EP3231537B1 - Production of elemental iron powder from pickling solutions - Google Patents
Production of elemental iron powder from pickling solutions Download PDFInfo
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- EP3231537B1 EP3231537B1 EP17162167.5A EP17162167A EP3231537B1 EP 3231537 B1 EP3231537 B1 EP 3231537B1 EP 17162167 A EP17162167 A EP 17162167A EP 3231537 B1 EP3231537 B1 EP 3231537B1
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- iron
- reduction
- process according
- compounds
- thermal decomposition
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims description 74
- 238000005554 pickling Methods 0.000 title claims description 25
- 238000004519 manufacturing process Methods 0.000 title description 3
- 238000000034 method Methods 0.000 claims description 64
- 230000008569 process Effects 0.000 claims description 43
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 40
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 34
- 230000009467 reduction Effects 0.000 claims description 34
- 229910052742 iron Inorganic materials 0.000 claims description 29
- 229910005084 FexOy Inorganic materials 0.000 claims description 25
- 239000000463 material Substances 0.000 claims description 19
- 239000002245 particle Substances 0.000 claims description 18
- 239000003638 chemical reducing agent Substances 0.000 claims description 17
- 239000000243 solution Substances 0.000 claims description 17
- 238000005979 thermal decomposition reaction Methods 0.000 claims description 17
- 229910000831 Steel Inorganic materials 0.000 claims description 15
- 239000010959 steel Substances 0.000 claims description 15
- 150000001875 compounds Chemical class 0.000 claims description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 11
- 239000003929 acidic solution Substances 0.000 claims description 8
- NMCUIPGRVMDVDB-UHFFFAOYSA-L iron dichloride Chemical class Cl[Fe]Cl NMCUIPGRVMDVDB-UHFFFAOYSA-L 0.000 claims description 8
- 238000010899 nucleation Methods 0.000 claims description 8
- 150000002506 iron compounds Chemical class 0.000 claims description 6
- 230000003381 solubilizing effect Effects 0.000 claims description 4
- 238000011282 treatment Methods 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 238000006722 reduction reaction Methods 0.000 description 30
- 239000002253 acid Substances 0.000 description 24
- 238000006243 chemical reaction Methods 0.000 description 18
- 239000007789 gas Substances 0.000 description 12
- 238000011084 recovery Methods 0.000 description 11
- 238000001465 metallisation Methods 0.000 description 10
- 239000000047 product Substances 0.000 description 9
- 239000001257 hydrogen Substances 0.000 description 8
- 229910052739 hydrogen Inorganic materials 0.000 description 8
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 7
- 230000002378 acidificating effect Effects 0.000 description 7
- 238000009792 diffusion process Methods 0.000 description 7
- 238000005245 sintering Methods 0.000 description 7
- 238000004140 cleaning Methods 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 230000002829 reductive effect Effects 0.000 description 6
- 238000000576 coating method Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 5
- 238000001878 scanning electron micrograph Methods 0.000 description 5
- 229910021577 Iron(II) chloride Inorganic materials 0.000 description 4
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 4
- 230000004888 barrier function Effects 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000354 decomposition reaction Methods 0.000 description 4
- 238000002474 experimental method Methods 0.000 description 4
- SZVJSHCCFOBDDC-UHFFFAOYSA-N ferrosoferric oxide Chemical compound O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 230000008929 regeneration Effects 0.000 description 4
- 238000011069 regeneration method Methods 0.000 description 4
- 238000004381 surface treatment Methods 0.000 description 4
- 239000002699 waste material Substances 0.000 description 4
- -1 alkaline-earth metal carbonates Chemical class 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000001419 dependent effect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- PTFCDOFLOPIGGS-UHFFFAOYSA-N Zinc dication Chemical compound [Zn+2] PTFCDOFLOPIGGS-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- IXCSERBJSXMMFS-UHFFFAOYSA-N hcl hcl Chemical compound Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 2
- FBAFATDZDUQKNH-UHFFFAOYSA-M iron chloride Chemical compound [Cl-].[Fe] FBAFATDZDUQKNH-UHFFFAOYSA-M 0.000 description 2
- RBTARNINKXHZNM-UHFFFAOYSA-K iron trichloride Chemical compound Cl[Fe](Cl)Cl RBTARNINKXHZNM-UHFFFAOYSA-K 0.000 description 2
- 229910000359 iron(II) sulfate Inorganic materials 0.000 description 2
