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METALURGIJA 42 (2003) 2, 107-111 107

J. BILIK at all.: ACTUAL POSSIBILITIES OF COAL UTILIZATION IN IRON METALLURGY


Received - Primljeno: 2002-07-25
Accepted - Prihvaceno: 2002-12-15
Review Paper - Pregledni rad
ISSN 0543-5846
METABK 42 (2) 107 (2003)
UDC - UDK 662.66:669.1:669.094.2220
J. BILIK, V. ROUBICEK, S. VILAMOVA, P. PUSTJOVSKA
J. Bilik, V. Roubicek, S. Vilamova, P. Pustjovska, VSB - Technical
University of Ostrava, Ostrava, Czech Republic
ACTUAL POSSIBILITIES OF COAL UTILIZATION IN IRON METALLURGY
This paper deals with actual possibilities of coal utilization in iron - and steelmaking. Particular attention is
devoted to coal utilization in the blast furnace process. Our paper presents also coal utilization as alternative
methods of iron production. The script notices even other possibilities of coal utilization in metallurgy. Concludingly,
orientation form is introduced for the further development of coal usage in iron metallurgy.
Key words: coal, iron, coke, reduction technology
Stvarne mogucnosti koristenja ugIjena u metaIurgiji zeIjeza. U radu se govori o stvarnim mogucnostima
iskoristavanja ugljena pri proizvodnji zeljeza i celika. Posebna paznja se posvecuje uporabi ugljena u procesu
visoke peci. Rad predstavlja i uporabu ugljena kao alternativne metode u proizvodnji celika. Rukopis se osvrce
i na druge mogucnosti uporabe ugljena u metalurgiji. Na kraju, donosi se zakljucak o daljnjem prosirivanju
mogucnosti uporabe ugljena u metalurgiji.
Kljucne rijeci: ugljen, zeljezo, koks, tehnologija redukcije
INTRODUCTION
In the connection with the changed internal and external
economic situation, a drop in oI metallurgical production
took place in the past years that changed the overall struc-
ture oI production in our country. As a consequence oI the
concentration process, a new iron-works, Blast Furnaces
Plant oI Ostrava, has come into existence. The concentra-
tion oI production into Iour modernized blast Iurnaces cre-
ated Iavourable condition Ior Iurther development.
There has been a long, historically established rela-
tionship between the coal mining and steel industry, which
is evidenced by the present statistics Ior the production/
consumption oI steel and coal worldwide. It is evident Irom
|1| that the percentage oI the steel total production ranks
only second as related to the most important coal consum-
ers represented by the producers oI electricity and heat.
It is Iurther to aIIirm that about 60 oI energy Ior
steel industry purposes comes Irom coal, and about 70
oI the steel total production depends directly on coal. Simi-
lar data can be applied not only world-wide but also re-
gionally, where a geographic correlation oI coal and steel
production oIten amount as a base oI the regional economy
development. No substantial modiIication oI the current
state is anticipated in the near Iuture.
COAL IN IRON PRODUCTION
The role played by coal in iron production is mani-
Iold. Coal provides not only energy Ior the process but
serves also as a reduction and protection agent. As such,
coal is Ior current technological routines indispensable.
The modern technology oI coal processing allows com-
bining coal with various waste recycled and environmen-
tal - Iriendly materials. Both a processed by-products can
be employed Ior iron production technologies (Table 1.).
Functional and product deIinitions have enabled chart-
ing Ior coal utilisation in individual metallurgical processes.
Figure 1. illustrates the outcome oI such structuring. It is

