppm) Ash Analysis SiO2, % Al2O3, % Fe2O3, % TiO2, % CaO, % MgO, % Alkalies (Na2O + K2O), SO3, % P2O5, % Others, % (depending on the injection rate) is useful for better gasification of coal particles. This will also help to maintain RAFT. l An even distribution of coal to all tuyeres has to be done to achieve stability and uniformity of the process l Raw material quality parameters like CSR of coke, RDI of sinter and ash fusion temperature of PCI coal are very important Quality of PCI Coal and Importers To obtain best results, PCI coal quality DESIRABLE ABSOLUTE LIMIT TABLE - 1 0

3 should be such that replacement ratio should be as high as possible. Low volatile coals give a replacement ratio of 0.90, while in case of medium volatile coals, it comes down to Hard grove grindability index and ash fusion temperature are also critical. Detailed indicative specifications are shown in table-1. China 21.1 Ash Fusion Temperature (Free Flow), C Size Range, mm -30 mm, % minimum -0 mesh, % maximum Japan India.7 Brazil 3.8 Benefits and Costs of Using PCI Benefits of using PCI may be summarised as under: l It replaces high cost coking coal which is used for manufacture of metallurgical coke. For every tonne of coal injected, about 0.9 tonnes of coke can be saved. While price of metallurgical coke was about $150/T in March, 2016 (coking coal cost was $ 90/T), that of PCI coal was about $ 70/T. At an injection rate of 150 Kg/THM, savings would be around $/THM. At higher injection rates, savings will be more. l Energy savings are estimated at 3.76 GJ/T injected coal l At an injection rate of 180 Kg/THM, MT of CO2 could be saved. l Coke making capacity can be reduced by about 00,000 TPY for a 3 MTPA blast furnace plant, if the PCI rate is 150 Kg/THM. Investment of coal grinding equipment could be around $ 50-55/T coal injected. Other TABLE - 2 Country Japan S. Korea Germany Russia India France USA UK Netherlands cost is for additional oxygen. Wear and tear of furnace lining could be slightly higher in case of PCI. Total cost is estimated at around $ 5/THM, thus giving a net benefit of $ 5/THM, at an injection rate of 150 KH/THM, without considering benefit due to reduction in metallurgical coke making capacity. PCI Use in Select Countries and Companies Average PCI rate (Kg/THM) in some selected countries during the period is shown in table-2. This is based on hot metal production (MT) and PCI consumption. In USA and Russia, PCI rate is low as low priced natural gas is available. In India, practice of PCI is yet to fully stabilise. In all other countries, injection rate is between 150 Kg/THM and 250 Kg/THM. In China, Bao Steel, Taiyuan Steel, Shougang Steel etc. use a PCI rate of more than 200 Kg/THM. PCI rate in Severstal, Russia is about 170 Kg/THM. Performance of some internationally bench marked blast furnaces is shown in table It may be noted from tables-2 &3 that except where natural gas is available at an economic price, coal injection is the norm and country averages for injection rate are in the range of 150 Kg/THM to 250 Kg/THM. Some specific companies are consistently using above 200 Kg/THM. Some blast furnaces, with inner volume more than 5000 m³ and using more than 150 Kg/THM PCI are: POSCO Pohang No (180), POSCO Gwangyang No (170), Hyundai Steel BF Nos 1-3 (180), JFE Fukuyama No (167), Shagang No 1 (190) and Thyssen Krupp Schwelgern No 2 (156). With an injection rate of 200 Kg/THM, the coke rate is around 300 Kg/THM and productivity is around 2.5 T/M³/D. As per consultancy firm CRU, demand for PCI coal will grow at the rate of 1.6% during the next three years compared to only 0.3% for coking coal. The Indian Scenario Indian steel plants have been slow to adapt to coal injection. Even today, it is below 50 Kg/THM in SAIL plants (except large capacity

