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The Asia-Pacific Partnership on Clean Development and Climate

4th Steel Task Force WorkShop 0

The
The FINEX
FINEX®®
Innovative
Innovative Ironmaking
Ironmaking Process
Process

April 16, 2008

Overview 1

■ What is FINEX ®?

■ How does FINEX ® perform?

■ Why FINEX ®?

Blast Furnace vs. FINEX 2 Blast Furnace FINEX Fine Ore Coking Coal Non-Coking Coal Fine Ore Sinter Plant Coke Oven Sinter Coke Fluidized-Bed Reactors Coal Briquetter HCI (Hot Compacted Iron) Blast Melter- Furnace Gasifier Hot Metal Hot Metal .

6 MT/Y Demo Plant 1.5 MT/Y Plant < 1999 ~ > < 2003 ~ > < 2007 ~ > .FINEX Process Development 3 150 T/D Pilot Plant 0.

FINEX Process Flow 4 Fine Ore Non-Coking Coal Hot DRI Coal R4 Compactor Briquetter R3 R2 CO2 Fluidized-bed R1 Power Plant Removal Reactors PCI Melter Gasifier O2 Oxygen Plant .

Overview 5 ■ What is FINEX ®? ■ How does FINEX ® perform? ■ Why FINEX ®? .

000 T/Y 6 Operation Start : June. 2003 .FINEX Demo Plant • 600.

FINEX Demo Plant Operational Performance 7 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 Coal CO2 PCI 3000 Briquette Removal 1250 2500 1150 Coal Rate (kg/t) (T/D) 2000 1.800 T/D (0.0 mt/y): 750 kg/thm (PCI 130 kg/thm) FINEX COREX .6MT) 1050 Production 1500 950 1000 850 500 750 *Pohang 1BF (1.

2007 .5 MT/Y 8 Operation Start : April.FINEX Plant • 1.

5 M FINEX Plant Operational Performance 9 4400 900 4300 t/d (1.5M t/y) 4100 Coal 850 COAL RATE (k g/THM) PRODUCTION (T/D) 3800 800 3500 750 3200 700 ’07/5/1 6/1 7/1 8/1 9/1 10/1 11/1 12/1 ’08/1/1 2/1 3/1 4/1 . 1.

1. 2008 t/y ≥ 1.45 M Production t/d ≥ 4.5M FINEX Plant Operational Performance 10 Indices Target Actual as of Mar.03 Hot Metal [Si] % ≤ 0.5 0.5 M 1.03 0.250 Availability % ≥ 95 94 Coal Rate kg/thm ≤ 750 732 PCI kg/thm ≥ 250 150 [S] % ≤ 0.65 .300 4.

FINEX Process Reliability 11 Days of Continuous FBR Operation Fine Ore 350 300 R4 300 R3 250 200 R2 Stick- Stick-and and 200 Clog-Free Clog-Free 150 Cyclone FBR FBROperation Operation 100 70 83 Stand R1 Pipe 37 50 1 st 2 nd 1 st 2 nd Distributor 2005 2006 2007~2008 Gas Demo Plant 1.5M Plant Plant availability is now on par with blast furnaces .

5 Metal [Si] (%) 0.250 HCI HCI Daily Tapping Times 9.20 Slag (Al2 O 3 ) (%) 15.027 0.65 [S] (%) 0. 2008 Pohang FINEX BF4 1.851 4.034 O2+ PCI Basicity 1.5 4.4 Temp (°C) 1.520 Hot [C] (%) 4.62 18.03 Hot Metal Volume (kg/thm) 298 290 .0 8.FINEX Hot Metal Quality 12 Mar.53 0.514 1.21 1.5M Coal Daily Production 8.

0 mt/y): 720 kg/thm .FINEX Coal Rate 13 CO 2 Higher Higher Gas Gas Removal Utilization Utilization by by Off-Gas Off-Gas Recycling Recycling Recycled with with CO CO22 Removal Removal Gas 30% Lower Lower Coal Coal Coal Gas 70% Consumption Consumption Coal 65% <700 <700kg/thm kg/thm Better Better Heat Heat Exchange Exchange inin Bed Bed by by Coal Coal Injection Injection through through Tuyeres Tuyeres PCI 35% *Pohang 4BF (3.

