EURASIA

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EURASIA MENA Mining,Industrial Minerals and
Mineable Energy Trade Investment SummitMAY
16TH -17TH , 2012 Istanbul-Turkey

• WORLD Coking Coal Supply for Integrated Iron and
  Steel Works and Possibilities of Erection of New
  Mines for
• Production of Coking Coal
• Dr.-Ing. Hayri Ergun
• Independent Consulting Engineer

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Miners who are involved in the production of
  coal, in the carbonization techniques and in the
  iron and steel industry who know the importance
  of Coking Coal for our Insutrial Development.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• In our Days the Wonder Word
• Clean Coal Technology
• is a Basic Assumption in Respect to cover the
  demand of the Iron and Steel Industry , to CO2
  as well as to Climatic Environmental Discussion.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The Institutions of the Montan and Mining
  Industry are therefore Germ Cells for
• the New Technologies and New Products.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The Readiness and the Courage for New Ways should
  be further in the Future
• Driving Forces for the Industry.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Only so we could secure the competitiveness and
  
• keep exisiting jobs and
• create new ones.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Therefore it should be one of our most important
  aimes to strengthen the Innovative Dynamic of the
  Economy

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• With the Coke Oven Schwelgern the Company
  ThyssenKrupp Stahl AG has the most modern and
  clean Coke Oven of the World in the industrial
  Location Duisburg in Germany since March 2003.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works
Coke Oven Schwelgern
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WORLD Coking Coal Supply for Integrated Iron and
Steel Works
Coke Oven Schwelgern
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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The Construction of the Coke Oven Schwelgern at
  the Turning Point to the 3rd millennium is
  however not one under many.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• By analogy to the altogether crisis - like
  development of the Hard Coal Mining and the Iron
  and Steel Industry in the past decades, also the
  number of the Coke Ovens were drastically
  decreased.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The term coal is comprising a very wide
  palette of carbon containing raw materials, that
  can be classified after the most varied
  viewpoints.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works
Bituminous Coal
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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• If one bases on the respective age as
  characteristic distinction features, one would
  designate the youngest coal as a turf coal and
  the oldest as an anthracite coal.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The coal can be classified after appearance,
  fields of application, chemical composition,
  carbonization technological characteristics, or
  also after coal microscopic viewpoints.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Corresponding to the age and the mineral deposit
  conditions, also the process technological
  treatment of the coal is undertaken in order to
  be able to use it for the Coke Production.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• A Mineral Beneficiation Processing of the coal is
  basically necessary in order to separate the Raw
  Material from mineral contaminations.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The classification of coal is generally based on
  the content of volatiles. However, the exact
  classification varies between countries.
  According to the German classification, coal is
  classified as follows.

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Coal Classification
German Classification English Designation Volatiles  C Carbon  H Hydrogen  O Oxygen  S Sulfur  Heat content kJ/kg
Braunkohle Lignite 45-65 60-75 6.0-5.8 34-17 0.5-3 lt28470
Flammkohle Flame coal 40-45 75-82 6.0-5.8 gt9.8 1 lt32870
Gasflammkohle Gas flame coal 35-40 82-85 5.8-5.6 9.8-7.3 1 lt33910
Gaskohle Gas coal 28-35 85-87.5 5.6-5.0 7.3-4.5 1 lt34960
Fettkohle Fat coal 19-28 87.5-89.5 5.0-4.5 4.5-3.2 1 lt35380
Esskohle Forge coal 14-19 89.5-90.5 4.5-4.0 3.2-2.8 1 lt35380
Magerkohle Non baking coal 10-14 90.5-91.5 4.0-3.75 2.8-3.5 1 35380
Anthrazit Anthracite 7-12 gt91.5 lt3.75 lt2.5 1 lt35300
Percent by weight Percent by weight Percent by weight Percent by weight Percent by weight Percent by weight Percent by weight Percent by weight

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Already in the Coal Preparation or later in the
  Coke Oven the grinding of the coal is undertaken.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The grinding and comminution of the coarse
  particles of the coal should create the
  prerequisite out of carbonization technological
  view point for a good mixing ability of several
  coal components.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The comminution of the coal is however also
  therefore necessary in order to control special
  processes in the carbonization (like expansion
  pressure).

