Asia-Pacific Partnership on Clean Development and Climate 3rd Steel Workshop, OCTOBER 25,2007, Wollongong, Australia

ENVIRONMENT & ENERGY ASPECTS OF COREX AT JSW STEEL LTD

R.T.SRINIVASA RAO Deputy General Manager

JSW Steel Limited, Vijayanagar

JSW STEEL LIMITED

R.T.SRINIVASA RAO

COREX Technology
COREX is the first Commercially established and industrially proven smelting reduction process based on non-coking coal.

It allows for flexible, cost efficient and environment friendly production of hot metal.

JSW STEEL LIMITED

R.T.SRINIVASA RAO

COREX- Consideration for Adoption

High raw material flexibility 0 % coke high lump ore price Large availability of Iron ore fines locally.

Hot metal quality comparable to BF easy integration. Lower hot metal production costs compared to BF route. Power from export gas utilisation Environmental benefits
JSW STEEL LIMITED R.T.SRINIVASA RAO

Blast Furnace Vs COREX

Coke Hot Air

Fuel Blast

Coal Oxygen Pellet /Ore

Melter Gasifier Reduction Shaft

Sinter/ Ore Raw material Pellet

By product COREX Gas BF Gas 800KCal/Nm3 2000KCal/Nm3

JSW STEEL LIMITED

R.T.SRINIVASA RAO

Clean Technology

POWER 2 X 130 MW

GAS HOLDER

COREX

JSW STEEL LIMITED

R.T.SRINIVASA RAO

COREX Process
Lump Ore / Pellets & Additives Top Gas Coal + Coke Scrubber Export Gas

Reduction Shaft Coal Screw

Reduction Gas DRI Screw

Scrubber

Ho t Gas Cyclone

Compressor

Melter Gasifier

Cooling Gas Dust burner Tuyere Oxygen Sludge Settling Pond

Slag & Hot metal

JSW STEEL LIMITED

R.T.SRINIVASA RAO

PERFORMANCE :
SL. Parameter NO 1 Availability Unit %

HIGHLIGHTS
Best of JSW 06 -07 95.11 Mod I 88.00 Mod II

Melting rate

t / hr

96.68 Mod I 98.0 Mod II

JSW STEEL LIMITED

R.T.SRINIVASA RAO

FURTHER IMPROVEMENTS
Use of BOF slag in Corex High pressure gas to Pellet Plant & Lime Plant Water addition through generator gas duct Dust Recycling modification System line Replaces limestone & improves the solid waste recycling Avoids gas boosters To eliminate the compressor system Improved the availability of plant and increased production Improved the availability of plant and increased production Improved the availability of plant and increased production Enhanced life of furnace

On Line Cleaning of Dust Lines On Line Cleaning of Scrubbers Gunniting of Melter Gasifier

ENVIRONMENT ASPECTS
Emits at least 15% less CO2 as compared to BF route for hot metal production. Air emissions lower than the conventional BF units. CO2 emission is 1420 Kg/thm as compared to 1900 Kg/thm for BF SO2 emission is only 53 Kg/thm as compared to 1410 Kg/thm in BFs Particulates and NOx emissions in the COREX unit are only 10% of the BF Route.

JSW STEEL LIMITED

R.T.SRINIVASA RAO

ENVIRONMENT ASPECTS (Contd)

Phenols - 0.04 g/thm, while BF has 100 g/ thm.

Sulphides 0.01 g/thm while for BF it is 180 g/ thm

Ammonia at 60 g/thm while for BF it is 900 g/ thm

Cyanide discharges in the waste-water are completely eliminated in the COREX route.

JSW STEEL LIMITED

R.T.SRINIVASA RAO

COREX TECHNOLOGY
Pollutant
SO2 emissions, g/thm NOX Waste water Discharge,g /thm.

THE GREENER OPTION

BF + Recovery type Coke oven
1400 1 Kg / tcs

COREX
53 90 % Lower

Phenol Sulphides Ammonia Cyanide

100 180 900 20

0.04 0.1 50 1

JSW STEEL LIMITED

R.T.SRINIVASA RAO

COREX v/s BLAST FURNACE

1400 1220 1000 1090 810

1400 1200 1000 800 600 400 200 0

310 53 S O 2 B F in 1 9 9 0 Dust B F in 2 0 0 0 130 114

Nox CO RE X

Pollutants in gas emissions g / thm

JSW STEEL LIMITED R.T.SRINIVASA RAO

COREX v/s BLAST FURNACE

1000 Vl e a ei l gsc l au s r n o ae 900 600 50 10 1 0.1 0.01

180

120

100 60 20 15

0.04

0.001
Ammonia Sulf ides Phenols Cyanides

BF in 1990

BF in 2000

Corex

Pollutants discharged in water g / thm

JSW STEEL LIMITED R.T.SRINIVASA RAO

Synergy of Corex-BF-NR Coke ovens-Sinter Plant

Non Coking Coal Imported, (Low ash)

Coal Fines to Power Plant
Coal Screening

Coking Coal Imported, (Low ash)

Coal Fines to Coke Oven

NR Coke Ovens

Coal Drying

Coal Fines to CDI

Coal Lump Nut Coke Lump Coke Coke Fines

COREX

Blast Furnace

Sinter Plant

JSW STEEL LIMITED

R.T.SRINIVASA RAO

SOLID WASTE MANAGEMENT

REUSE OF COREX SLAG IN CEMENT MAKING

REUSE OF COREX SLUDGE IN PELLET PLANT

JSW STEEL LIMITED

R.T.SRINIVASA RAO

COREX & ENERGY

Energy consumption COREX route at 5.19 Gcals /thm BF route 4.88 Gcals/thm

COREX route being dependent on non coking coal contributes to conservation of coking coal reserves that are barely 3% of the total coal reserves.

COREX based steel making is a power surplus process, thus it supplies energy to the grid also.
JSW STEEL LIMITED R.T.SRINIVASA RAO

CO2 EMISSIONS FROM COREX VS BF ROUTE

CO2 EMISSIONS FROM COREX Vs BF ROUTE
2000 1900 1700 1500 1450

kg CO2 / TON HOT METAL

1000

500

0 Conventional BF route 1980 Conventional BF Route Target 2000 COREX

JSW STEEL LIMITED

R.T.SRINIVASA RAO

Use of COREX GAS

Corex gas has a calorific value of ~ 2000 kcal/Nm.

Corex gas
Pellet plant Ladle heating

JSW STEEL LIMITED

R.T.SRINIVASA RAO

COREX is Environmentally Friendly Technology

THANK YOU
JSW STEEL LIMITED R.T.SRINIVASA RAO