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910021578 Iron(III) chloride Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 239000012159 carrier gas Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000010960 commercial process Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000000502 dialysis Methods 0.000 description 1
- 238000004821 distillation Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000000909 electrodialysis Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- BAUYGSIQEAFULO-UHFFFAOYSA-L iron(2+) sulfate (anhydrous) Chemical compound [Fe+2].[O-]S([O-])(=O)=O BAUYGSIQEAFULO-UHFFFAOYSA-L 0.000 description 1
- SURQXAFEQWPFPV-UHFFFAOYSA-L iron(2+) sulfate heptahydrate Chemical compound O.O.O.O.O.O.O.[Fe+2].[O-]S([O-])(=O)=O SURQXAFEQWPFPV-UHFFFAOYSA-L 0.000 description 1
- 238000011866 long-term treatment Methods 0.000 description 1
- 239000002069 magnetite nanoparticle Substances 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- MJGFBOZCAJSGQW-UHFFFAOYSA-N mercury sodium Chemical compound [Na].[Hg] MJGFBOZCAJSGQW-UHFFFAOYSA-N 0.000 description 1
- 229910001510 metal chloride Inorganic materials 0.000 description 1
- 229910021645 metal ion Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 239000012429 reaction media Substances 0.000 description 1
- 238000011946 reduction process Methods 0.000 description 1
- 229910001023 sodium amalgam Inorganic materials 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000001117 sulphuric acid Substances 0.000 description 1
- 235000011149 sulphuric acid Nutrition 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/16—Making metallic powder or suspensions thereof using chemical processes
- B22F9/30—Making metallic powder or suspensions thereof using chemical processes with decomposition of metal compounds, e.g. by pyrolysis
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/06—Metallic powder characterised by the shape of the particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
- C23G1/36—Regeneration of waste pickling liquors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Definitions
- the present invention relates to a method for producing elemental iron powder from acidic solutions formed as a result of acidic pickling which is performed during surface treatment of iron-containing materials. More particularly, the invention relates to a method for the recovery of iron compounds from acidic solutions formed after the pickling procedure, treatment of the same in a specific process, and obtaining of elemental iron with high metalization ratio.
- the flat steel products which are used in automotive, white goods, electricity pylons, barriers etc. are usually surface cleaned acidically prior to coating with different metals (zinc, nickel, chromium, etc.), so called galvanization, in order to provide a longer service life.
- different metals zinc, nickel, chromium, etc.
- galvanization so called galvanization
- an acidic bath HCl, H 2 SO 4
- sulfuric acid baths were used commonly for the purpose of pickling in iron & steel industry, but as from 1960s, hydrochloric acid (HCl)-containing baths have started to become widespread with the aim of obtaining the product with more quality and more homogenized surface.
- Hydrochloric acid (HCl) is a particularly preferred acid bath due to the fact that it provides obtaining of a faster result, consuming low amount of acid and its pyrometallurgical regeneration is easier and more economic. 0.30 kg HCl is being used for 1 ton of steel during pickling.
- the waste solution which is also called spent acid, formed following the pickling applied for the surface cleaning of steel sheets is an iron rich solution. Beside this, said solution may contain hydrochloric acid, metal ions which are present in steel composition and soluble in HCl as well as certain amounts of zinc ions if an incorrect recovery is carried out.
- the pickling solutions formed as a result of the reactions with hydrochloric acid vary in very wide ranges in composition, and establishing the method to be applied for recovering of these solutions is quite difficult.
- the methods of recovering the acidic cleaning solutions are gathered in two groups. The first one is the recovery of acid and the second one is the recovery of the metal formed in the acid.
- the methods that are used for the acid recovery or regeneration are electrodialysis, diffusion dialysis, membrane distillation, evaporation and spray drying. For the recovery of metal, methods such as extraction, retardation, ion exchange and crystallization are used.
- GB 1,219,674 discloses the reduction of iron oxide compounds (Aman oxide) by way of treating them with hydrogen by heating at high temperatures up to 1200 °C, preferably between 860-1200 °C, followed by sintering.
