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Home PROCESS ENGINEERING Iron Making Processes Direct Reduction Fluidized Bed Processes Circored
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Manager's Role with Calibre Global
Process Engineering Manager's role with
Circored is a 2 stage process employing a circulating fluidised bed (CFB) for the first stage of Calibre Global
reduction and a fluidised bubbling bed (FBB) as the second stage of reduction. Iron Ore and Iron Making capabilities
added
Mineral Sands capabilities added
Rare Earth capabilities added
Proposal for a mineral sands mine
development study with SMEC
Rio Tinto contract successfully
completed
Innovation Project Capabilities added
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A r t i c l e s
CAPABILITY STATEMENTS
BENCHMARKING
BUSINESS PROCESSES
PROCESS ENGINEERING
Iron Making Processes
Direct Reduction
Kiln Processes
Shaft Processes
Fluidized Bed Processes
FIOR
The CFB was selected to achieve a pre-reduction of degree of between 60 and 80%, due to its Finmet
high slip velocity between the gas and solids, allowing excellent heat and mass transfer and a Circored
short retention time in the reactor. High gas velocities of between 4 and 6 m/s allow for a Circofer
smaller reactor size, saving on capital cost. The CFB also allows dust laden off-gas from the FBB Single Stage Iron Carbide
to be used as a secondary gas, enhancing the overall gas utilization. Two Stage Iron Carbide
Hearth Furnaces
The FBB was selected for the 2nd stage of the process to achieve the final metallization of 93%
Hot Briquetting
due to its slower rate of reaction. The FBB is characterized by lower gas velocities, between 0.5
Smelting
and 0.6 m/s and longer retention times up to 4 hours.
GRAPHICS
The CFB and FBB technologies are well known to Lurgi from their use in other metallurgical
processes.

Circored uses hydrogen, obtained from natural gas reforming, as its only reductant source (ie no
CO is used) in the process, resulting in a product with no carbon. An operating temperature
below 650C was chosen for the process to avoid the sticking tendency of the reduced iron ore
fines. The low operating temperature requires higher specific process gas volumes, hence an
operating pressure of 4 bar was chosen to reduce the actual gas flow rates.
The process:
Iron ore fines are dried and pre-heated in a CFB heater to 800C, before being charge to the first
stage CFB reactor. The ore is pre-reduced in the first stage CFB reactor to between 60 and 80%

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metallisation with a short residence time. The pre-reduced ore is charged into the second stage
FBB reactor which is a long compartmentalized horizontal cylindrical vessel to ensure that the
necessary residence time is achieved to produce the desired levels of reduction. The metallized
DRI fines are discharged from the FBB at approximately 630C, and 93% metallization. A flash
heater, using pre-heated make up hydrogen, is used to heat the DRI up to a temperature of
approximately 680oC, which is necessary for hot briquetting.
The compressed process gas is preheated to approximately 750oC in 2 gas fired pre-heat
furnaces, to be injected into each stage of the process (ie the CFB and FBB). Off-gas from the
FBB is fed as secondary process gas to the CFB. The gas exiting the CFB recycle cyclone is
cooled in the process gas heat exchanger, passed through a multi-clone to recover ultrafine
particles which are recycled to the FBB, scrubbed and quenched in the process gas scrubber
before being compressed and then re-heated in the process heat exchanger for re-injection into
the process.
Claimed advantages
Uses iron ore fines

2013, Downstream Consulting Pty Ltd

COPYRIGHT:
The concepts and information contained in this document are the property of Downstream
Consulting Pty Ltd. Use or copying of this document in whole or in part without the written
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Finmet up Circofer

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