CO2 Removal Operation 14 Off-Gas Power Plant Tail Gas (CO2 : 66%) CO CO22 Removal Removal Excess Gas Product Gas (CO2 : 3%) Reducing Gas (CO2 : 7%) M/G Gas (CO2 : 9%) Coal Consumption reduced & Overall Energy Efficiency enhanced .

g) Maintenance Tar Filter Item Period Tar Cleaning (Filter.0 bar.7~1.15 bar.CO2 Removal Equipment 15 FINEX Off Gas Typical Performance ( 0. Cooler) 3 Month PSA Unit Compressor Overhaul 3 year Product Gas PSA Absorbant Change 3 year to FB Reactors ( 6 bar.g ) Power Composition (%) Plant Gas Demister CO CO2 H2 N2 Tar Filter Off-Gas 36 33 15 11 Product Gas 53 3 25 18 Recycle Compressor Tail Gas 17 66 4 3 Tail Gas (0.g) .

190 Reduction 480 Mcal/t-HM Recovery Off Gas 710 Recovery 480 Product Gas 1190 Mcal/t-HM Consumption Electricity 170 Gain 310 Net Energy Gain by CO 2 Removal : 310 Mcal/t-HM .Energy Gain by CO2 Removal 16 Off-Gas 710 Mcal/t-HM Energy Balance Unit: Mcal/tHM Electric Energy for Gas Compressing Energy Use for 170 Mcal/t-HM Product Gas 1.

Overview 17 ■ What is FINEX ®? ■ How does FINEX ® perform? ■ Why FINEX ®? .

Advantages of FINEX Technology 18 Flexibility in Raw Materials Elimination of sintering & coke-making processes No blending of ore & coal Use of Low-grade ore & low-ranked coal Easy & Flexible Operation Independent control of reduction & melting processes Easy & hassle-free operational control Environmental Friendliness Far less emission of SOx. BF . NOx & dust Applicability to the CO2 sequestration Cost Competitiveness Lower cost in both capital investment & operation vs.

A.T.T. for BF Reduction Sinter Sinter and Hot Stove and Hot Stove Coal [S] Gas SOx NOx Dust 100 BF H2 S 52% in Gas Ironmaking Ironmaking without without Sinter and Coke Sinter and Coke 50 Sinter Making Making Processes Processes 19% 10% Oxygen Coke 0 BF FINEX BF FINEX BF FINEX B.Environmental Friendliness 19 Process Emission Fine Ore [S] SOx NOx Dust Flux 100 BF Desulfurization Desulfurization Sinter in in Fluidized-Bed Fluidized-Bed 50 28% Reactors Reactors Coke 3% 1% CaS 0 into Flux BF FINEX BF FINEX BF FINEX No No Atmospheric Atmospheric Combustion Combustion like like Applying environmental B.A. : Best Available Technology .

etc.CO2 Mitigation 20 Power Plant CO2 Sequestration at Supercritical Sate CO CO22 Tail Gas CO CO22 Purification Purification Removal Removal (( CO CO22 >> 95% 95%)) Geologic CO2 Storage (e.g. Natural Gas Well. 2008 50 100 94 56 0 BF FINEX FINEX World Target after Average Sequestration .) CO 2 Emission 96% 100 April.

0MT) FINEX (Green Field 1.Comparison of Energy Balance – BF vs. FINEX 21 BF (Green Field 3.5MT×2) Coal Coal (720 kg/t-p) (720 kg/t-p) Cokes / Sinter / BF FINEX 48MWh BFG/COG FOG 92 MWh 95MWh CCPP ( η : 40% ) 38MWh CCPP ( η : 45% ) 180Mwh ASU 297Mwh TRT TRT CDQ 94MWh ASU / HRSG 110 MWh 17MWh Hot Stove 15MWh Electric Power Electric Power (113 MWh) (125Mwh) .

0 mt/y (Oxygen and power plants are included in comparison) 100 100 80 85 50 0 Blast Furnace FINEX FINEX Route Capital Cost Operating Cost .Cost Effectiveness 22 Production Basis: 3.

23 T hank Y ou .