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Based on the worldwide shortage of the good
  quality coking coal and the endeavoring emerging
  from that to expand the raw material basis for
  the carbonization, following procedure lines have
  been developed for the coal blend

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works
procedure lines developed for the coal blend

• Optimization of the coal blend,
• Conditioning through supplement of pitch and
  special grog,
• Intensification through tramping,
• Mixture through Partial Briquetting,
• Formed Coke Production.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• With the goal of increasing on the one hand the
  capacity of the coke ovens, on the other hand to
  reduce the harmful material emission, around
  through it to increase the environment
  contractual situation, the following ways have
  been followed in the course of the last decades

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Reduction of the chamber width (1960-1970)
• Reduction of the Runner Stone Thickness
• Increase of the Flue Chamber Temperature
• Pre-drying of the coal blend
• Pre-heating of the coal blend
• Intensification through special binders
• Compacting through tramping
• Coke Dry Quenching
• Increasing of the chamber width (1980-1990)

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• Coal is a very inconsistent material. This
  heterogeneity is to be attributed to the
  inconsistent genetic material and in addition
  also on the different temporal and geothermal
  influences with the Coalification. Already early
  was recognized that all coals do not suit
  themselves to the Carbonization. Prerequisite
  for a Coking Coal is a sufficient baking capacity.

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WORLD Coking Coal Supply for Integrated Iron and
Steel Works

• The special characteristic to form a firm baked
  residue, is to be found only in certain
  bituminous coals and since beginning of the 20th
  century again and again object of numerous
  research investigations.

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A Bituminous Coal SEAM  IN Pennsylvania, USA
Coastal Exposure of the Point Aconi Seam
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Transportation of Coal by Rail Cars

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Coke Oven in Wales, UnitedKingdom

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A Coal Mine in Wyoming / United States.
The United States with the world's largest coal
reserves

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Proved Recoverable Coal Reserves at 2008 (million
tons (teragrams)
Proved recoverable coal reserves at end-2008 (million tons (teragrams)) Proved recoverable coal reserves at end-2008 (million tons (teragrams)) Proved recoverable coal reserves at end-2008 (million tons (teragrams)) Proved recoverable coal reserves at end-2008 (million tons (teragrams)) Proved recoverable coal reserves at end-2008 (million tons (teragrams)) Proved recoverable coal reserves at end-2008 (million tons (teragrams))
Country Bituminous Anthracite SubBituminous Lignite TOTAL Percentage of World Total
 United States 108,501 98,618 30,176 237,295 22.6
 Turkey 529 0 1,814 2,343 0.3
 Germany 99 0 40,600 40,699 4.7
 China 62,200 33,700 18,600 114,500 12.6
 Russia 49,088 97,472 10,450 157,010 14.4
 Australia 37,100 2,100 37,200 76,500 8.9
 Indonesia 1,520 2,904 1,105 5,529 0.6

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Proved Recoverable Coal Reserves WHERE IS COAL
FOUND?

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Coal is stacked onto a stockpile

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COAL STATISTICS
Coal provides 29.6 of global primary energy and
generates 42 of the world's electricity

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COAL STATISTICS
 World Total Coal Production  (including hard
coal and lignite) 7 229 Mt (2010) 6 823 Mt
(2009) 4 677 Mt(1990)

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COAL STATISTICS
  World Total Bituminous Coal Production 6 185
Mt (2010)  891 Mt coking coal 5 294 Mt
steam coal 5 789Mt (2009)  782Mt coking
coal 5 007 Mt steam coal 3 493Mt (1990) 
598Mt coking coal 2 894 Mt steam coal

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Coal Steel
  Approximately 13 of total hard coal production
is currently used by the steel industry and over
60 of total global steel production is dependent
on coal.