- sintering is a major problem in obtaining pure iron and flow paths can easily be clogged in dynamic systems such as fluidized bed.
- sintered product is not preferred and it needs to be grinded.
- GB 1137525 A discloses a process for producing pure iron powder and product thereof and US 2005/191231 A1 discloses a synthesis of magnetite nanoparticles and the process of forming Fe-based nanaomaterials.
- elemental iron should have high purity (>%99). Since the kinetics of reduction reactions depend on the diffusion of the reductive substance, elemental iron is hard to obtain at high ratio, or long term treatment is essential, when the reaction occurs within the fixed bed reactors or other conventional equipments.
- a decomposition step is carried out at the first stage in a fluidized bed for the recovery of the acid in the spent acid composition while pure iron oxide (Fe x O y ) is obtained from the iron-containing compounds (FeCl 2 and low amount of FeCl 3 ) formed in the spent acid, and HCl is obtained as the spent product.
- the second process step within the scope of the method is based on reduction of pure iron oxide (Fe x O y ) compounds in a fludized bed system with hydrogen and/or CO-like reductant gas.
- the present invention provides a process for obtaining elemental iron from the acidic solution of a pickling process wherein an iron-containing material, particularly steel is surface treated.
- the process basically comprises the following steps:
- Said thermal decomposition can be carried out preferably in a fluidized bed and at a temperature between 500 °C and 1000 °C.
- H 2 or CO preferably H 2 or CO
- H 2 is used as a reductant.
- removal of the water occurring in this step is particularly preferred.
- Said reduction can be carried out at a temperature above 500 °C as mentioned above.
- the reduction can be carried out at temperatures of between 600-800 °C, more preferably about 650 °C.
- the reductant used herein may comprise H 2/ N 2 gas mixture having a volumetric ratio of higher than 1:1, more preferably 2:1 or more.
- Fe x O y particles by way of seeding during formation of Fe x O y compounds in thermal decomposition has certain advantages. Ultimately, due to this reason, elemental iron is obtained in a layered structure. Said Fe x O y particles treated with reduction have the preferred particle size of between 300 ⁇ m and 1000 ⁇ m, more preferably between 300 ⁇ m and 600 ⁇ m. Thus, the additional operations affecting quality of the material in the negative way such as grinding are eliminated.
- a process for the production of elemental iron powder from the waste acidic solutions formed at the end of the acidic (HCl) pickling treatment which is applied during surface treatments of iron-containing materials, particularly steel materials is disclosed.
- Said process optionally comprises the steps of regeneration and recovery of the spent acid used in the process.
- the oxides on the surface of steel or iron-containing material treated with a pickling procedure are eventually cleaned and the material is prepared for subsequent surface treatments.
- the process bath there exist usually the used HCl, iron ions, zinc ions and iron chloride compounds.
- metal chlorides coming from the steel structure which can be soluble in acid.
- HCl and iron chloride-containing dirty acid solution decomposes, and as a result, HCl is obtained along with Fe x O y compounds as the side product.
- the invention in another aspect, may comprise an additional process step besides obtaining of emental iron which allows the recovery of gaseous HCl occurring after thermal decomposion in order to use it again in the pickling bath.
- the regenerated gaseous acid can be removed from the medium, cooled and stored by way of conventional techniques, or it can be fed back to the pickling procedure. It has been observed that gaseous regenerated acid can be recovered more easily and efficiently if the thermal decomposition is carried out in a fluidized bed.
- the regenerated acid for instance, can be seperated from iron oxide particles by way of drawing it into a cyclone by means of a fan. Afterwards, acid vapor comes to a venturi and its temperature can be decreased till 100 °C.
- a ready-to-use acidic solution can be formed by spraying water onto the regenerated acid which can be taken into absorbers.
