CA1069313A - Process for the direct reduction of iron oxide-containing materials in a rotary kiln - Google Patents

Process for the direct reduction of iron oxide-containing materials in a rotary kiln

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Publication number
CA1069313A
CA1069313A CA243,570A CA243570A CA1069313A CA 1069313 A CA1069313 A CA 1069313A CA 243570 A CA243570 A CA 243570A CA 1069313 A CA1069313 A CA 1069313A
Authority
CA
Canada
Prior art keywords
rotary kiln
solid carbonaceous
process according
charged
carbonaceous reducing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA243,570A
Other languages
French (fr)
Inventor
Gerhard Reuter
Wolfram Schnabel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GEA Group AG
Original Assignee
Metallgesellschaft AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Metallgesellschaft AG filed Critical Metallgesellschaft AG
Application granted granted Critical
Publication of CA1069313A publication Critical patent/CA1069313A/en
Expired legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/08Making spongy iron or liquid steel, by direct processes in rotary furnaces
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/0066Preliminary conditioning of the solid carbonaceous reductant
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/10Reduction of greenhouse gas [GHG] emissions
    • Y02P10/134Reduction of greenhouse gas [GHG] emissions by avoiding CO2, e.g. using hydrogen

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Manufacture Of Iron (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE

A process for the direct reduction of iron oxide-containing materials to produce sponge iron by a treatment with solid carbonaceous reducing agents in a rotary kiln at a temperature below the softening and melting point of the charge, in which the kiln atmosphere flows opposite to the direction of movement of the charge, at least part of the solid carbonaceous reducing agents is charged in agglomerated form into the rotary kiln at the charging end thereof, and oxygen-containing gases are fed into the rotary kiln. The process is characterized in that highly reactive, solid carbonaceous reducing agents which contain 20-50% volatile constituents are charged in agglomerated form into the rotary kiln at the charging end thereof and are heated up at such a rate that they disintegrate into fine particles substantially in and before the end of the heating-up zone of the rotary kiln. The process of the invention enables the use of highly reactive solid carbonaceous reducing agents in an economical and technically simple manner and an optimum utilization of the volatile constituents in the rotary kiln; the losses due to dust entrained by the exhaust gases are small, and optimum operating conditions in conjunction with a high throughput can be obtained.

Description

`` 1069313 ~ his invention relates to a process for the direct reduction of iron oxide-containing materials, preferably iron ores, to produce sponge iron by a treatr~lent with solid carbonaceous reducing agents in a rotary kiln at a temperature below the softening and ~nelting point of the charge, in which the kiln at~l~osphere flows opposite to the direction of movement of the charge, at least part of the solid carbonaceous reducing agents is charged in agglomerated form into the rotary kiln at ' the charging end thereof, and' oxygen-containing gases are fed 1 n into the rotary kiln.
The use of highly reactive solid carbonaceous reducing agents having a high content of volatile constituents has the advantage that the reaction rate i8 increased, the volatile constituents can be used for the reduction and heat supply in the rotary kiln, and inexpensive reducing agents can be used.
On the other hand, the problem arises to enable a utilization in the rotary kiln of those volatile constituents which are ' released near the charging end and to minimize the quantity of fine-grained reducing agent entrained by the exhaust gas from 20 the rotary kiln.
For this reason, in processes in which such reducing agents are used, at least a considerable part of these reducing agents is blo~m or thrown into the rotary kiln at the discharge end thereof and is distributed along the rotary kiln over a certain distance (British Patent Specification 1,222,1 23; British Patent Specification 1,307,869; "Stahl und Eisen", 85, (1965), page 1375; Australian Printed Application 423,616). As a result, a large part of the volatile constituents is released in the rear part of the rotary kiln and can be utilized in the 30 rotary kiln. In that process, however, a highly exact, defined and uniform distribution of the reducing agent to the several zones of the rotary kiln is required in order to avoid trouble due to ~ !