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Coal Trade for SteelProduction
International Hard Coal Trade Steam 676 Mt
Coking 262 Mt Total 938 Mt

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The Way from Coking Coal to Steel

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Coal Steel
Worldwide Coking Coal Deficit is estimated to
approximaetly 200 MT/a. For the year 2015 it is
estimated that the coking coal deficit of China
and India will be together around 200 MT/a.

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Coal Steel
Coking coal price surged to US 300 per tonne
in the first quarter of the calendar year
2011. Supply disruptions caused by flooding
over Christmas in Australia influenced also
the coking coal price.

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Coal Steel
Because of Shortage of Coking Coal worldwide the
possibility of utilizing of non-coking coals for
metallurgical coke production especially by
Advanced Carbonization Technologies like Formed
Coke processes are gaining on increasing
importance.

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Advanced Carbonization Techniques
The sucessfull application of the proposed
formed coke processes would result in
considerable saving by the substitution of
essential amounts of coking coals through
non-coking coals.

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Advanced Carbonization Techniques FORMED COKE
PRODUCTION
The Briquetting of the coal blend under aid of
pitch is the first level the Formed Coke
Production.

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Advanced Carbonization Techniques FORMED COKE
PROCESS
Herewith the components are usually finely
ground up, mixed through well and brought by
presses in close contact.

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Advanced CarbonizatiON Techniques FORMED COKE
PROCESS
The briquettes as such could be carbonized if
formed coke is supposed to be produced

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Advanced CarbonizatiON Techniques FORMED COKE
PROCESS
The Carbonization cannot take place in the
Horizontal Chamber Coke Oven because the Coke
Cake has no sufficient Stability.

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Advanced CarbonizatiON Techniques FORMED COKE
PROCESS
For this reason new coke oven reactor had to be
developed for the formed coke production this is
based partially upon the old vertical type coke
oven technology.

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Advanced CarbonizatiON Techniques FORMED COKE
PROCESS
Non- coking coal continuously to compact and to
carbonize, busied the profession already in the
'1950's.

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Advanced CarbonizatiON Techniques FORMED COKE
PROCESS
With Formed Coke, that was produced in a Vertical
Chamber Coke Oven, industrial attempts were
accomplished in a Blast Furnace in Japan
whereby the Formed Coke ratio amounted to up to
25.

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Possibilities of Erection of New Mines for
Production of Coking Coal

• Dr.-Ing. Hayri Ergun
• Independent Consulting Engineer

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Possibilities of Erection of New Mines for
Production of Coking Coal
Metallurgical coal is an essential raw material
in the production of steel which is used in
buildings, household items and other goods and
services that modern societies need.

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Possibilities of Erection of New Mines for
Production of Coking Coal
As an Example for increasing Coking Coal
production- BHP Billiton Mitsubishi Alliance
(BMA) owns and operates seven Bowen Basin mines
Goonyella Riverside, Broadmeadow, Peak Downs,
Saraji, Norwich Park, Gregory Crinum, and
Blackwater and the Hay Point terminal near
Mackay.  The mines are located in the coal-rich
Bowen Basin of Central Queensland, which covers
an area of 75,000km² of Permian Age BHP Billiton
owns 50 per cent of BMA..

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Possibilities of Erection of New Mines for
Production of Coking Coal
Opening New Coal Mines needs big Investments and
long time periods for preparation of the
Mine Remote Continuous Miner HM21 Joy Used for
Underground Coal Mining .

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Possibilities of Erection of New Mines for
Production of Coking Coal
Processing of Coal needs also Coal Wash plants
with huge capital demand Coal wash plant
in Clay County, Kentucky.

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S y n o p s i s
As Synopsis we can make the Observation
that Worldwide there is a deficit of good
quality coking coal for the iron and steel
industry in a yearly amount of approximately 200
MT. There are advanced technologies to produce
metallurgical coke from non-coking coals, which
however should be further developed. New Mines
for Coking Coal should be opened to cover the
worldwide demand for good quality coking coal.

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Thank you for your Attention