Coal Processing By - product for Steel Production
Coking Coke, Gas, Tar, Pitch
Gasification Gas, Tar
Underground gasification,
Carboniferous gas mining
Gas
Table 1.
Tablica 1.
Relationships between coal processing and its products
in iron production
Odnos izmedu obrade ugljena i njegovih produkata u
proizvodnji zeljeza
METALURGIJA 42 (2003) 2, 107-111 108
J. BILIK at all.: ACTUAL POSSIBILITIES OF COAL UTILIZATION IN IRON METALLURGY
evident that coal has its role in nearly all metallurgy pri-
mary production, commencing with burden sintering and
blast Iurnace raw iron production through basic oxygen Iur-
nace (BOF) and electric arc Iurnace steel production up to
the Iinal products eventual disposal oI unwanted and harm-
Iul substances. Related to individual process, also the Iorm
oI coal employed has been changing. In the primary pro-
cesses, solid Iorms oI coal - coke and coal are dominate.
Contrary to this, gaseous Iorms predominate in steel pro-
duction Iinal stages. Coke and gasiIied coal are most com-
mon Iorms oI coal employed in steel metallurgy.
BLAST FURNACE PROCESS
Presently a substantial accent is laid upon the changes
in the raw material and energy supply with the objective
to attain optimum blast Iurnace burden, and minimal Iuel/
energy rates.
Coal in the Iorm oI coke plays a dominant role in the
blast Iurnace process. As such, coke production, coal
charge composition, and coke properties are subject oI
continuous study and research. The coke-making process
development goes beyond its traditional limits, as regards
emission decrease or new coking equipment (JRC). Test-
ing Ior brown coal coke application (low shaIt Iurnace, as
well as direct charging) is obsolete and it is necessary to
wait Ior a new impetus. The evaluation oI metallurgical
coke properties became a priority oI the Czech blast Iur-
nace technologists in the second halI oI the eighties in
connection with the eIIort to decrease the coke rates, as
well as to Iind a potential auxiliary Iuel. A new test, the
NSC, has been added to the existing classical testing pro-
cedure, and introduced to all cokemaking and blast Iurna-
ce plants in the country. In our opinion, not all technologi-
cal routines known Ior increasing quality oI hard coal coke
and coking process have been Iully exploited. The required
coke properties are commonly known but the quantiIica-
tion oI individual data reIers closely to the economy oI
preparing the coal mixture and its constituents. For this
reason, interaction between crucial properties oI coal and
coke - chemical composition, granulometry, strength (wear
resistance), reactivity - are subject oI constant care. In this
context, investigations have been perIormed at the Tech-
nical University oI Ostrava that succeeded in establishing
the relationship between the CSR index and dominant vari-
ables: volatile matter content and plasticity properties,
which have proved to be dominant Ior the Czech coals.
In 1995 a joint research team oI VSB-TU Ostrava and
Nova hut Ostrava started experimenting, monitoring and
researching in this subject. The experimental equipment
Surrogate fuel for BF
Fuel and Reduction Agent
in processes of direct
smeltin reduction
Basic fuel for sintering
and BFs
Slag foaming in EAF
Carburisation of steel
Surrogate fuel for sintering
Rediction gases into
BF schaft

Converter jets cooling
Filling agent for
porousrefractories
Removal of unwanted
and harmful substances
Surrogate fuel for BF
Processed Coal
Pitch
Gas
Coke
Tar
Actived Carbon
Liqnefaction
Underground
gasification
Carboniferous
gases
Coal Mining
and Processing
Coking

