Regeneration and enhanced catalytic activity of ptc. Two processes, midrex and hylenergiron, share most of the dr. By adding pure carbon support to improve the redispersion of platinum pt, a sintered ptc electrocatalyst for methanol electrooxidation was effectively regenerated in activity and doubled in amount on the basis of a onestep liquid oxychlorination. The reason why midrex process covers 60% of world dri production is due to high performance of stable and simple operation. Pdf hydrogen reduction kinetics of hematite concentrate. Presently, the majority of steel production is through the blast furnace which has to rely on ever decreasing amounts of coking coal. Technical developments in the middrex process abhilasha gulhane, gaurav kumar. However, the experiments were conducted in a batch reactor. The process design allows for new operational strategies and businesses beyond traditional steelmaking, such as grid balancing through load shifting and largescale oxygen production.
Mar 11, 2016 the presentation describes different processes for the production of direct reduced iron. This book provides an outstanding overview of process chemistry in the pharmaceutical industry. Currently, there are 47 midrex dr modules operating in 16. Midrex recently hosted a panel of five iron ore suppliers anglo american, baffinland, bahrain steel, rio tinto, and vale. The midrex process the worlds most reliable and productive. One exception is the fluidized bed process which requires sized iron ore particles. Very interesting story about how structure based drug design has led to a very potent molecule to inhibit the hiv protease. Accordingly a corex plant has shaft unit, where iron ore pellets with or without some closely sized lump ore is reduced by gases emanating from the second unit to make hot.
As an integral part of developing a novel ironmaking process, the hydrogen reduction kinetics of hematite concentrate particles average particle size 21 m was measured in the temperature range. Midrex recently hosted a panel of five iron ore suppliers anglo american, baffinland, bahrain steel, rio tinto, and vale at the annual international conference on midrex technology, where we heard their views on the market, as well as industry news and updates. The air emissions are also lower than the conventional bf units. The eaf operates as a batch melting process producing batches of molten steel known as. Overview of sulb dr plant in 2010 sulb company made a contract with kobe steel, ltd. Surplus coke oven gases cogs and low grade hematite ores are abundant in shanxi, china. Hot direct reduced iron hdri is dri that is transported hot, directly from the reduction furnace, into an electric arc furnace, thereby saving energy. Ep3045549a2 method to produce an encapsulated pressed. Dr plant was envisaged to supply hot dri to adjacent melt shop along with extra cold dri to be available for sale in gcc market.
Midrex plants are designed to minimize air, water, and noise pollution. Materials free fulltext reduction of haematite using. They generally therefore work on a single target molecule and define the best route to that target. The main focus was given to the blast furnace process, which is still the dominating technology for ironmaking.
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. Hydrogen reduction of hematite ore fines to magnetite ore. Accordingly a corex plant has shaft unit, where iron ore pellets with or without some closely sized lump ore is reduced by gases emanating. The midrex process is unsurpassed in the direct reduction industry in terms of. Pdf modelbased energy analysis of an integrated midrex. The chemical formulas for the iron ore reduction reactions are. Circored process, energiron process, flash ironmaking process, hydrogen, hydrogen plasma, midrex process, natural gas, steam reforming, hydrogen gas and its use in iron and steel industry. Midrex the worlds leading directreduced iron production process. The atomic number of hydrogen element is 1 and atomic. Optimization of the iron ore direct reduction process. Ore chemistry and oxide mechanical properties both influence.
The heart of the midrex process is its shaft furnace. The process can be flexible in production and electricity demand through storage of hydrogen and hotbriquetted iron, or variations in the share of scrap used. Water vapor was found to be advantageous for lowering feo uptake mohassabahmed and sohn, 2014a. The monroe clarifier is designed to give you the performance you require with longterm reliability. Outotec direct reduction technologies include solutions for the full range of plant types, and have been developed through extensive research and testing with a wide range of raw materials and process parameters. Pdf this article presents modeling and simulations of an integrated plant for. Midrex the worlds leading directreduced iron production. Pdf modelbased energy analysis of an integrated midrexbased. In order to provide a solution which provides a direct reduced iron product which has an improved performance in respect to its capability to be transported over long distances and in respect to its melting properties in primary metallurgical steel making processes and which is suitable as a scrap substituting material, a method to produce a capsulated pressed reduced iron compound 5 is. Abstract this paper presents an overview of the history of the technical developments in midrex process, as well as the latest developments in this field. Dr iron production, with the two main processes being midrex 65%. However, coalderived synthesis gas production is generally not the dominant process on an industrial scale when natural gas is available.
Direct reduction is the process of converting iron ore into metallic iron without melting. Further visual and detailed information on tenovas advanced technologies for lithium recovery can be found here. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. A simple schematic of the midrex process is shown in figure 1. Building a model for the reduction of iron ore and complex process in this process iron ore is reduced to iron in solid phase with coke as the reducing agent. The corex process is a smelting reduction process created by siemens vai as a more environmentally friendly alternative to the blast furnace. Table 1 compares the chemical and physical properties of dri and. It is a cylindrical, refractorylined vessel and is a key component of the direct reduction process.
The direct reduction process uses pelletized iron ore or natural lump ore. Midrex technology which is the most important gasbased direct reduced iron dri process in the world, includes reduction, transition and cooling zones. There is a technical challenge in decreasing the capital investment and the operating cost to direct production of. Reuse of steel slag as an aggregate to asphaltic road. The midrex process converts iron ore to direct reduced iron dri 67% of world dri production of 37 million tons 47 plants in 16 countries. Midrex ng process first plant built in 1969 over 70 units constructed worldwide over a. Direct reduced iron and production of dri part 2 youtube.
