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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Also the export gas can make the process highly inefficient. The outputs can be used either by integrated mills or EAF electric arc furnace mills. In the two-stage operation of the process DRI produced from a shaft furnace is pdocess into a melter-gasifier for smelting. This being a two stage process, i. The process has three stages. Due to this increased gas utilization which is based on gas recycling, gas production provess the melter gasifier can be significantly lowered, which is directly reflected in lower fuel and oxygen consumption.

Corex Process | Industrial Efficiency Technology & Measures

The pressure of Corex gas supplied to various consumers is normally around mm water column. The first stage of the process takes place in the reduction shaft, where iron ore burden is reduced by gases emanating from the cores and is converted to hot DRI. The general applicability of this first generation process was limited and a lot of technical problems procss to be solved.

The plant rated capacity is ranging fromtons per year totons per year. So, the phosphorous content of ore and coal should be as low as possible.

Corex Process for Production of Iron |

As far as coal is concerned, the non-coking coals having too high volatile matter VM or too low fixed carbon FC cannot be used in corex process of iron making. The process gasifies non-coking coal in a smelting reactor, which also produces liquid iron.


A recycling system consisting of a compressor station and CO2 removal makes it possible to utilize more export gas for metallurgical work. In the process third stage which takes place in the upper part of the melter-gasifier, a fluidized bed of coal char is maintained.

In Siemens first completed a life cycle assessment for pig iron production, looking at both conventional production in a blast furnace and the more environmentally friendly COREX and FINEX processes. Posted by Satyendra on Feb 22, in Technical 0 comments.

Sulphides discharge is around 0. The commissioning was in 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.

Advantages of the Corex process include i reduction in the specific investment cost compared with conventional blast furnace route of production, ii lower production cost, iii better environmental performance because of lower emissions and discharges, iv higher calorific value of export gas makes it suitable for use in a wide range of applications, v flexible with regards to the raw material uses since a wide procss of iron ores and coals can be used, vi good operational flexibility with respect to production capacity, production stops cotex raw material changes.

Reducing gas for the shaft furnace is produced by partial combustion of coal with oxygen in the fluidized bed of the melter-gasifier. Retrieved October prlcess, 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 tuyeresand iii hearth zone lower part below oxygen tuyeres.

Corex Process

Furthermore, it has also been found that Corex plants require large amounts of oxygen which can be expensive. 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 metallization degree of the DRI and the calcination of the additives are strongly dependent on four parameters namely i amount and quality of the reduction gas, ii temperature of the reduction gas, iii reducibility of the iron bearing burden, and iv average particle size and the distribution of the solids charged.


Because of many peripheral requirements, the total cost of a Corex project can be relatively high. Phenols discharge is around 0.

Corex Process for Production of Iron

Leave a Reply Cancel reply Your email address will not be published. Many of the gases resulting from this process can then be recycled or used to produce electricity. After being reduced, the DRI is redirected to the char bed where the iron and slag are melted and then directed to the hearth zone. This raises export gas utilization to a higher level and improves the overall economics of the process besides making it more environmentally friendly. Also, waste-water emissions from the COREX process are far lower than those in the conventional blast-furnace route.

The gas is cleaned in a hot cyclone to recycle entrained fines. Metallurgical coal is not only costly but is associated with environmental issues during its conversion to BF coke in the coke oven batteries. The exothermic combustion provides the energy to complete the reduction of the hot DRI and to melt the slag and iron. The emission levels with the Corex process are much lower than the BF route of production which consists of blast furnace, cores plant and the coke ovens.