Activation
Coal District
Sintering Fuel:
* Ignition head
* Extra heating
Fuel for various
metallurgical furnaces
Pre-heating of scrap
in converter
* Charge admixture
* Jet injection (KMS)
Reactor
gasification
Completion of converter
thermal balance
Figure 1.
Slika 1.
Coal utilisation overview for steel metallurgy
Pregled iskoristavanja ugljena u metalurgiji celika
METALURGIJA 42 (2003) 2, 107-111 109
J. BILIK at all.: ACTUAL POSSIBILITIES OF COAL UTILIZATION IN IRON METALLURGY
oI the pilot coking plant at Nova Hut enabled the experi-
mental coking oI particular coal types mono charge and
the targeted selection oI coal mixtures. The acquired data
were subjected to a detailed processing to quantiIy their
causal relations |2|.
Figures 2. and 3. illustrate results oI model calcula-
tions. The model was developed in two options: a regres-
sive non-linear statistical model, and a selI-learning neu-
ron network. The predictive quality oI both options has
been practically the same.
The consumption oI Iuel in a blast Iurnace varies betwe-
en 300 - 600 kg per ton oI iron, which is primarily given by
the content oI impurities in the burden. While the consumpti-
on oI coke is one oI cost primary items, it has been the obje-
ctive oI iron producers to employ various substitute Iuels:
heavy oils, natural gas, tars, etc. Injecting pulverised coal
(PCI), which can theoretically decrease the signiIicant pro-
portion oI coke consumption, has dominated lately. Decreas-
ing consumption oI metallurgical coke demands a better qua-
lity oI coke employed Ior the purpose. The consumption oI
injected coal increases all over the world. Nevertheless Ior
a concrete blast Iurnace and its operational conditions, deIi-
nite limits exist that cannot be exceeded. Investigations into
blast Iurnace processes have shown that the principal limit-
ing Iactors are in Iact the same Ior all kinds oI Iuels and
substitutional Iuel variants. Charge rate principal limiting
Iactors are represented by permeability stock oI solids (es-
pecially in the Iurnace lower part), and Iurnace Iocus Iire
temperature. When considering injection, it is burning abil-
ity/granularity oI coal, and particularly the chemical com-
position that inIluences the coeIIicient oI interchange abil-
ity Ior coke/coal, and some iron quality indicators. Data oI
utmost signiIicance Ior establishing the injection cost eIIec-
tiveness, as the investment cost are generally well managed.
For variant calculations oI the blast Iurnace process and
optimizing surrogate Iuel charges, a system Ior blast Iur-
nace process modelling has been developed at the Techni-
cal University oI Ostrava, which Iacilitates establishment
oI basic technological data Ior cost eIIectiveness calcula-
tions, staying within the boundaries oI the process elemen-
tary limits. Figure 4. illustrates rough outlines oI the model-
ling. A detailed model description has been provided by
papers oI Bilik at al., 1995 |3|. Apart Irom common mate-
rial and heat balances, the original modelling Ior coke deg-
radation and kinetics oI ore charge reduction should be es-
pecially brought to the IoreIront. One oI particular calcula-
tions actual coke consumption is illustrated in Figure 5.,
which clearly demonstrates boundaries given by thermal and
thermo-dynamical conditions, reduction kinetics, and gas-
dynamic balance. It seems promising to employ the model-
ling Ior assessment oI various technological and burden
variations, as well as other innovations. The modelling sys-
tem is being continuously custom-tailored and improved.
analyse
Gas dynamical
model
Thermodyna-
mical model
* reducibility of burden * reactivity * coke strength
Special tests:
* theoretical and
real minimum
fuel rate
* real fuel rate
prediction
* prediction of
direct reduc-
tion rate
* burden
optimization
Coke degra-
dation model
Kinetical gasre-
duction model
Material
balance
Process data
Heat balance
Boudouard-
reaction model
Figure 4.
Slika 4.
Blast furnace process modelling
Modeliranje visokopecnih procesa
Analitical model:
20
30
40
50
60
70
20 25 30 35 40 45 50 55 60 65 70
CSR predicted [ % ]
C
S
R

