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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The process has three stages. Corex process was developed by the Austrian technology supplier VOEST in the late s, and its feasibility was confirmed during the s. Views Read Edit View history. Fig 3 Comparison of concepts of blast furnace route and Corex route. Due to this increased maming 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.

This page was last edited on 10 Mayat It takes only half an hour to stop the plant and only four hours to restart it.

Corex Process | Industrial Efficiency Technology & Measures

Retrieved November 3, Many of the gases resulting from this process can then be recycled or used to produce electricity. Leave a Reply Cancel reply Your email address will ieon be published.

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 rest of the hot gas is then cooled and sent into the reduction shaft resulting in the Corex export gas which is used to control pressure in the plant. The main reagents for the Corex process are iron orenoncoking coaland oxygen.

Corex Process – Wikipedia

In a Corex process, the blast furnace concept is used but forex blast furnace is virtually split into two halves at the makig zone interface Fig 3.

The temperature of liquid slag is around deg C to deg C. So, the phosphorous content of ore and coal should be as makking as possible. Due to its high calorific value, this gas can be recycled for reduction work or used for heat or energy generation. Limitations of cirex 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 of 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 makibg, vi melter-gasifier is subjected to high occurrence of pressure peaks on account of use of raw coal with poor char bed conditions resulting into jamming of dust recycling systems corrx 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.


This calls for high heat transfer efficiency. Smelting reduction processes come in two basic varieties, two-stage or single-stage. Hot DRI is mechanically transferred to the melter-gasifier where the second and third stage of the process takes place. The hot metal produced has carbon and silicon contents similar to blast furnace hot metal. Meanwhile, in a two-stage process, like Corex, the ore is reduced proceds one shaft and melted and purified in another.

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.

Emission values are already far below the maximum values allowed by future standards. The remaining gas is mixed with the cleaned off gas from the shaft furnace and the mixture is used as export fuel gas. The air emissions are also lower than the conventional BF units. After being reduced, the DRI is procees to the char bed where the iron and slag are melted and then directed to the hearth zone.

It is an industrially and commercially proven direct smelting reduction process which allows for cost-efficient and environmentally compatible production of hot metal directly from iron ore and non-coking coal.

Corex Process for Production of Iron

The first stage of the process takes place in the reduction shaft, where iron ore burden is reduced by gases emanating from the melter-gasifier and is converted to hot DRI.


Procsss the process third stage which takes place in the upper part of the melter-gasifier, a fluidized bed of coal char is maintained.

Smelting reduction process is that process which is based on smelting reduction technology and hence in this process the production of hot metal is carried out without the use of metallurgical coke.

Non-coking coal, limestone, and quartzite are charged by means of a lock hopper system into the freeboard above the fluidized bed area where they are heated rapidly to deg C to deg C. The melter-gasifier can largely be divided into three reaction zones namely i gaseous free board zone upper part or domeii char bed zone middle part above oxygen clrexand iii hearth zone lower part below oxygen tuyeres.

Languages Deutsch Italiano Edit links. However, nearly all of the sulphur in the non-coking coal enters the slag and hot metal.

Typical specific consumption figures in per ton of hot metal are around kg for dry non-coking coal, kg for additives and cum for oxygen. The use of lump ore or pellets also dispenses with the need for sinter plants.

This module has a hearth diameter of 7. Use of high purity oxygen in the Corex process generates of nitrogen free top gas. Sulphides discharge is around 0. In this regards, organic sulphur in the coal gasifies and is absorbed by the DRI and returned to the melter-gasifier as iron sulphide. Also the export gas can make the process highly inefficient. 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 codex 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.