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Commercial gasifiers have been in operation for over 50 years. In general, gasification can be defined as a partial oxidation process in which a carbonaceous fuel (gas, liquid, or solid) reacts at high temperature and usually at high pressure with oxygen and possibly steam to produce a synthesis gas. This gas can then be used to fuel the MIDREX Direct Reduction Process. Utilizing a gasifier to generate reducing gases is a technically and commercially viable method for innovative steelmakers to produce DRI in areas where low cost natural gas is not available. Even better economics can be derived when the project includes a meltshop and an Integrated Gasification Combined Cycle-based power plant. This Integrated Mini-mill complex is able to utilize low cost coal, and petroleum refining by-products to produce reasonably priced DRI and low cost electricity to allow competitive manufacture of liquid steel. The world’s first gasifier plus DRI plant combination started-up in 1999 at Saldanha Steel in South Africa. This facility includes a COREX® Plant, which uses a melter/gasifier to simultaneously produce pig iron and a by-product synthesis gas which feeds a MIDREX MEGAMOD™. |
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