CA2890506A1 - Use of h2 obtained from thermal decomposition of natural gas for iron ore reduction - Google Patents
Use of h2 obtained from thermal decomposition of natural gas for iron ore reduction Download PDFInfo
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- CA2890506A1 CA2890506A1 CA2890506A CA2890506A CA2890506A1 CA 2890506 A1 CA2890506 A1 CA 2890506A1 CA 2890506 A CA2890506 A CA 2890506A CA 2890506 A CA2890506 A CA 2890506A CA 2890506 A1 CA2890506 A1 CA 2890506A1
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- Canada
- Prior art keywords
- ore
- iron
- mixture
- gas
- hydrogen gas
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- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/10—Reduction of greenhouse gas [GHG] emissions
- Y02P10/143—Reduction of greenhouse gas [GHG] emissions of methane [CH4]
Abstract
The present disclosure concerns a process for reducing an iron ore. The process comprises (i) thermally decomposing, in a decomposer, a natural gas (CH4) into an hydrogen gas (H2) and carbon black (C);(ii)reducing said iron ore with a reducing gas comprising the hydrogen gas of step (i) to provide: a first gaseous mixture comprising the hydrogen gas and a water vapor; and a second mixture comprising at least one target product of the iron ore; (iii) separating, in a separator, the second mixture to enrich the at least target product in the second mixture; (iv) condensing, in a condenser, the water vapor of the first gaseous mixture into liquid water to separate the hydrogen gas from the liquid water; and (v)recycling the hydrogen gas of step (iv) in the reducer of step (ii).
Description
NATURAL GAS FOR IRON ORE REDUCTION
TECHNOLOGICAL FIELD
This disclosure relates to the use of by-products obtained from natural gas thermal decomposition in iron ore reduction.
BACKGROUND
Natural gas has been used in metallurgical process such as in reforming processes for generating CO and H2 as reductant gases. CO gas reduces ore more actively than H2 gas but generates green-house gas (GHG). The use of natural gas in metallurgical processes suffers from several setbacks: off-gas from a reducer contains CO2 which requires rather expensive systems for its separation. In addition, high oxygen potential (and operating temperature) is preferable in order to avoid mechanical problems due to carbon-deposition, which decreases the reduction efficiency of gas.
It would be highly desirable to be provided with an improved process for reducing iron ores.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the accompanying drawing, showing by way of illustration, a preferred embodiment thereof, and in which:
Figure 1 illustrates an embodiment of the process described herein. The natural gas is thermally decomposed into carbon black (solid carbon or C) and hydrogen gas (H2) in a decomposer. The hydrogen gas produced from the thermally decomposed natural gas is used (either alone or in combination with other gases) to reduce an iron ore in a reducer. The ore reduction by-products and target products (H2/H20, Fern or TiO2 for example) can either be submitted to a condensation step in a condenser to separate water (H2O) from the hydrogen gas (H2, which is recycled back in the reducer) or to a separation step (in a smelter or aerator) to generate target products (e.g., iron (Fe) and/or titanium dioxide (TiO2, in an embodiment in the form of a titania slag or a synthetic rutile)).
DETAILED DESCRIPTION
The process described herein concerns the reduction of an iron using H2 from the thermal decomposition of natural gas as well as from recycling H2 (from the condenser) as the reducing gas/reductant gas. The reducing/reductant gas is obtained from the thermal decomposition of natural gas (CH4) and from the condenser. In an embodiment, the process
TECHNOLOGICAL FIELD
This disclosure relates to the use of by-products obtained from natural gas thermal decomposition in iron ore reduction.
BACKGROUND
Natural gas has been used in metallurgical process such as in reforming processes for generating CO and H2 as reductant gases. CO gas reduces ore more actively than H2 gas but generates green-house gas (GHG). The use of natural gas in metallurgical processes suffers from several setbacks: off-gas from a reducer contains CO2 which requires rather expensive systems for its separation. In addition, high oxygen potential (and operating temperature) is preferable in order to avoid mechanical problems due to carbon-deposition, which decreases the reduction efficiency of gas.
It would be highly desirable to be provided with an improved process for reducing iron ores.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the accompanying drawing, showing by way of illustration, a preferred embodiment thereof, and in which:
Figure 1 illustrates an embodiment of the process described herein. The natural gas is thermally decomposed into carbon black (solid carbon or C) and hydrogen gas (H2) in a decomposer. The hydrogen gas produced from the thermally decomposed natural gas is used (either alone or in combination with other gases) to reduce an iron ore in a reducer. The ore reduction by-products and target products (H2/H20, Fern or TiO2 for example) can either be submitted to a condensation step in a condenser to separate water (H2O) from the hydrogen gas (H2, which is recycled back in the reducer) or to a separation step (in a smelter or aerator) to generate target products (e.g., iron (Fe) and/or titanium dioxide (TiO2, in an embodiment in the form of a titania slag or a synthetic rutile)).
