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Static Thermochemical Model of COREX Melter Gasifier

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Abstract

COREX is one of the commercial smelting reduction processes. It uses the finer size ore and semi-soft coal instead of metallurgical coke to produce hot metal from iron ore. The use of top gas with high calorific value as a by-product export gas makes the process economical and green. The predictive thermochemical model of the COREX process presented here enables rapid computation of process parameters such as (1) required amount of ore, coal, and flux; (2) amount of slag and gas generated; and (3) gas compositions (based on the raw material and desired hot metal quality). The model helps in predicting the variations in process parameters with respect to the (1) degree of metallization and (2) post-combustion ratio for given raw material conditions. In general reduction in coal, flux, and oxygen, the requirement is concomitant with an increase in the degree of metallization and post-combustion ratio. The model reported here has been benchmarked using industrial data obtained from the JSW Steel Plant, India.

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(Adapted from Gudenau et al.[40])

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Abbreviations

THM:

1 ton of hot metal

n b a :

Amount (in kg-mole) of any “a” in “b”, per kg-mole of Fe

p b a :

Composition of any “a” in “b” (in wt pct)

M a :

Moisture content in “a”

X :

Degree of metallization (in mol pct)

pcr:

Post-combustion ration (in vol pct)

ΔG :

Gibbs-free energy (kJ)

Bc :

Slag basicity

B :

Actual basicity

T :

Temperature (K)

ΔH m :

Heat of mixing per kg-mole of Fe (kJ)

ΔH s :

Sensible heat per kg-mole of Fe (kJ)

ΔH f :

Heat of formation per kg-mole of Fe (kJ)

ΔH e :

Heat of endothermic reaction per kg-mole of Fe (kJ)

coal:

Coal

L:

Limestone

D:

Dolomite

HM:

Hot metal

slag:

Slag

ore:

Ore

sg:

Surplus gas

tg:

Top gas

pc:

Post-combustion

mg:

Gas from the melter gasifier

r:

Reducing gas

MG:

Melter gasifier

DVC:

Devolatization of coal

sp:

Supplied

dem:

Demanded

o:

Output

A:

Active

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Acknowledgments

The authors would like to acknowledge JSW Steel Ltd., Toranagallu, Bellary, India, for providing the plant data.

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Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, IIT Madras, Chennai, 600036, India

    C. Srishilan & Ajay Kumar Shukla

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  1. C. Srishilan
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Correspondence to C. Srishilan.

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Manuscript submitted June 23, 2017.

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Srishilan, C., Shukla, A.K. Static Thermochemical Model of COREX Melter Gasifier. Metall Mater Trans B 49, 388–398 (2018). https://doi.org/10.1007/s11663-017-1147-x

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