o
b
s
e
r
v
e
d

[

%

]
Neural model: R-sq. = 82 %
Stat. model: R-sq. = 74 %
Figure 3.
Slika 3.
The results of model calculations
Rezultati izracunavanja modela
Figure 2.
Slika 2.
Relationship between the CSR and the quality of coal
charge (VM, b)
Odnos izmedu CSR i kvalitete ugljene sarze (VM, b)
55
50
60
45
40
35
25
26
27
28
b
Vdaf
24
60 58 61 59 62 63
CSR
METALURGIJA 42 (2003) 2, 107-111 110
J. BILIK at all.: ACTUAL POSSIBILITIES OF COAL UTILIZATION IN IRON METALLURGY
Inter alia, the modelling system has been employed Ior
establishing limit values oI coal charge under the conditi-
ons in oI the Czech Republic. The algorithm is based on the
assumption that when the burden ceases descending, equi-
librium has been attained between the weight oI the charge
granules and liIt power oI the ascending gases. Such an equi-
librium condition enables establishing critical voidage, epsk-
rit, oI which the Iailure stops the descent oI the burden colu-
mn. A continuous Ilow oI gas through the blast Iurnace plas-
tic zone, passing smoothly down through liquid slag and
molten metal, is conditioned by the presence oI suIIicient
amount oI coke. This coke amount may be assumed as a
minimum boundary Ior its consumption without limiting the
blast Iurnace productivity. A carbon deIiciency can be outba-
lanced by injecting pulverised coal. The maximum proporti-
on is deIined by the point oI intersection Ior curves oI plas-
tic zone actual voidage, epsbosh, and critical voidage. The
dependence also illustrates the inIluence oI coke strength
characterized by the index CSR. Reliability and good predic-
tion value (130 - 180 kg/t) have been veriIied by comparing
calculations with the actual parameters Ior coal injection as
regards the blast Iurnaces abroad. This is the reason Ior curre-
nt employment oI the combined injection oI oil-coal suspen-
sion and gas Irom mining and surIace degassing measures.
SMELTING REDUCTION PROCESSES
As regards alternative processes oI reduction (DRI/
HBI, SRI), an extensive range oI assessment papers and
comparative studies exist Irom various points oI view, e.g.
the LOCKWOOD GREENE, 2000 |4|. II we neglect the
use oI coal Ior reduction gas production, a direct coal em-
ployment is characteristic Ior processes that have been
summarized under the term oI smelting reduction. The cha-
racteristics oI representative processes (COREX, Grids-
melter,Romelt, DIOS, CCF, HIsmelt, Tecnored, Plasmas-
melt, Redsmelt, IronDynamics, Fastmet/Fastmelt, IFCON)
are obviously Irom numerous reIerences. The processes
can be Iundamentally split into smelting reductions with
or without pre-metallization. The principal diIIerence oI
these processes vis-a-vis blast Iurnace constitutes a com-
plete exclusion oI metallurgical coke Irom the process oI
liquid metal production. Coal serves the role oI primary
reduction agent and Iuel or carburiser, as the case might
be. The elimination oI coke Irom the process demands coke
substituting or otherwise solving the problem oI coke sup-
portive skeleton deIiciency whose skeleton presence is in-
dispensable Ior the blast Iurnace zones oI soItening and
smelting. These solution oI the problem within the pro-
cesses oI smelting reduction is either in dividing oI reac-
tion spaces and excluding the soItening zone by an abrupt
change oI temperature (COREX), supplying burden indi-
vidual portions oI pre-reduced charge or deleting pre-re-
duction and concentrating all processes in one high tem-
perature bath and single reaction space (Romelt). Both
solutions have their weak points:
- big waste oI Ilue gas energy, both thermal and chemical,
(in spite oI post-combustion),
- heavy load, wear, and consumption oI reIractories,
- velocity oI heat supply to bath, which concerns all pro-
cesses, wstit in particular,
- optimum combination and concurrent separation oI en-
dothermic carbon reaction and exothermic combustion
(post combustion) oI the originating CO by oxygen,
- problematic control oI processes and Iinal stability in
product composition.
A comparison between a premetalization degree and
reductions gas rate Ior various process intensity with origi-
nal model oI indirect reduction |5| illustrates the Figure 6.
1
2
3
4
5
6
7
8
3.5
3.0
2.5
2.0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
D
i
r
e
c
t
r
e
d
u
c
t
i
o
n
d
e
g
r
e
e
Burden residence time in zone
of indirect reduction (hours) kmol Carbon / t iron
0.8-0.9
0.7-0.8
0.6-0.7
0.5-0.6
0.4-0.5
0.3-0.4
0.2-0.3
0.1-0.2
0-0.1