Since commercialization of continuous dr technology in the late. Oct 12, 2017 directlyreduced iron meaning directlyreduce. Featuring over references, tables, and illustrations, process chemistry in the pharmaceutical industry is sure to find its way to the bookshelves of organic, physical, analytical, process, and medicinal chemists and biochemists. Alternative iron sources aisssteelmaking routes such as the fastmet process, the itmk3 process, fasteel, fastox, corex and hismelt. Model studies on the effects of composition differences of. In this work, lowtemperature hydrogen reduction of hematite ore fines was performed in a fixedbed reactor with a stirring apparatus, and a laboratory davis magnetic. Richter masterpieces in process chemistry ii11106 group meeting hiv protease inhibitors. Emission levels for the midrex process meet all applicable 1998 world bank standards. The process temperature is typically 800 to 1200 c. Midrex process introduction the importance of iron and steel as a basis. This has occurred gradually over the years in the course of overall process development. This chapter describes the ironmaking technology and outlines the process essentials. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. Our innovations focus on improving plant performance, reliability, and sustainability, while reducing capital investment and.
We consider eight heterogeneous and two homogeneous chemical. Corresponding to each temperature interval, typical reactions will take place. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Potential for co2 emissions reduction in midrex direct. Detailed modeling of the direct reduction of iron ore in a shaft. The ironmaking process in the blast furnace is a heat and mass transfer process, and the furnace can be divided into different zones according to physical and chemical state of the feed and temperature. Direct reduced iron dri is used as a high quality feed material in electric arc furnace steelmaking, oxygen steelmaking, ladle metallurgy, blast furnace ironmaking, and foundries. Richter masterpieces in process chemistry ii group meeting. This total process will vary based upon feed solution chemistry and desired final product. Modernday direct reduction of iron first developed as a smallscale, low capital and operating cost alternative to the blast furnace. Modelbased energy analysis of an integrated midrexbased ironsteel plant article pdf available in chemical engineering communications 20112. In 1998, 67% of all dri was produced using the midrex process.
Monroe circular clarifiers use widely accepted settling technology based on the density difference between water and suspended solids. The physical and chemical properties such as particle size, montmorillonite content, swelling degree, water absorption, and blue absorption of a, b, and c bentonites were studied under laboratory conditions. Ironmaking process an overview sciencedirect topics. Alternative methods known as direct reduction are used in over a score of countries, but less than 5 percent of iron is made this way. The primary objective of iron making is to release iron from chemical combination with oxygen, and, since the blast furnace is much the most efficient process, it receives the most attention here. The focus of this study is to simulate the furnace of the midrex technology. Carbon dioxide emissions are becoming a concern and in this regard, the midrex planteaf route to steelmaking has an advantage versus the traditional blast furnacebof route. An overview of the process can be seen in figure 1, which illustrates a midrex process 1,2,3,4. As a discovery chemist, i found this book provided me with an indepth understanding of not only the principles but the strategies behind process development. The midrex direct reduction process is the worlds leading technology for production of dri products dri products are orebased metallic raw materials made by removing chemicallybound oxygen from iron oxide pellets and lump ores without melting.
Dr processes are very sensitive to chemical and physical. Detailed modeling of the direct reduction of iron ore in a. The emerging alternative ironmaking technologiesdirect reduction and smelting reductionare only briefly introduced, and will be described in a. Hydrogen is a chemical element, ranking first in the periodic table with element symbol of h. The reduction zone in the midrex process, the main purpose of the reduction zone is to metallize the iron to the desired product metallization using reductants co and h 2 produced by the midrex reformer. Corex process emits at least 15 % less co2 as compared to bf route for hot metal production. Aug 21, 2015 metallic iron used in steel industries is mostly obtained from a direct reduction process. The presentation describes different processes for the production of direct reduced iron. Midrex process for direct reduction of iron ore ispatguru. Synthesis gas production with an adjustable h2co ratio. Indeed, the midrex process has the flexibility to produce dri with controllable and. The production of steel in the eaf generates significant quantities of eaf corresponding author.
Assessment of hydrogen direct reduction for fossilfree. Another common process is the energiron process hyl 5. It is this continual improvement that made the midrex 174 process the worlds leading technology for the direct reduction of iron ore. Our key proprietary technology, the midrex direct reduction process, is the dominant technology for making dri. The effects of adding different quality and different proportion of bentonite on falling strength, compression strength, and shock temperature of green pellet were investigated. Pdf the midrex process and the nigerian steel industry ijesrt. This is done by changing the process conditions, such as the production rate for the drfurnace.
The blast furnace concept has been used, virtually splitting it into two at the cohesive zone interface. In contrast, process chemistry involves development of practical, safe and cost effective processes for the synthesis of compounds on a larger scale kg to several tonnes that have been selected to progress from medicinal chemistry. Metallic iron used in steel industries is mostly obtained from a direct reduction process. Our group proposes a new process that could simultaneously enrich ch 4 from cog and produce separated magnetite from low grade hematite. Midrex process is simple to operate and involves three major unit operations namely i iron ore reduction, ii gas preheating, and iii natural gas reforming. While the process is labeled as being attributed to, it is actually our own independent midrex interpretation of midrexpatents, literature, and discussions with representatives, so the design may not. Scribd is the worlds largest social reading and publishing site. The reduction zone considered as a counter current gassolid reactor. In contrast, commercial steel production via the direct reduction. Effect of bentonite on the pelleting properties of iron. Iron by direct reduction kirkothmer encyclopedia of. The conventional way of iron and steel making consumes high fuel and even causes emission of carbon dioxide. Definitions of the process technologies considered herein can be found elsewhere in these proceedings in the paper titled influence of ais chemistry on eaf steelmaking. Hydrogen gas and its use in iron and steel industry.
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