- the inventors have found that the abovementioned diffusion limitation can be eliminated by using fluidizied bed at the reduction step. Since the contact surface of iron oxide particles with the reductant gas has been increased, a considerable increase in the efficiency has been observed. However, even though it has positive effect, it has been observed that the desired ratio of metalization could not be achieved and sintering is still a problem. To overcome these problems, the inventors have carried out a seeding procedure in thermal decomposition step and obtained the layered iron oxide compounds as shown in Figure 1 . The seeding can be carried out by addition of iron oxide seeds to the decomposition reaction medium. It has been unexpectedly observed that this layered structure has eliminated particularly the diffusion barrier problem, enhanced the reduction kinetics of Fe x O y compounds and it plays a significant role in obtaining the metalization at a higher ratio (>%99 Fe).
- the iron oxide (Fe x O y ) compounds which are formed via seeding at the end of the decomposition, are being contacted with a reductant in a fluidized bed and elemental iron powder (Fe) is eventually obtained.
- Said reductant is preferably H 2 or CO, more preferably H 2 gas.
- reductant gases which are known in the prior art like CH 4 can also be used.
- H 2 usage as a reductant the reduction of Fe x O y compounds in the fluidized bed is basically carried out in three steps.
- reaction steps are as follows: 3Fe 2 O 3 + H 2 ⁇ 2Fe 3 O 4 + H 2 O 2Fe 3 O 4 + 2H 2 ⁇ 6FeO + 2H 2 O 6FeO + 6H 2 ⁇ 6Fe + 6H 2 O
- Figure 4a presents the SEM image of the resultant iron particles obtained through the reduction procedure which has been carried out for 60 minutes wherein the volumetric ratio of H 2/ N 2 was 2:1 at 500 °C. In this experiment, 46% metalization was achieved.
- Figure 4b presents the SEM image of the resultant iron particles obtained through the reduction procedure which has been carried out for 60 minutes wherein the volumetric ratio of H 2/ N 2 was 2:1 at 1000 °C. In this experiment, %99.98 metalization was achieved.
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- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Nanotechnology (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
- Chemically Coating (AREA)
Description
- The present invention relates to a method for producing elemental iron powder from acidic solutions formed as a result of acidic pickling which is performed during surface treatment of iron-containing materials. More particularly, the invention relates to a method for the recovery of iron compounds from acidic solutions formed after the pickling procedure, treatment of the same in a specific process, and obtaining of elemental iron with high metalization ratio.
- The flat steel products which are used in automotive, white goods, electricity pylons, barriers etc. are usually surface cleaned acidically prior to coating with different metals (zinc, nickel, chromium, etc.), so called galvanization, in order to provide a longer service life. Apart from that, coating of steel and iron based sheet metals, bolts, nuts and wires having different purposes is an application used prevalently.
- In the case of presence of grease, dirt or rust from previous processes on the steel materials to be coated, a successful coating can not be accomplished. Besides, pickling is applied prior to the galvanization in order to provide better adhesion of paint or coating on the steel material. Therefore, said steel materials are exposed to surface treatment prior to the galvanization just as all of the coating processes.
- "Pickling", which is also known as the acidic surface cleaning stage, is performed in order to provide a clean and standart surface to the steel by way of cleaning surface of the same by solubilizing the oxide layer on the surface in an acidic bath (HCl, H2SO4). In the past, sulfuric acid baths were used commonly for the purpose of pickling in iron & steel industry, but as from 1960s, hydrochloric acid (HCl)-containing baths have started to become widespread with the aim of obtaining the product with more quality and more homogenized surface. Hydrochloric acid (HCl) is a particularly preferred acid bath due to the fact that it provides obtaining of a faster result, consuming low amount of acid and its pyrometallurgical regeneration is easier and more economic. 0.30 kg HCl is being used for 1 ton of steel during pickling.
- The waste solution, which is also called spent acid, formed following the pickling applied for the surface cleaning of steel sheets is an iron rich solution. Beside this, said solution may contain hydrochloric acid, metal ions which are present in steel composition and soluble in HCl as well as certain amounts of zinc ions if an incorrect recovery is carried out.
- There are variety of reactions occuring depending on the acid bath used in pickling and the structure of oxide which is formed on the surface of the iron. The pickling solutions formed as a result of the reactions with hydrochloric acid vary in very wide ranges in composition, and establishing the method to be applied for recovering of these solutions is quite difficult. The methods of recovering the acidic cleaning solutions are gathered in two groups. The first one is the recovery of acid and the second one is the recovery of the metal formed in the acid. The methods that are used for the acid recovery or regeneration are electrodialysis, diffusion dialysis, membrane distillation, evaporation and spray drying. For the recovery of metal, methods such as extraction, retardation, ion exchange and crystallization are used.
