The Burden Structure and Its Consumption in the Melter Gasifier of the Corex Process

A major advancement in the Corex ironmaking process is the usage of lump coal considering the shortage of coking coal resources worldwide. However, the burden similar to that of the blast furnace is still essential for the enlarged melter gasifier. The notable difference is that the burden of the melter gasifier is composed of char formed from lump coal with a small amount of coke. The burden structure of the melter gasifier was investigated by the tuyere probing while the plant was shut down at different operating conditions. The specimens representing the different positions of lump zone, cohesive zone, and dripping zone were analyzed by means of coke/char size distribution and X-ray diffraction (XRD) for the degree of graphitization of coke. A chemical analysis of metal composition has also been performed to get a better understanding of the final reduction in the melter gasifier. The burden structure is supposed to be divided into three zones: active zone, outer of deadman, and deadman core, where coke/char was consumed differently. Based on these analyses, some technical advice to improve the Corex operation is given.