DETAILED DESCRIPTION
The process described herein concerns the reduction of an iron using H2 from the thermal decomposition of natural gas as well as from recycling H2 (from the condenser) as the reducing gas/reductant gas. The reducing/reductant gas is obtained from the thermal decomposition of natural gas (CH4) and from the condenser. In an embodiment, the process
- 2 -is advantageous at least because no green-house gases are produced during the ore reduction since no carbon units (e.g. solid carbon or gaseous carbon such as CO) participate in the reduction process. Further, this process allows the production of lucrative by-products (carbon black/solid carbon) target products (titania slag, synthetic rutile and iron) as well as recyclable by-products (e.g., H2 gas). Further, the use of H2 from the thermal decomposition of natural gas as a reducing/reductant gas is associated with fast reduction kinetics or a higher global gas reduction efficiency (even at low temperature), easy recycling of reducer off-gas and easy off-gas cleaning (allowing recycling of the H2 gas) as well as high global gas reduction efficiency.
The present disclosure thus provides processes for reducing an iron ore.
Broadly, the said process comprises: (i) thermally decomposing, in a decomposer, a natural gas (CH4) into an hydrogen gas (H2) and carbon black (C); (ii) reducing said iron ore with a reducing gas comprising the hydrogen gas of step (i) to provide: (a) a first gaseous mixture comprising the hydrogen gas and a water vapor; and (b) a second mixture comprising at least one target product of the iron ore; (iii) separating, in a separator (e.g., a smelter or an aerator), the second mixture to enrich the at least target product in the second mixture;
(iv) condensing, in a condenser, the water vapor of the first gaseous mixture into liquid water to separate the hydrogen gas from the liquid water; and (v) recycling the hydrogen gas of step (iv) in the reducer of step (ii). In an embodiment, the process further comprises, after step (iv), recuperating the liquid water. In another embodiment, the process further comprises, after step (i), recuperating carbon black.
In an embodiment, the reducing gas can comprise additional gases such as hydrogen gas which was not generated from natural gas, one or more carrier gas, air, oxygen and/or CO
gas, etc. In another embodiment, the reducing gas consists essentially of or consists of the hydrogen gas of step (i). In still a further embodiment, the reducing gas is devoid or substantially devoid of CO gas. In another embodiment, the hydrogen gas which has been used as a reducing gas can also be used to provide heat.
In an embodiment, the second mixture is a solid mixture, a liquid mixture or a combination of a solid mixture and a liquid mixture.
In an embodiment, the iron ore that can be submitted to this process is an iron oxide ore.
Exemplary iron oxide ores include, but are not limited to hematite (Fe203-containing ore), wustite (FeO-containing ore), magnetic ore (Fe3SO4-containing ore) as well as combinations thereof. In such embodiments, the at least one target product comprises iron.
The present disclosure thus provides processes for reducing an iron ore.
Broadly, the said process comprises: (i) thermally decomposing, in a decomposer, a natural gas (CH4) into an hydrogen gas (H2) and carbon black (C); (ii) reducing said iron ore with a reducing gas comprising the hydrogen gas of step (i) to provide: (a) a first gaseous mixture comprising the hydrogen gas and a water vapor; and (b) a second mixture comprising at least one target product of the iron ore; (iii) separating, in a separator (e.g., a smelter or an aerator), the second mixture to enrich the at least target product in the second mixture;
(iv) condensing, in a condenser, the water vapor of the first gaseous mixture into liquid water to separate the hydrogen gas from the liquid water; and (v) recycling the hydrogen gas of step (iv) in the reducer of step (ii). In an embodiment, the process further comprises, after step (iv), recuperating the liquid water. In another embodiment, the process further comprises, after step (i), recuperating carbon black.
In an embodiment, the reducing gas can comprise additional gases such as hydrogen gas which was not generated from natural gas, one or more carrier gas, air, oxygen and/or CO
gas, etc. In another embodiment, the reducing gas consists essentially of or consists of the hydrogen gas of step (i). In still a further embodiment, the reducing gas is devoid or substantially devoid of CO gas. In another embodiment, the hydrogen gas which has been used as a reducing gas can also be used to provide heat.
In an embodiment, the second mixture is a solid mixture, a liquid mixture or a combination of a solid mixture and a liquid mixture.
In an embodiment, the iron ore that can be submitted to this process is an iron oxide ore.
Exemplary iron oxide ores include, but are not limited to hematite (Fe203-containing ore), wustite (FeO-containing ore), magnetic ore (Fe3SO4-containing ore) as well as combinations thereof. In such embodiments, the at least one target product comprises iron.