- Recovery of acid and also iron compounds from acidic pickling solutions has been the focus of interest from the beginning of 1900s since it has an economical value. For instance, it is foreseen in
GB 190300423-A - An attempt regarding the recovery of iron compounds from a pickling solution containing FeSO4 has been disclosed in
GB 656,003 -
GB 1,219,674 - Furthermore
GB 1137525 A US 2005/191231 A1 discloses a synthesis of magnetite nanoparticles and the process of forming Fe-based nanaomaterials. - On the other hand, obtaining a high metallizing ratio in the reduction of iron oxide compunds with hydrogen is a significant problem. In order to have an economical value, elemental iron should have high purity (>%99). Since the kinetics of reduction reactions depend on the diffusion of the reductive substance, elemental iron is hard to obtain at high ratio, or long term treatment is essential, when the reaction occurs within the fixed bed reactors or other conventional equipments. In the present invention, a decomposition step is carried out at the first stage in a fluidized bed for the recovery of the acid in the spent acid composition while pure iron oxide (FexOy) is obtained from the iron-containing compounds (FeCl2 and low amount of FeCl3) formed in the spent acid, and HCl is obtained as the spent product. The second process step within the scope of the method is based on reduction of pure iron oxide (FexOy) compounds in a fludized bed system with hydrogen and/or CO-like reductant gas. Due to the fact that the final products of the reactions occured in this process are elemental iron (Fe) and water vapor, it is possible to produce elemental iron powder which has high metallizing ratios (>%99) without causing any environmental waste. While the particle size of pure iron oxide (FexOy) can be controlled by the parameters such as processing temperature, amount of the seed material and retardation time, it is possible to reduce the size of pure iron oxide particles by using the fact that iron oxide particles (FexOy) can be grinded easily. The aim of the invention is to obtain the acid and elemental iron from pickling solutions in a short time with the desired quality and low cost, thereby minimizing the problems and limitations of the foregoing prior art. These objectives are achieved through a method as disclosed in claim 1.
- The present invention provides a process for obtaining elemental iron from the acidic solution of a pickling process wherein an iron-containing material, particularly steel is surface treated. The process basically comprises the following steps:
- treating the iron-containing material with an acid comprising hydrochloric acid (for the purpose of removing the oxide layer present on the surface or preparing for another process or obtaining a proper solution just for this process),
- solubilizing with comprising hydrochloric acid (surface cleaning) followed by applying thermal decomposition to iron chloride compounds present in said solution,
- seeding by addition of iron oxide to the medium during thermal decomposition and obtaining layered FexOy compounds,
- obtaining iron oxide particles, contacting the obtained layered FexOy compounds with a reductant substance in a fluidized, fixed or rotating bed and reduction of the iron compounds, and
- cooling the elemental iron powder at the end of the reduction by preventing re-oxidization of the powder, and obtaining iron powder of commercial grade.
- Said thermal decomposition can be carried out preferably in a fluidized bed and at a temperature between 500 °C and 1000 °C.
- In the reduction step of the process which is for reducing FexOy compounds, preferably H2 or CO is used, more preferably H2 is used as a reductant. Besides, removal of the water occurring in this step is particularly preferred. Said reduction can be carried out at a temperature above 500 °C as mentioned above. However, in order to minimize the negative effects of sintering, it has been observed that the reduction can be carried out at temperatures of between 600-800 °C, more preferably about 650 °C. The reductant used herein may comprise H2/N2 gas mixture having a volumetric ratio of higher than 1:1, more preferably 2:1 or more.
- It has been found that obtaining FexOy particles by way of seeding during formation of FexOy compounds in thermal decomposition has certain advantages. Ultimately, due to this reason, elemental iron is obtained in a layered structure. Said FexOy particles treated with reduction have the preferred particle size of between 300 µm and 1000 µm, more preferably between 300 µm and 600 µm. Thus, the additional operations affecting quality of the material in the negative way such as grinding are eliminated.