4 Analysis TABLE - 3 Parameter Netherlands Ijimuiden, BF 7 Gwangyang BF 2&3 Gwangyang BF 1&5 Germany Thyssen BF 2 Japan NSC Kimitsu BF 3 Working Volume, m³ Sinter, % Pellet, % Nil Tuyeres, Nos % Oxygen enrichment Productivity, T/m³/D Top Pressure, bar HBT, C Coke Rate, Kg/THM, Kg/THM Coke Ash, % Hot Metal Si % Slag Rate, Kg/THM new furnaces). For instance, in Bhilai, shop average PCI rate was 2 Kg/THM in In other SAIL plants, it is more or less at the same level. In RINL, there was no provision for coal injection in 3 MT stage. The envisaged rate in BF 3, which came up in 6.3 MT stage, is 150 Kg/THM. In BFs 1&2, provision for PCI has been made during capital repairs. Private sector performance is better in this regard. In Tata steel, shop average injection rate ranged between 121 Kg/THM and 133 Kg/THM during the period to Injection rate improved to 168 Kg/THM in (coke rate was 380 Kg/THM). JSW is achieving an injection rate of Kg/THM. JSPL is reported to have achieved a rate close to 200 Kg/THM in BF No 2. In SAIL Rourkela s Blast furnace No 5, an injection rate of 160 Kg/THM was achieved during performance guarantee tests. Corresponding coke rate was 370 Kg/THM. Generally, in Indian plants, total fuel rate is about 550 Kg/THM against international norm of 500 Kg/THM. Reasons for late adaption of this technology, low injection rates and higher total fuel rates could be attributed to following factors. l In many cases, provision was not made for this technology originally. In some case there are space constraints to introduce this subsequently. l Many furnaces are of smaller size and they operate with lower blast temperature and lower top pressure. l Use of agglomerated burden is generally below 80%. l Al2O3 load through iron ore is higher resulting in higher Al2O3 in slag. l In spite of using imported coke in the blend, ash in coke is above 12% and in some cases 15% (in Tata steel who use up to 50% indigenous coking coal). l Oxygen enrichment of blast is only about 5%, against international practice of %. l In some older furnaces, cooling system and refractory cannot withstand high injection rates. l Required quality of coal is not available in India. Hence, Indian steel companies have to depend on imports for both coking coal and PCI coal. Some new furnaces commissioned recently have been provided with most of the required features (a few more will be commissioned shortly). Some old furnaces have been modified. With this injection rates are expected to go up. A list of such furnaces is given in table-. Above 20 blast furnaces add up to a capacity of about 50 MTPA of hot metal and all of them have provision for average injection rate being plus 150 Kg/THM. When all these furnaces fully stabilise, country s average injection rate is expected to be Kg/THM against about 82 Kg/THM achieved in 201. Apart from the above, BF-3 of SAIL, Bhilai (1719 m³) BF-, SAIL DSP (1800 m³); BF- SAIL, RSP (1658 m³); BF-2, JSPL, Raigarh (1681 m³); BFs 1, 3, and 5 of Bokaro (2000 m³ ); Blast furnaces of Essar Steel (2000 m³) & JSW, Dolvi (2518 m³); Tata steel BF-F (1800 m³) and BF of NINL (1915 m³) have provision for coal injection. These 12 furnaces add up to about 20 MT of hot metal capacity. PCI facility is available in some other smaller furnaces and some MBFs also. BF-2 of JSPL is the best performing furnace with an injection rate of 200 Kg/T, hot blast temperature of 1200 C and productivity close to 3.0 T/M³/D. The company has asked Danieli-Corus to examine the technical feasibility of further increasing the injection rate to 250 Kg/THM. Conclusion India will continue to depend on Blast furnace for achieving the future steel capacity and production targets. It is therefore essential to take measures to get high productivity and low coke rate in blast furnaces. This will also help in reducing greenhouse gas emissions. 2

5 TABLE - Company / Furnace Useful Volume, m³ Hearth Diameter, m Annual Production, MT Number of Tuyeres Other Features Remarks Jamshedpur BF-H, RINL BF-3, Bhushan steel BF SAIL, ISP, Burnpur Jamshedpur BF-G SAIL, RSP, BF JSW Torangallu BF- 3&, JSPL, Patratu SAIL, Bhilai BF BPSL BF SAIL, Bokaro BF SAIL, Bhilai BF RINL BF JSW, Torangallu, BF Kalinganagar BF-1 Jamshedpur BF-I NMDC, Nagarnar BF JSPL, Anugul TRT MW PCI TRT- 6.0 MW, PCI Copper Copper TRT MW, Copper TRT-1.0 MW, TRT- 1.5 MW, TRT, Bhushan s Furnace to be commissioned JSPL s Patratu Furnace to be Furnace to be BF-2 will be Similar After Capital Repairs Under Commissioning To be In Planning Stage Pulverised coal injection along with high blast temperature, high top pressure, oxygen enrichment of blast and up to 90% use of agglomerates will help in achieving these objectives. Efforts have to be made to achieve PCI rate of 150 Kg/THM by 2020 and 200 Kg/THM by 2025 (country average) in order to meet the targets for steel production. During capital repairs, capacities of older furnaces should be suitably enhanced and latest technological features should be incorporated. To take care of space problem, if any, near the blast furnace, provision of intermediate transfer station could be considered. These stations can handle long distances of up to 1.5 Km between pulverising & drying facility to the injection facility. References ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; 3

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