Technological Advance of the FINEX Ironmaking Process
FINEX Process Outline Ⅱ Advances in Commercial Operation Ⅲ Scale-up to 2.0 MTPA FINEX Ⅳ Ⅴ Environment and Energy Synergy
Comparison of Process Conventional Blast Furnace Process Sinter Plant Cooler Sinter Fine Iron Ore Pellet Plant Roasting Cooler 5~50 mm Pellet Blast Furnace Lumpy Iron Ore Coking Coke Plant CDQ & Quenching 10~16mm Coke 5~75 mm Reduction & Hot Blast Melting (1,200 o C) Hot Metal (1,500 o C) FINEX Process FBR (Reduction) FINEX HCI 5~30 mm Fine Iron Ore Non-coking No need for raw material pretreatment process Briquettes 50 mm Melter Gasifier (Melting) Oxygen Hot Metal (30 ) (1,500 o C) *FRB: Fluidizing Bed Reactor, HCI: Hot Compacted Iron
Scale-up History Jun. 2003 0.6 MTPA FINEX (Demo) Apr. 2007 1.5 MTPA FINEX Jan. 2014 2.0 MTPA FINEX FINEX R&D Kick-off 1992 Model Plant (15t/d) Pilot Plant (150t/d) No.1 FINEX (0.6 MTPA) No.2 FINEX (1.5 MTPA) 1996 1999 2003 2007 No.3 FINEX (2.0 MTPA) 2014 2.0 1.5 1.0 0.5 0.0 Annual Production (MTPA)
Panoramic View No.2 FINEX (1.5 MTPA) No.1 FINEX (0.6 MTPA) No.3 FINEX (2.0 MTPA)
FINEX Process Flow Ore Fine Non-Coking R4 Hot DRI Compaction Briquettes R3 R2 Fluidized Bed Reactor R1 CO 2 Removal Power Plant Meltergasifier PCI Oxygen Oxygen Plant
Hot Compacted Iron DRI Fine HCI Item Unit HBI HCI Flux % 0 13 Density % 5.0 3.8 ~ 4.5 Reduction % 95 60 ~ 75 Size mm 110 60 30 15 cc 200 9 HCI Machine Item Unit HBI HCI Capacity t/h 35 75 Hot Charging Conveyor Roll Tire Life Time month 3~5 10 Avg. ton 80,000 18,000
Briquettes Fine Binder Cold Strength (%) 78 95 100 Mixing Lump Briquettes Coke Hot Strength (%) 100 46 35 Briquettes Lump Briquettes Coke
Ⅰ FINEX Process Outline Advances in Commercial Operation Ⅲ Scale-up to 2.0 MTPA FINEX Ⅳ Ⅴ Environment and Energy Synergy
Operational Results (1.5 & 2.0 MTPA) Indices No.2 FINEX Design Normal Cokeless No.3 FINEX Production Fuel Rate MTPA 1.5 1.5 1.3 2.0 t/d 4,200 4,300 3,600 5,800 820 720 790 710 Coke 70 60 0 130 kg/t-hm B.Q - 475 560 425 PCR 140 160 230 155 Hot Metal Slag [S] wt% 0.030 0.030 0.045 0.020 [Si] wt% 0.80 0.65 0.26 0.70 Volume kg/t-hm - 280 340 280 Al 2 O 3 wt% - 18.0 16.5 17.0
Mean Size(mm) Flexibility in Iron Ore 10.00 1.00 Lump R Y Sinter Feed A Hematite OMC M P H M S C G W Fine & Semi Magnetite B S 0.10 N Magnetite C Pellet Feed 0.01 Goethite Hematite Magnetite H 2 O (%) FeO (%) A C B : Operation up to 100% (Al 2 O 3 content 2.0 ~ 3.0%) In Blast Furnace, Al 2 O 3 content is less than 2.0% : Operation up to 30% magnetite, Final target 50% magnetite
Flexibility in Indices V.M (%) Ash (%) FSI BF FINEX Demo Commercial Semi Anthracite Semi Coking Hard Coking Thermal Briq. Thermal Semi- Soft Coking 30~38 < 17 0~2 28~34 < 10 1~6 40% Coke 40% Briq. 60% 15% Briq. 75% 100% 80% 60% 28% 42% 14% 49% Hard Coking 20~25 < 10 6~9 60% 10% 40% 20% 30% 11% 25% PCI Semi- Anthracite 10~15 < 15 0~2 PCI 0% BF FINEX Further efforts will be made to increase the use of low grade coal
Ⅰ FINEX Process Outline Ⅱ Advances in Commercial Operation Scale-up to 2.0 MTPA FINEX Ⅳ Ⅴ Environment and Energy Synergy
Design of Fluidized Bed Reactor Lower CAPEX by 3-stage FBRS (optimum reduction degree)
Burden Distribution Simplified Equipment Uniformity of Distribution 1.5 MTPA 2.0 MTPA 1.5 HCI MTPA 2.0 MTPA HCI Shaft furnace (700m 3 ) Screw (8ea.) Flap (8ea.) Gimbal Gimbal Screw (Mixing) Point charging Mixed charging Uniform distribution of HCI/coal mixture by changing from separate charging to mixed charging, enhanced flexibility in selecting various distribution modes
Features of Slim FINEX
Ⅰ FINEX Process Outline Ⅱ Advances in Commercial Operation Ⅱ Scale-up to 2.0 MTPA FINEX Environment and Energy Ⅴ Synergy
Waste Heat and Dust Recycling Picture of Waste Heat Recovery System Schematic for Waste Heat and Dust Recycling
Solution to Air Pollution Ore Fine S Flux CaS into Flux SOx Desulfurization by flux in fluidized bed reactor 100 SO x BF NO x Dust S Reduction Gas NOx combustion by not air but oxygen 50 Sinter Coke 28% Oxygen H 2 S in Gas Dust Integrated process from resources charging 0 3% 1% to pig iron BF FINEX BF FINEX BF FINEX
Ⅰ FINEX Process Outline Ⅱ Advances in Commercial Operation Ⅱ Scale-up to 2.0 MTPA FINEX IV Environment and Energy Synergy Effects
Synergy effects on Brown Field Works Blast Furnace (Benefits) Synergy FINEX (Contributions) 35~75mm Coke Over-sized coke Yield increase Under-size (10~35mm) Coke-dust ( 0.1mm) Under-sized coke Dust recycling Sinter Yield increase Quality improve 3~50mm Under-size ( 3mm) High Al 2 O 3 ore Low Al 2 O 3 ore Sinter fine High Al 2 O 3 ore BF High production & High efficiency Low price O 2 /electricity High efficiency power plant & O 2 plant
Synergy Effect with Chemical Plants
Summary Since initiation of R&D activity of FINEX in 1992, FINEX has been scaled up to 2.0 Mt/y. FINEX proocess was proven to have flexibility to various kinds of raw material which are limited in the blast furnace process. The combination of FINEX with blast furnaces and chemical plants creates significant synergy effects in terms of raw materials. FINEX is expected to sharpen the competitive edge by continuous challenges of the improvement of operation and facility.
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