- 3 -In another embodiment, the iron ore that can be submitted to this process is an iron titanium oxide ore. Exemplary iron titanium oxide ores include, but are not limited to ilmenite (FeTiO3-containing ore). Ilmenite can be obtained in the form of an ilmenite-hematite mixture, a weathered ilmenite, a titano-vanadium-magnetite as well as combinations thereof. In such embodiment, the at least one target product comprises TiO2 and Fe. Further, in some embodiments, the second mixture is titania slag or synthetic rutile.
While the invention has been described in connection with specific embodiments thereof, it will be understood that the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
While the invention has been described in connection with specific embodiments thereof, it will be understood that the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
Claims (14)
1. A process for reducing an iron ore, said process comprising:
(i) thermally decomposing, in a decomposer, a natural gas (CH4) into an hydrogen gas (H2) and carbon black (C);
(ii) reducing said iron ore with a reducing gas comprising the hydrogen gas of step (i) to provide:
.cndot. a first gaseous mixture comprising the hydrogen gas and a water vapor; and .cndot. a second mixture comprising at least one target product of the iron ore;
(iii) separating, in a separator, the second mixture to enrich the at least target product in the second mixture;
(iv) condensing, in a condenser, the water vapor of the first gaseous mixture into liquid water to separate the hydrogen gas from the liquid water; and (v) recycling the hydrogen gas of step (iv) in the reducer of step (ii).
(i) thermally decomposing, in a decomposer, a natural gas (CH4) into an hydrogen gas (H2) and carbon black (C);
(ii) reducing said iron ore with a reducing gas comprising the hydrogen gas of step (i) to provide:
.cndot. a first gaseous mixture comprising the hydrogen gas and a water vapor; and .cndot. a second mixture comprising at least one target product of the iron ore;
(iii) separating, in a separator, the second mixture to enrich the at least target product in the second mixture;
(iv) condensing, in a condenser, the water vapor of the first gaseous mixture into liquid water to separate the hydrogen gas from the liquid water; and (v) recycling the hydrogen gas of step (iv) in the reducer of step (ii).
2. The process of claim 1, wherein the reducing gas consists essentially of the hydrogen gas of step (i).
3. The process of claim 1 or 2, wherein the separator is a smelter.
4. The process of claim 1 or 2, wherein the separator is an aerator.
5. The process of any one of claims 1 to 4, further comprising, after step (iv), recuperating the liquid water.
6. The process of any one of claims 1 to 5, wherein the iron ore is an iron oxide ore.
7. The process of claim 6, wherein the iron oxide ore is hematite (Fe2O3-containing ore), wustite (FeO-containing ore) or magnetic ore (Fe3SO4-containing ore).
8. The process of claim 6 or 7, wherein the at least one target product comprises iron.
9. The process of any one of claims 1 to 5, wherein the iron ore is an iron titanium oxide ore.
10. The process of claim 9, wherein the iron titanium oxide ore is ilmenite (FeTiO3-containing ore).
11. The process of claim 10, wherein ilmenite is an ilmenite-hematite mixture, a weathered ilmenite or a titano-vanadium-magnetite.
12. The process of any one of claims 9 to 11, wherein the at least one target product comprises TiO2 and Fe.
13. The process of claim 12, wherein the second mixture is titania slag or synthetic rutile.
14. The process of any one of claims 1 to 13 further comprising, after step (i), recuperating carbon black.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201462026185P | 2014-07-18 | 2014-07-18 | |
| US62/026,185 | 2014-07-18 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2890506A1 true CA2890506A1 (en) | 2016-01-18 |
Family
ID=55130713
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2890506A Abandoned CA2890506A1 (en) | 2014-07-18 | 2015-05-01 | Use of h2 obtained from thermal decomposition of natural gas for iron ore reduction |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2890506A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108726480A (en) * | 2018-05-30 | 2018-11-02 | 东南大学 | A kind of device and method preparing the adjustable synthesis gas of C/Hratio using ferriferous oxide and natural gas |
| CN111302679A (en) * | 2020-03-02 | 2020-06-19 | 中国地质科学院矿产综合利用研究所 | Cement admixture containing vanadium titano-magnetite tailings and preparation method and application thereof |
| CN112921141A (en) * | 2021-01-25 | 2021-06-08 | 王文超 | Hydrogen energy iron-making device |
-
2015
- 2015-05-01 CA CA2890506A patent/CA2890506A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108726480A (en) * | 2018-05-30 | 2018-11-02 | 东南大学 | A kind of device and method preparing the adjustable synthesis gas of C/Hratio using ferriferous oxide and natural gas |
| CN111302679A (en) * | 2020-03-02 | 2020-06-19 | 中国地质科学院矿产综合利用研究所 | Cement admixture containing vanadium titano-magnetite tailings and preparation method and application thereof |
| CN112921141A (en) * | 2021-01-25 | 2021-06-08 | 王文超 | Hydrogen energy iron-making device |
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| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |
Effective date: 20180501 |