-
-
Figure 1 is the SEM image of the FexOy particles which are obtained by seeding in the thermal decomposition step of the process according to the present invention. -
Figure 2 shows the phase stability diagram which is dependent on the partial pressure of hydrogen and the ambient temperature. -
Figure 3 is the diagram showing the temperature dependent H2/N2 ratio and % metalization. -
Figure 4a presents the SEM image of the resultant iron particles of the reduction procedure which was carried out for 60 minutes wherein the volumetric ratio of H2/N2 was 2:1 at 500 °C. -
Figure 4b presents the SEM image of the resultant iron particles of the reduction procedure which was carried out for 60 minutes wherein the volumetric ratio of H2/N2 was 2:1 at 1000 °C. - Within the scope of the present invention, a process for the production of elemental iron powder from the waste acidic solutions formed at the end of the acidic (HCl) pickling treatment which is applied during surface treatments of iron-containing materials, particularly steel materials is disclosed. Said process optionally comprises the steps of regeneration and recovery of the spent acid used in the process.
- Within the scope of said method, initially Thermal Decomposition is applied to the waste acidic solution formed as a result of the acidic cleaning which is applied to the metallic materials, and finally, iron oxide compounds (FexOy) are obtained. Then, elemental iron powder is obtained with high value by carrying out reduction of FexOy compounds via a reductant in the fluidized bed.
- Some of the reactions occured during pickling procedure applied to metallic materials which constitute first step of the process are as follows:
Fe2O3 + Fe + 6HCl → 3FeCl2 + 3H2O Fe3O4 + Fe + 8HCl → 4FeCl2 + 4H2O FeO + 2HCl → FeCl2 + H2O 2Fe3O4 + 18HCl + 1/2O2 → 6FeCl3 + 9H2O 6FeCl3 + 3Fe → 9FeCl2 - The oxides on the surface of steel or iron-containing material treated with a pickling procedure are eventually cleaned and the material is prepared for subsequent surface treatments. In the process bath, there exist usually the used HCl, iron ions, zinc ions and iron chloride compounds. There exist in the composition of the solution also metal chlorides coming from the steel structure, which can be soluble in acid.
- In the pickling process carried out within the scope of the present invention, preferably 60-200 g/l Fe2+ ions and 25-100 g/l HCl can be present. As a result of the pickling procedure, iron chloride compounds in general are obtained in FeCl2 (and partially FeCl3) form.
- It is aimed in the second step of the process according to the invention to obtain iron oxide compounds by way of applying a Thermal Decomposition procedure to the pickling solution containing iron chloride and HCl. Some of the reactions occured during this application are as follows:
4FeCl2 + 4H2O + O2 → 8HCI(gas) + 2Fe2O3 6FeCl3 + 9H2O → 18HCl(gas) + 2Fe3O4 + 1/2O2 2FeCl3 + FeCl2 + 3H2O → 8HCl(gas) + Fe3O4 - During thermal decomposition, HCl and iron chloride-containing dirty acid solution decomposes, and as a result, HCl is obtained along with FexOy compounds as the side product. In preferred embodiments of the invention, it is possible to accelerate the decomposition reactions and facilitating removal of HCl gas by way of carrying out this operation in a fluidized bed. It has been observed during the operation that the reactions can be carried out ideally when the temperature is preferably between 750 °C and 950 °C, and more preferably between 850 °C and 900 °C.
- The invention, in another aspect, may comprise an additional process step besides obtaining of emental iron which allows the recovery of gaseous HCl occurring after thermal decomposion in order to use it again in the pickling bath. Accordingly, the regenerated gaseous acid can be removed from the medium, cooled and stored by way of conventional techniques, or it can be fed back to the pickling procedure. It has been observed that gaseous regenerated acid can be recovered more easily and efficiently if the thermal decomposition is carried out in a fluidized bed. The regenerated acid, for instance, can be seperated from iron oxide particles by way of drawing it into a cyclone by means of a fan. Afterwards, acid vapor comes to a venturi and its temperature can be decreased till 100 °C. For instance, a ready-to-use acidic solution can be formed by spraying water onto the regenerated acid which can be taken into absorbers.
