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Innovate Steel, Design Future 1 POSLAB 1
5 November 2013
Status and Future of FINEX® Process
for Reducing CO2 Emissions
Innovate Steel, Design Future 2 POSLAB
Contents
1. Introduction of FINEX® Process
2. Direct Reduction of CO2 Emissions
3. Indirect Reduction of CO2 Emissions
4. Future of FINEX® Process
Innovate Steel, Design Future 3 POSLAB
Contents
1. Introduction of FINEX® Process
2. Direct Reduction of CO2 Emissions
3. Indirect Reduction of CO2 Emissions
4. Future of FINEX® Process
- Scale up History
- FINEX® Process Flow
- Characteristics of FINEX® Process
Innovate Steel, Design Future 4 POSLAB
1996 1999 2003 2007
Pilot Plant
(150t/d)
No.1 FINEX®
(0.6 MTPA)
Model Plant
(15t/d)
1992
Annual
Production
(MTPA)
2014
No.3 FINEX® (2.0 MTPA)
(Construction Site)
No.2 FINEX®
(1.5 MTPA)
2.0
1.5
1.0
0.5
0.0
Jun. 2003 0.6 MTPA FINEX® (Demo.)
Apr. 2007 1.5 MTPA FINEX®
Dec. 2013 2.0 MTPA FINEX®
FINEX® R&D
Kick-off
Scale-up History
Innovate Steel, Design Future 5 POSLAB
No.1 FINEX®
(0.6 MTPA)
No.2 FINEX®
(1.5 MTPA)
Panoramic Views
No.3 FINEX®
(2.0 MTPA) Melter-gasifier
Fluidized bed Reactor
Innovate Steel, Design Future 6 POSLAB
CO2
Removal
(PSA)
Power Plant
Oxygen Plant
Ore Fine Non-Coking
Coal
Melter Gasifier
Fluidized Bed Reactors
PCI
Oxygen
Coal Briquetter
Hot DRI Compactor
R2
R1
FINEX® Process Flow
R2
R1
R3
R4
Scrubber
Innovate Steel, Design Future 7 POSLAB
No pretreatment plants
Flexibility of raw materials in use
Environmentally-friendly process
Flexibility of hot metal production
Characteristics of FINEX® Process
Innovate Steel, Design Future 8 POSLAB
Contents
1. Introduction of FINEX® Process
2. Direct Reduction of CO2 Emissions
3. Indirect Reduction of CO2 Emissions
4. Future of FINEX® Process
- Coal Briquette
- CO2 Removal Process - Pulverized Coal Injection
Innovate Steel, Design Future 9 POSLAB
Briquettes
Binder
Coal Fine
Mixing
46
35
100
Lump
Coal
Coal
Briquette Coke
95 78
100
Lump
Coal
Coal
Briquette Coke
Cold Strength
Hot Strength
Coal Briquette
Innovate Steel, Design Future 10 POSLAB
CO2 Removal Process
Production (t/d)
Co
al C
on
sum
ptio
n R
ate
(k
g/t
HM
)
After CO2 Removal
Before CO2 Removal
1000
1100
1200
1300
1500 1800 2100 2400 2700
700
800
900
Coal
Heat
Gas
DRI
Off Gas Recycling
Innovate Steel, Design Future 11 POSLAB
Pulverized Coal Injection
Continuous Operation (days)
Reduction Degree (%)
37
83
200
300
Pulverized
Coal
Gas + Dust
Coal Pyrolysis
Hot Metal
Coal Briquettes
Coal Bq. Coal PC
Pyrolysis,
Dust loss
Dome,
Char Bed -
56% Raceway 100%
Gas
Carbon solution loss
Combustion
Fluidized Bed Reactor Availability
Innovate Steel, Design Future 12 POSLAB
FINEX COREX
Pro
du
ctio
n (
T/D
)
CO2 Rmv.
PCI
500
1000
2000 1,800 T/D (0.6MT)
1500
Co
al R
ate
(k
g/t
)
750
850
1050
950
2500 1150
1250 3000 Coal Briq.
2003 2004 2005 2006 2007
7 9 11 1 3 5 7 9 11 1 3 5 7 9 11 1 3 5 7 9 11 12 1 2 3 4
FINEX® Demo Plant Operational Performance
Innovate Steel, Design Future 13 POSLAB
Operating Parameters of No. 2 FINEX®
Indices Target
(designed)
Operation
(2008)
Production Mt/y 1.5 1.5
t/d ≥ 4,200 4,300
Coal Rate
kg/t-HM
≤ 730 720
Coke ≤ 70 60
PCR ≥ 140 150
Hot
Metal
[S] % ≤ 0.030 0.027
[Si] % ≤ 0.80 0.81
11
FINEX® Comm. Plant Operational Performance
Innovate Steel, Design Future 14 POSLAB
Contents
1. Introduction of FINEX® Process
2. Direct Reduction of CO2 Emissions
3. Indirect Reduction of CO2 Emissions
4. Future of FINEX® Process
- Heat Recovery System
- Dry Dust Collectors
- Recycling of By-products
Innovate Steel, Design Future 15 POSLAB
Heat Recovery System
Demineralized water
Steam 40 t/hr
260 ºC
13.5 bar
Off gas 300 kNm3/h,
380 ºC
230 ºC
Scrubber
Heat Recovery System
Reducing Gas Water Treatment System Heat Recovery System
Innovate Steel, Design Future 16 POSLAB
Dry Dust Collectors
Ceramic Filter
(Commercial Stage)
Multi-Cyclone
(Commercial Stage)
Bag Filter
(Pilot Stage)
Bag Filter
(Commercial Stage)
DRI Feed Bin
Fluidized Bed Reactors
700 ºC
380 ºC 230 ºC
Innovate Steel, Design Future 17 POSLAB
Recycling of By-products
Sludge
Hot Briquetter
DRI Feed Bin Dust
Fluidized Bed Reactors
DRI
Dryer
Melter-Gasifier
Composition(%) Total Fe RD C SiO2 CaO Al2O3 MgO
By-products 50~55 15~20 5~10 4~6 3~4 3~4 ~ 1
Agglomeration
Agglomerates
Innovate Steel, Design Future 18 POSLAB
Contents
1. Introduction of FINEX® Process
2. Direct Reduction of CO2 Emissions
3. Indirect Reduction of CO2 Emissions
4. Future of FINEX® Process
Innovate Steel, Design Future 19 POSLAB
CO2 Removal
Power Plant
Oxygen Plant
Ore Coal
Melter Gasifier
Fluidized Bed Reactors
PCI
Oxygen
Coal Briquetter
R2
FINEX® Process Flow
R1
R2
R3
TRT
Prep.
Tail Gas
CO2 Purification (CO2 > 95 %)
CO2 Sequestration
Product Gas
Heat Ex. Filter Scrubber
Chemical Plant
Innovate Steel, Design Future 20 POSLAB
After starting R&D activities of FINEX® in 1992, it is being scaled up to 2.0 Mt/y
CO2 emissions from FINEX® drastically fell down because POSCO has
developed coal briquetting process and has optimized the FINEX process
by adopting CO2 removal system and pulverized coal injection
A series of technical developments such as heat recovery system, dry dust
collectors and recycling by-products could reduce CO2 emissions furthermore
FINEX® has lots of potential for lowering coal consumption rate and saving energy
as a developing process
Summary
Innovate Steel, Design Future 21 POSLAB