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    3A3. Direct Iron Ore Smelting Reduction Process (DIOS)

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    Imran Hanif Lubis
    1. The Direct Iron Ore Smelting Reduction Process (DIOS) directly uses noncaking coal and iron ore without coke or sintering to produce molten iron in a smelting reduction furnace. 2. A feasibility study and pilot plant testing from 1988-1995 demonstrated that DIOS could reduce investment costs by 35% and molten iron production costs by 19% compared to blast furnaces, while using similar amounts of coal with lower emissions. 3. Testing of a 500 tonne-per-day pilot plant confirmed that DIOS could directly use powdered and granular raw materials to achieve high thermal efficiency as a promising alternative to traditional blast furnaces.

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    3A3. Direct Iron Ore Smelting Reduction Process (DIOS)

    Uploaded by

    Imran Hanif Lubis
    56 views2 pages
    1. The Direct Iron Ore Smelting Reduction Process (DIOS) directly uses noncaking coal and iron ore without coke or sintering to produce molten iron in a smelting reduction furnace. 2. A feasibility study and pilot plant testing from 1988-1995 demonstrated that DIOS could reduce investment costs by 35% and molten iron production costs by 19% compared to blast furnaces, while using similar amounts of coal with lower emissions. 3. Testing of a 500 tonne-per-day pilot plant confirmed that DIOS could directly use powdered and granular raw materials to achieve high thermal efficiency as a promising alternative to traditional blast furnaces.

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    1. The Direct Iron Ore Smelting Reduction Process (DIOS) directly uses noncaking coal and iron ore without coke or sintering to produce molten iron in a smelting reduction furnace. 2. A feasibility study and pilot plant testing from 1988-1995 demonstrated that DIOS could reduce investment costs by 35% and molten iron production costs by 19% compared to blast furnaces, while using similar amounts of coal with lower emissions. 3. Testing of a 500 tonne-per-day pilot plant confirmed that DIOS could directly use powdered and granular raw materials to achieve high thermal efficiency as a promising alternative to traditional blast furnaces.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    56 views2 pages

    3A3. Direct Iron Ore Smelting Reduction Process (DIOS)

    Uploaded by

    Imran Hanif Lubis
    1. The Direct Iron Ore Smelting Reduction Process (DIOS) directly uses noncaking coal and iron ore without coke or sintering to produce molten iron in a smelting reduction furnace. 2. A feasibility study and pilot plant testing from 1988-1995 demonstrated that DIOS could reduce investment costs by 35% and molten iron production costs by 19% compared to blast furnaces, while using similar amounts of coal with lower emissions. 3. Testing of a 500 tonne-per-day pilot plant confirmed that DIOS could directly use powdered and granular raw materials to achieve high thermal efficiency as a promising alternative to traditional blast furnaces.

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    Part 2 CCT Overview

    Iron Making and General Industry Technologies (Iron Making Technologies)

    3A3. Direct Iron Ore Smelting Reduction Process (DIOS)


    Research and development: Japan Coal Energy Center; and Japan Iron and Steel Federation
    Period: 1988-1995 (8 years)

    Technology Overview

    1. Overview

    3. Results of study

    The Direct Iron Ore Smelting Reduction Process (DIOS) directly

    A feasibility study was undertaken on the installation of a new

    uses noncaking coal in a powder or granular form, and iron ore

    commercial blast furnace plant and of DIOS in a waterfront area.

    without the use of coke or a sintering process, which are normally

    Considering its superiority to the blast furnace process as

    required in blast furnace processes. The noncaking coal is

    described below, the feasibility of DIOS can be demonstrated for

    directly fed to a smelting reduction furnace, while the iron ore is

    a 6,000 ton molten iron model production facility (annual

    preliminarily reduced before being fed to the furnace, thus

    production of 2 million tons).

    producing molten iron.

    1. Investment cost reduced by 35%.


    2. Molten iron production cost decreased by 19%.

    2. Features

    3. Coal consumed, 730-750 kg per 1 ton of molten iron production,

    1. Possibility of utilizing inexpensive raw materials and fuel

    equivalent to that of the blast furnace process.

    (noncaking coal, in-house dust, etc.)

    4. Net energy consumption decreased by 3 to 4%.

    2. Low operating cost

    5. CO2 emissions in the iron making process decreased by 4 to

    3. Responds flexibly to variations in production rate

    5%.

    4. Compact and small incremental investment


    5. Stable, high-quality supply of iron source available
    6. Effective use of coal energy
    7. Easy co-production of energy (co-generation)
    8. Low environmental load (low SOx, NOx, CO2, dust generation,
    no coke oven gas leaks)
    4. Research and development progress
    Table 1 Research and development progress
    Fiscal year

    1988

    1989

    1990

    1991

    1992

    1993

    1994

    1995

    Core technology study

    Construction
    Test operation

    Pilot plant test

    1) Core technology study (FY1988-FY1990)

    2. With various raw materials, the equipment and operating

    Core technologies necessary for the construction of the pilot

    specifications to achieve high thermal efficiency, as an alternative

    plant were established. These core technologies include an

    to the blast furnace, were determined.

    increase in the thermal efficiency of a smelting reduction furnace

    3. Technology

    for

    water-cooling

    the

    furnace

    body

    was

    (SRF), the technology to be integrated with a preliminary

    established. A conceptual design and an economic evaluation

    reduction furnace (PRF), the molten slag discharge technology,

    (FS) for commercial facilities was conducted. The conditions of

    and the scale-up of an SRF.

    the facilities and of the operations to prove the superiority versus

    2) Pilot plant test (FY1993-FY1995)

    the blast furnace, as shown in the results of the research, was

    1. The possibility of directly using powder, granular ore, and coal

    clarified.

    was confirmed, and necessary equipment specifications were


    determined.

    47

    Clean Coal Technologies in Japan

    Coal
    952kg

    Flux
    80kg

    Plant size

    500 t-molten iron/day

    Smelting reduction
    furnace

    Height 9.3m
    Inner diameter 3.7m
    Pressure less than 2.0kg/cm2 G (300kPa)

    Pre-reduction
    furnace

    Height 8.0m
    Inner diameter 2.7m

    Iron ore
    1450kg
    Pre-heating
    furnace

    RD 8.7%
    2,326Nm3
    2,789Mcal (11.7GJ)

    RD 8.6%
    600 C
    O

    Pre-reduction
    furnace
    Venturi scrubber
    RD 27.0%
    779 C
    O

    O2
    608Nm3

    RD 27.1%

    Pressure control valve

    OD 31.6%
    Off-gas

    Tapping device
    Smelting reduction
    furnace
    1.9kg/cm2 G (290kPa)
    Molten iron

    24.7t/h
    1,540OC
    1,000kg
    Legend

    N2 70Nm3

    OD: Oxidation degree


    RD: Reduction degree

    Fig. 1 Process flowchart for DIOS pilot plant (per 1,000kg of molten iron)

    48

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