Figure 6.
Slika 6.
Carbon rate for indirect reduction in connection with the
process intensity
Brzina sagorijevanja ugljika u neizravnoj redukciji u vezi
s intenzitetom procesa
0
Direct reduction degree
900
1000
800
700
600
500
400
300
200
100
Kinetical
boundary
Gasdynamical boundary
(coke carbon only)
Thermo-
dynamical
boundary
Heat boundary Operation
point
Figure 5.
Slika 5.
Model trials calculation for fuel consumption minimum
Model probnih izracuna minimalne potrosnje goriva
C
a
r
b
o
n

r
a
t
e

[

m
/
t

H
M
]
!
0.5 0.6 0.7 0.8 0.9 0.4 0.3 0.2 1.0 0.1 0.0
METALURGIJA 42 (2003) 2, 107-111 111
J. BILIK at all.: ACTUAL POSSIBILITIES OF COAL UTILIZATION IN IRON METALLURGY
Exclusion oI piecing together the burden is employed
only in a Iew oI the processes. In analogous way the prod-
uct oI the majority oI the processes is only raw iron and
not raw steel or at least a kind oI liquid metal with a low
content oI carbon. The eIIectiveness oI these alternative
processes is relative, more than oI any other, to local con-
dition and national environmental legislation. The model-
ling mentioned can be without any major problem tailored
also to processes oI smelting reduction.
ORIENTATION FOR THE FURTHER DEVELOP-
MENT OF COAL USAGE IN IRON METALLURGY
Any summing up investigation is oI importance only iI
the summary oI the subject enables Iormulation oI current
weaknesses and though this token can provide impetus Ior
Iurther research and development or, as the case might be,
Iacilitate a cost-eIIective optimum. Regarding this, we can
sum up:
1. At higher temperature, many iron metallurgy processes
provide volatile matter that is not used and constitutes
a nuisance (dedusting). In this case only anthracite coals
are used. ThereIore it is purposeIul to develop Iurther
iron metallurgy technologies, as well as the ensuing
processes, so that also less expensive coals oI lesser
coaliIication value can be used.
REFERENCES
|1| World Coal Institute (2001). http://www.wci-coal.com/
Iatcscoal99.htm
|2| V. Machek, V. Roubicek, J. Kret, J. Bilik: Proceedings 3rd Euro-
pean Ironmaking Congres, Gent, 1996, 38-45
|3| J. Bilik, R. Luzny, W. SchtzenhIer: Hutnicke listy, LIV (1999),
7/8, 13-16
|4| LOCKWOOD GREENE, Ironmaking Process, Alternatives
Screening Study, 2000, 147
|5| J. Bilik, W. SchtzenhIer, H. Hiebler: Berg- und Httenmnnische
MonatsheIte 143, (1998) 5, 166-169
2. Coal brings by itselI slag Iorming or unwanted substances
(sulphur, phosphorus) in metallurgical processes. There-
Iore it is purposeIul to reduce ash content in coal to a
cost-eIIective permissible level, as depends on individual
usage mode, or remove sulphur Irom coal. Also the em-
ployment oI super clean coal produced by chemical tech-
nologies cannot be excluded.
3. It is purposeIul Iurther to develop coal based metallurgi-
cal processes, especially the processes oI smelting reduc-
tion and blast Iurnace process, aiming at increasing eIIec-
tiveness oI coal use or, as the case might be, employ
coal by-products that are diIIicult to exploit in basic pro-
cesses. At the same time observe environmental- Iriendly
character oI the process.

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