"` lO~g31~

fluctuations of temperature, pressure and gas composition. ~o ensure the required distribution of the reducting agent, its particle size distribution must be constant. If part of the reducing agent having a high content of volatile constituents is fed into the rotary kiln at the charging end thereof, only part or none of the volatile constituents released in the first part of the rotary kiln can be utilized in the rotary kiln.
It is also known to pelletize the surplus carbonaceous material separated from the material discharged from the kiln and to recycle the pelletized surplus carbonaceous material to the charging end of the rotary kiln. Due to its pelletization, the surplus carbonaceous material resists disintegration in at least part of the length of the kiln and the losses due to solids entrained by the exhaust gases are minimized (British Patent Specification 1,264,452). Whereas this practice results in a reduction of the losses caused by the entrainment of recycled surplus carbon which has been devolatilized, it does not constitute a suggestion how the problems described herein-before can be solved.
It is known from the U.S. Patent SpeciPication 3.097.090 to charge the rotary kiln with fine-grained coal and with surplus coal in the form of lump coal or coal pellets.
The lump coal should form a protective layer covering the surface of the charge and is recycled when it has been screened from the matter discharged from the kiln. A use of highly reactive coal having a high content of volatile constituents is not mentioned and would result in an excessively high content of volatile constituents in the exhaust gas.
It is known from the British Patent Specification 1,110,667 to impregnate coked coal pellets with liquid hydro-carbons and then to charge them into the rotary kilns in zones in which the charge is already at a temperature of at least 600C.

