COREX PROCESS Meaning and
Definition
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The Corex process is a type of ironmaking technology that utilizes non-coking coal as a reductant and energy source to produce liquid iron directly from iron ore fines. It is a two-stage process that involves the reduction of iron ore in a melter gasifier, followed by the production of liquid iron in a smelter reactor.
In the first stage of the Corex process, iron ore fines and non-coking coal are mixed together and fed into a melter gasifier. Inside the gasifier, the coal is gasified by injecting a mixture of oxygen and recycled gas, resulting in the production of reducing gases such as carbon monoxide and hydrogen. These reducing gases then react with the iron ore, reducing it to metallic iron. The unreacted iron ore moves downward through the melter gasifier by gravity, while the gases generated rise to the top.
In the second stage, the reduced iron ore enters a smelter reactor where it comes into contact with hot and highly carbonaceous iron, known as the "hot metal." The carbon content in the hot metal facilitates the removal of impurities from the reduced iron ore and promotes the formation of liquid iron. The liquid iron, along with the remaining impurities, is tapped and collected at the bottom of the smelter reactor.
The Corex process offers several advantages over traditional blast furnace ironmaking, including lower energy consumption, reduced environmental impact, and the ability to use non-coking coal as a reductant. It has found applicability in regions with limited availability of high-quality coking coal and has the potential to revolutionize the iron and steel industry.
Etymology of COREX PROCESS
The term "Corex process" is derived from the words "coal" and "orex" (from ore).
The Corex process is a method of iron-making developed by the Siemens company in the early 1980s. It is an alternative to the traditional blast furnace route for producing pig iron. The process utilizes non-coking coal and iron ore fines as raw materials and operates at lower temperatures compared to the blast furnace. By replacing coke as a reducing agent with non-coking coal, the term "corex" was coined to represent the "coal" component of the process.
The Corex process combines coal and iron ore fines into a single process, allowing for greater flexibility in raw materials and reduced environmental impact. It has been widely adopted in iron and steel production, particularly in countries with limited supply of high-quality coking coal.
