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Ironmaking
ArticleName Technological tendencies of blast furnace practice and evaluation of iron ore and coal resources
ArticleAuthor H. B. Lungen, J. Noldin, P. Schmole
ArticleAuthorData

Steel Institute VDEh (Düsseldorf, Germany):

Lüngen H. B., Director Technology

 

Lhoist S.A. (Nivelles, Belgium):
Noldin J., Strategic Project Director, e-mail: jose.naldin@lhoist.com


ThyssenKrupp Steel Europe AG (Duisburg, Germany):
Schmöle P., Head of Competence Center Metallurgy

Abstract

This paper shows the evolution of raw materials and implications in Europe, discussing how the players are reacting and the most acceptable trends. Hot metal production increased at a rate of 6 %/a over the last ten years, leading to a degradation of the chemical and physical quality of iron ore and coals that can be observed in the following processes: low physical iron ore quality leading to more fines and high handling costs; lump ore with low strength, high fines; coke: volatile quality caused by changing coal blends; fine ore: increasing SiO2 and Al2O3 contents, critical RDI values with higher Al2O3 contents in sinter; lower Fe contents, especially in the sinter. The effects on blast furnace performance were clear: higher total consumption of reducing agents; higher CO2 emissions; higher slag rate; lower productivity; changing hot metal quality. Cost effects were as follows: higher costs caused by lower blast furnace performance; additional increasing costs to compensate the lower productivity; shrinking profit for high technological steel producers, exploding profits for raw material miners. Therefore, a strong response was given by ironmakers to improve process control, control costs, optimize PCI and coke rates, and search to increase efficiency in all and every areas. Profitability remains a challenge though. Looking ahead, increasing demand for raw materials on a sufficient quality level with persist. Nevertheless, there could be also a trend to increase the use of pellets in blast furnaces at the same time that sinter plants are likely to increase the use of ultra-fines which shall enable a vast adoption of new practices (increase use of burnt lime) and adoption of new equipment (Intensive Mixer, HPS). Despite the challenges, blast furnace ironmaking shall continue as the main source of high-quality hot metal in the foreseeable future.

keywords Raw materials, iron ore, coal, coke, quality, mining, charge materials, dust content, blast furnaces, ironmaking, metallurgical technologies
References

1. CRU International Ltd, Crude Steel Market Outlook, 2014, p. 210.
2. Lüngen, Η. В.: Internal report, Steel Institute VDEh, Düsseldorf, 2014.
3. J. P. Morgan, Iron Ore, 2014, p. 53.
4. Schmöle, P.: Quality of iron ores and coke — influence on blast furnace performance and hot metal composition, Steel Institute VDEh, Committee on Metallurgical Fundamentals, 4 June 2014, Düsseldorf, Germany.
5. Aoki, H.: ISIJ Intern. 54 (2014) No. 11, p. 2425.
6. Lüngen, Η. В.; Peters, Μ.; Schmöle, P.: Ironmaking in Western Europe, ICSTI 2012. 6th Intern. Congress on the Science and Technology of Ironmaking, 42nd ABM Ironmaking Seminar, 14–18 Oct 2012, Rio de Janeiro, Brazil.
7. Noldin Jr., J. H.; Schmöle, P.; Lüngen, Η. В.: Trends in ironmaking given the new reality of iron ore and coal resources, 44th Ironmaking and Raw Materials Seminar. 15–18 Sept 2014, Belo Horizonte, Brazil.

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