1069~13 ~or this reason, the pellets rnust be blown or thrown into the rotary kiln or fed through the ~qhell thereof.
It is an obàect of the invention to provide a technically simple and economic process which enables the use of highly reactive coal having a high content of volatile ; constituents whereas the above-mentioned disadvantages of the known processes are avoided. Specifically, the volatile constituents should be utilized to a high degree in the rotary kiln, the losses of solid reducing agent due to entrainment by the exhaust gases should be minimized, and a uniform operation of`the kiln and high throughput rates are to be achieved.
~his object is accomplished according to the invention in that highly reactive, solid carbonaceous reducing agents which contain 20-50% volatile constituents are charged in agglomerated form into the rotary kiln at the charging end thereof and are heated up at such a rate that they disintegrate into fine particles substantially in and before the end of the heating-up zone of the rotary kiln.
~he oxygen-containing gases - generally air - may be blown in by means of shell tubes, which are spaced along the kiln, and1or in a jet from the discharge end of the rotary kiln.
Preferred highly reactive solid carbonaceous reducing agents which contain 20-50% volatile constituents are brown coal and subbituminous coal. The reducing agent may be agglo~erated by being pelletized or briquetted. ~he agglomerates have preferably a particle size in the range of about 1-7 cm.
~rag~ents of agglomerates may also be used. ~he disintegration of the agglomerates in and before the end of the heating-up zone of the rotary kiln is controlled in such a manner that the disintegration takes place throughout the length of the heating-up zone whereas a complete disintegration of all ~0693~3 r agglomerates in the initial portion of the heating-up zone is avoided ~he reducing zone begins approximately at that point of the rotary kiln where the temperature of the charge has reached the reducing temperature and remains virtually constant.
It will be understood that a reduction resulting in lower iron oxides takes place even before the reducing zone thus defined.
~he disintegration in the heating-up zone should result in a particle size which is desirable for the reduction, i.e., which is as small as possible, below 5 mm and in any case below 8 mm.
A small disintegration or continued disintegration in the reducing zone is not disturbing.
According to a preferred feature of the invention, !
the highly reactive solid carbonaceous reducing agents are charged in the form of briquettes into the rotary kiln at the charging end thereof. Briquettes are highly suitable and can be made more economically than pellets because the reducing ~;agents which are used can be briquetted without binders when they have the particle size which results from drying and they need not be disintegrated to pelletizable particles and be pelletized with addition o~ binders. The briquetting may be effected at the temperature at which the coal is discharged from the dryer or to which the coal cools down before entering the presses. lhe briquettes leaving the presses are at a temperature of about 40-60C. Cylindrical briquettes are preferred.
According to another preferred feature of the invention, part of the solid carbonaceous reducing agent is blown into the rotary kiln at the discharge end thereof in the direction of flow of the kiln atmosphere. In this way, the sponge iron product can be protected in the final part of the reducing zone even if only a very small amount of residual carbon is left in the charge. Only a small required surplus of carbon is - : : . ~ . .. :..................... , required in the discharged material in this case.
According -to a further preferred feature, the agglomerated solid carbonaceous reducing agent has a particle size of 1-7 cm. ~his particle size range results in very good operating conditions.
- According to a further preferred feature, the agglomerated reducing agent is heated up in the heating-up zone of the rotary kiln at a rate of 7-15C/min, preferably 9-12C/min. Atthis heating-up~ate,the agglomer~tes ~the reducing agentare devolatilized at a lower rate than the same reducing agent when it is not agglomerated. This results in a more uniform devola- ;
tilization throughout the heating-up zone and in a smaller heat consumption. A heating-up rate in this range results also in a particularly desirable disintegration of the .
agglomerated reducing agent and in lower losses due to a formation of dust and burning.
According to yet another preferred feature, the charge is at a temperature of 900-950C in the reducing zone.
Most of the volatile constituents of the agglomerates of the reducing agent are released up to this ternperature range so that the H2 content of the degasified reducing agent reaches its maximum when the reducing zone is reached. In the reducing zone, the reducing agent is gasified and the gasification products are optimally utilized for the reduction in the reducing zone. ~hese temperatures result also in a low-tempera-ture coke having a sufficiently high strength for its continued movement in the reducing zone of the kiln.
According to another preferred feature, the carbon contained in the matter discharged from the rotary kiln amounts to less than 2~ by weight, preferably less than 1% by weight, of the quantity of iron oxide-containing material which has been charged. ~his simplifies the separation of surplus carbon `` ~0693~3 from the material which has been discharged or eliminates the need for such separation. Any separated carbonaceous material can be recycled into the rotary kiln.
According to a ~urther preferred feature, a solid carbonaceous reducing agent of low reactivity i9 charged into the rotary kiln in a quantity of up to about 0 1% by weight carbon per 1% by weight Fe in the iron oxide-containing material which is charged. ~he reducing agent of low reactivity may be charged into the rotary kiln at the charging end thereof or may be blown in at the discharge end. The reducing agent of ~--low reactivity is circulated almost without losses due to burning and formation of dust! ~his practice avoids a depletion of carbon in the charge in the final part of the rotary kiln and permits of the use of only a small surplus of carbon re~uired for the sake of safety.
According to a further preferred feature, a reducing flame is maintained in the final portion of the reducing zone.
This permits also of the use of only a small surplus of carbon required for the sake of safety. The reducing flame may be produced by a central burner which is fed with oil or gas and with a deficienty of air.
According to a further preferred feature, at least 80% of highly reactive solid carbonaceous reducing agent are .
charged in agglomerated form into the rotary kiln at the charging end thereof. Particularly good operating conditions result from that practice.
~he advantages of the invention reside in that highly reactive solid carbonaceous reducing agents are used in an ~
economical and technically simple manner and an optimum utiliza- -tion of the volatile constituents in the rotary kiln is enabled, the losses due to dust entrained by the exhaust gases are small, and optimum operating conditions in conjunction with a high throughput rate can be obtained.