- At the third step of the process according to the present invention invention, reduction of FexOy compounds is carried out by using a reductant, and iron is obtained in elemental form. Since several problems has been encountered in carrying out this operation, there has been no improvement with the commercial processes (reduction in fixed bed systems) in prior art going beyond obtaining of the iron oxide compounds and commercialisation could not be achieved with an efficient process up to now. Within the scope of the present invention and in the studies for overcoming these problems, it is noted that the reactions of FexOy with a reductant are limited kinetically with a diffusion barrier. Besides, the reduction reactions are largely affected with the temperature and the ratio of reductant/carrier gas. It has been observed from the experiments that, even when the temperature was increased up to 1100 °C and the ratio of reductant (H2)/carrier (N2) was 1:1, the metalization ratio has stayed in the level of 21-22%. Moreover, sintering is a major problem and FeO film layer formed in the reduction step has significant role in sintering.
- The inventors have found that the abovementioned diffusion limitation can be eliminated by using fluidizied bed at the reduction step. Since the contact surface of iron oxide particles with the reductant gas has been increased, a considerable increase in the efficiency has been observed. However, even though it has positive effect, it has been observed that the desired ratio of metalization could not be achieved and sintering is still a problem. To overcome these problems, the inventors have carried out a seeding procedure in thermal decomposition step and obtained the layered iron oxide compounds as shown in
Figure 1 . The seeding can be carried out by addition of iron oxide seeds to the decomposition reaction medium. It has been unexpectedly observed that this layered structure has eliminated particularly the diffusion barrier problem, enhanced the reduction kinetics of FexOy compounds and it plays a significant role in obtaining the metalization at a higher ratio (>%99 Fe). - Accordingly, the iron oxide (FexOy) compounds which are formed via seeding at the end of the decomposition, are being contacted with a reductant in a fluidized bed and elemental iron powder (Fe) is eventually obtained. Said reductant is preferably H2 or CO, more preferably H2 gas. However, reductant gases which are known in the prior art like CH4 can also be used. In the case of H2 usage as a reductant, the reduction of FexOy compounds in the fluidized bed is basically carried out in three steps. Said reaction steps are as follows:
3Fe2O3 + H2 → 2Fe3O4 + H2O 2Fe3O4 + 2H2 → 6FeO + 2H2O 6FeO + 6H2 → 6Fe + 6H2O - Accordingly, the total reaction is as follows:
FexOy + yH2 → xFe + yH2O - In
Figure 2 , the phase stability diagram which is dependent to the partial pressure of hydrogen and the ambient temperature is shown. It is possible to remove the water vapor which is the product of the reaction from the medium so as to decrease the partial pressure of hydrogen and increase the reaction rate. The water formed in the reaction can be removed by dewatering. Process is accelerated due to the fact that the only gaseous product is water vapor in the reaction and it can be removed by condensation. Dewatered gas can be fed back to the system and continuation of the reactions can be ensured. A considerable increase in the % metalization ratio has been noted in the case of carrying out the abovementioned reduction process at a temperature of 600°C or more. Besides, an increase in the % metalization ratio has again been observed in the case that the volumetric ratio of H2/N2 is higher than 1:1, and more preferably higher than 2:1 when hydrogen/nitrogen mixture was fed to the reduction medium of a reduction gas system. These effects can clearly be seen from the experimental results given inFigure 3 . Therefore, it is preferred in the reaction conditions where best effects were observed that the temperature is between 650 °C and 1000°C in the reduction conditions and the volumetric ratio of H2/N2 is higher than 1:1 in the case of using H2/N2 reductive system. Besides, it has been noted that sintering is unexpectedly minimized when the size of FexOy particles treated with reduction is kept between 300 µm and 600 µm, and in this case reductive diffusion doesn't cause a limitation for reaction kinetics. -
Figure 4a presents the SEM image of the resultant iron particles obtained through the reduction procedure which has been carried out for 60 minutes wherein the volumetric ratio of H2/N2 was 2:1 at 500 °C. In this experiment, 46% metalization was achieved. -
Figure 4b presents the SEM image of the resultant iron particles obtained through the reduction procedure which has been carried out for 60 minutes wherein the volumetric ratio of H2/N2 was 2:1 at 1000 °C. In this experiment, %99.98 metalization was achieved. - Both of the experiments show that temperature has significant effect on the metalization ratio. Besides, considering
Figures 4a and 4b together, it has been clearly observed that the reduction proceeds from outside to inside topochemically. Due to the structure of FexOy in layered form on the seeding material in acid regeneration system (at thermal decomposition step), the same form was observed in the reduced structure as well. Due to the fact that this layered structure facilitates the gas transition during reduction and removal of water which is product of the reaction, formation of any diffusion barrier that blocks or obstruct reduction in the experimental studies has not been observed. It is possible to keep the reduction time shorter than 60 minutes with the effect of this structure. In the case of using pure hydrogen, it becomes possible to shorten the process time further.
