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The commissioning of Corex facility marks a major milestone in Essar's Steel's history. While this environment friendly facility gives us tremendous rawmaterial flexibility, it will also improve overall efficiency of operation
56 November 2011
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plant, plant was further scaled up 2 times and first C2000 module was designed and put into operation at POSCO, in South Korea. Other C2000 modules were put into operation by JSW, India (2 nos) & Saldanha, South Africa (1 no) and installed at Hanbo (2 nos). A typical Corex iron making plant comprises of melter gasifier, reduction shaft and gas handling plant within the Corex proper area. The reduction shaft concerts the iron bearing materials such as ore / pellets into metallised iron or Direct reduced iron (DRI), which is smelted in bottom vessels called melter gasifier. The energy for melting of iron is derived from combustion of non-coking coal with pure Oxygen. The gases generated in the process are cleaned and used as reducing gases in the reduction shaft. A typical flow-sheet of Corex plant is shown on the next page. The surplus process gases from melter gasifier and used top gases from the shaft are energy rich and can be used for various applications such as power generation, DRI
(sponge iron) production etc. A typical Corex iron making plant will have following major facilities, among others: l tower comprising melter gasifier, Corex reduction shaft, gas handling plant including hot gas cyclones, scrubbers, etc and charging equipment such as charging bins, lock hoppers etc. l Cast-house for tapping of hot metal & slag. The cast house equipment includes drilling machine, mud gun, hot metal & slag runners. l Coal blending, coal drying and conveyors etc., l treatment plant including clarifiers, Water cooling tower and pump house. The water systems include process water system, machine cooling water system and staves cooling system. l Slag granulation plant is used to granulate the Corex slag. The equipment includes blowing box, granulation tank, chimney, dewatering drum, conveyor etc.
57 November 2011