Claims (12)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A process for the direct reduction or iron oxide-containing materials to produce sponge iron by a treatment with solid carbonaceous reducing agents in a rotary kiln at a tempe-rature below the softening and melting point of the charge, in which the kiln atmosphere flows opposite to the direction of movement of the charge, at least part of the solid carbonaceous reducing agents is charged in agglomerated form into the rotary kiln at the charging end thereof, and oxygen-containing gases are fed into the rotary kiln, characterized in that highly reactive, solid carbonaceous reducing agents which contain 20-50% volatile constituents are charged in agglomerated form into the rotary kiln at the charging end thereof and are heated up at such a rate that they disintegrate into fine particles substantially in and before the end of the heating-up zone of the rotary kiln.
2. A process according to claim 1, characterized in that the highly reactive solid carbonaceous reducing agents are charged in the form of briquettes into the rotary kiln at the charging end thereof.
3. A process according to claim 1, characterized in that part of the solid carbonaceous reducing agent is blown into the rotary kiln at the discharge end thereof in the direction of flow of the kiln atmosphere.
4. A process according to claims 1, 2 or 3, characterized in that the agglomerated solid carbonaceous reducing agent has a particle size of 1-7 cm.
5. A process according to claim 1, characterized in that the agglomerated reducing agent is heated up in the heating-up zone of the rotary kiln at a rate of 7-15°C/min.
6. A process according to claim 5, characterized in that said rate is 9-12°C/min.
7. A process according to claims 1, 3 or 5, characterized in that the charge is at a temperature of 900-950°C in the reducing zone.
8. A process according to claim 1, characterized in that the carbon contained in the matter discharged from the rotary kiln amounts to less than 2% by weight of the quantity of iron oxide-containing material which has been charged.
9. A process according to claim 8, characterized in that said carbon amount is less than 1% by weight.
10. A process according to claim 1, characterized in that a solid carbonaceous reducing agent of low reactivity is charged into the rotary kiln in a quantity of up to about 0.1% by weight carbon per 1% by weight Fe in the iron oxide-containing material which is charged.
11. A process according to claim 1, characterized in that a reducing flame is maintained in the final part of the reducing zone.
12. A process according to claim 1, characterized in that at least 80% of highly reactive solid carbonaceous reducing agent are charged in agglomerated form into the rotary kiln at the charging end thereof.
CA243,570A 1975-01-14 1976-01-13 Process for the direct reduction of iron oxide-containing materials in a rotary kiln Expired CA1069313A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE19752501182 DE2501182A1 (en) 1975-01-14 1975-01-14 PROCESS FOR THE DIRECT REDUCTION OF FERROUS OXYDE-CONTAINING MATERIALS IN THE ROTARY FURNACE

Publications (1)

Publication Number Publication Date
CA1069313A true CA1069313A (en) 1980-01-08

Family

ID=5936385

Family Applications (1)

Application Number Title Priority Date Filing Date
CA243,570A Expired CA1069313A (en) 1975-01-14 1976-01-13 Process for the direct reduction of iron oxide-containing materials in a rotary kiln

Country Status (9)

Country Link
AU (1) AU498225B2 (en)
BR (1) BR7508574A (en)
CA (1) CA1069313A (en)
DE (1) DE2501182A1 (en)
GB (1) GB1532969A (en)
IN (1) IN143905B (en)
IT (1) IT1054732B (en)
NL (1) NL7513171A (en)
TR (1) TR18932A (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2653512C2 (en) * 1976-11-25 1983-10-06 Metallgesellschaft Ag, 6000 Frankfurt Process for the direct reduction of oxidic ferrous materials
DE2719422C2 (en) * 1977-04-30 1982-04-29 Metallgesellschaft Ag, 6000 Frankfurt Process for the direct reduction of materials containing iron oxides to sponge iron in a rotary kiln
DE2835866A1 (en) * 1978-08-16 1980-02-28 Metallgesellschaft Ag METHOD FOR DIRECTLY REDUCING MATERIALS CONTAINING IRON OXIDE
DE3509505A1 (en) * 1985-03-16 1986-09-18 Metallgesellschaft Ag, 6000 Frankfurt Process for the direct reduction of iron oxide-containing materials in a rotary kiln

Also Published As

Publication number Publication date
DE2501182A1 (en) 1976-07-15
NL7513171A (en) 1976-07-16
IN143905B (en) 1978-02-25
BR7508574A (en) 1976-08-24
IT1054732B (en) 1981-11-30
AU8678475A (en) 1977-05-26
TR18932A (en) 1977-12-20
GB1532969A (en) 1978-11-22
AU498225B2 (en) 1979-02-22

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