Claims (14)
- A process for obtaining elemental iron from an acidic solution of a pickling process wherein an iron-containing material is surface treated, said process comprises the steps of:- solubilizing of the iron-containing material with an acidic solution comprising hydrochloric acid,- applying thermal decomposition to iron chloride compounds formed in said solution following the solubilizing,- seeding by adding iron oxide to the medium during thermal decomposition and obtaining FexOy compounds in layered form,- obtaining iron oxide particles, contacting the so formed layered FexOy compounds with a reductant material in a fluidized bed, and reduction of iron compounds, and- obtaining elemental iron powder as a result of the reduction.
- A process according to Claim 1, wherein the iron-containing material is flat steel.
- A process according to Claim 1, wherein the thermal decomposition is carried out in a fluidized bed or a rotating furnace.
- A process according to Claim 1, wherein the temperature in the thermal decomposition treatment is between 750 °C and 950 °C.
- A process according to Claim 3, wherein the process further comprises obtaining regenerated HCl solution by drawing of HCl gas from the fluidized bed and cooling it in the thermal decomposition step.
- A process according to Claim 1, wherein the reductant material is H2 or CO.
- A process according to Claim 6, wherein the reductant material is H2.
- A process according to Claim 1, wherein the process comprises the removal of water which is formed during reduction of the iron compounds.
- A process according to Claim 1, wherein the reduction is carried out at a temperature between 500 °C and 1000 °C.
- A process according to Claim 9, wherein the reduction is carried out at a temperature between 600 °C and 800 °C.
- A process according to Claim 1, wherein H2 is fed as reaductant along with N2 as a carrirer and wherein the volumetric ratio of H2/N2 is higher than 1:1.
- A process according to Claim 11, wherein the volumetric ratio of H2/N2 is higher than 2:1.
- Layered FexOy particles which are obtained in the thermal decomposition step according to the process of Claim 1.
- Layered Fe particles which are obtained in the reduction step according to the process of Claim 1.
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CA844536A (en) * | 1970-06-16 | Kudryk Val | Recovery of sulfur and iron oxide from pyritic materials | |
GB190300423A (en) | 1903-01-07 | 1903-12-10 | Henry William Hemingway | Improvements in the Treatment of Waste Pickle Liquor for the Removal or Utilisation of Free Acid Contained therein. |
GB662051A (en) * | 1948-01-06 | 1951-11-28 | Davide Primavesi | Improved chemical process for producing powdered iron |
GB656003A (en) | 1948-03-18 | 1951-08-08 | Erzhutte Ag | A process for the simultaneous recovery of base metals in powder form and of metallic salts |
SE306096B (en) * | 1965-06-23 | 1968-11-18 | Centro Speriment Metallurg | |
GB1219674A (en) | 1968-10-07 | 1971-01-20 | British Iron Steel Research | Process for the production of iron powder from aman oxide |
US4414021A (en) * | 1982-05-06 | 1983-11-08 | Welbon William W | Process for the synthesis of iron powder |
JPS59145707A (en) * | 1983-02-10 | 1984-08-21 | Furukawa Mining Co Ltd | Production of ferromagnetic metallic powder |
AT399516B (en) * | 1993-07-21 | 1995-05-26 | Andritz Patentverwaltung | METHOD FOR REGENERATING Hydrochloric Acid From Pickling Plants |
US6962685B2 (en) * | 2002-04-17 | 2005-11-08 | International Business Machines Corporation | Synthesis of magnetite nanoparticles and the process of forming Fe-based nanomaterials |
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