GB1595575A - Method and apparatus for producing metallic iron particles - Google Patents

Method and apparatus for producing metallic iron particles Download PDF

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Publication number
GB1595575A
GB1595575A GB44831/77A GB4483177A GB1595575A GB 1595575 A GB1595575 A GB 1595575A GB 44831/77 A GB44831/77 A GB 44831/77A GB 4483177 A GB4483177 A GB 4483177A GB 1595575 A GB1595575 A GB 1595575A
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United Kingdom
Prior art keywords
gas
cooling
inlet
furnace
reducing
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Expired
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GB44831/77A
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Midrex Corp
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Midrex Corp
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Filing date
Publication date
Priority claimed from US05/632,137 external-priority patent/US4046557A/en
Application filed by Midrex Corp filed Critical Midrex Corp
Publication of GB1595575A publication Critical patent/GB1595575A/en
Expired legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/0073—Selection or treatment of the reducing gases
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/02—Making spongy iron or liquid steel, by direct processes in shaft furnaces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/02—Making spongy iron or liquid steel, by direct processes in shaft furnaces
    • C21B13/029—Introducing coolant gas in the shaft furnaces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/20—Increasing the gas reduction potential of recycled exhaust gases
    • C21B2100/22—Increasing the gas reduction potential of recycled exhaust gases by reforming
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/20—Increasing the gas reduction potential of recycled exhaust gases
    • C21B2100/28—Increasing the gas reduction potential of recycled exhaust gases by separation
    • C21B2100/282—Increasing the gas reduction potential of recycled exhaust gases by separation of carbon dioxide
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/40—Gas purification of exhaust gases to be recirculated or used in other metallurgical processes
    • C21B2100/44—Removing particles, e.g. by scrubbing, dedusting
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/60—Process control or energy utilisation in the manufacture of iron or steel
    • C21B2100/64—Controlling the physical properties of the gas, e.g. pressure or temperature
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/60—Process control or energy utilisation in the manufacture of iron or steel
    • C21B2100/66—Heat exchange
    • 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
    • Y02P10/122—Reduction of greenhouse gas [GHG] emissions by capturing or storing CO2
    • 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
    • Y02P10/134—Reduction 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 Of Iron (AREA)

Description

(54) METHOD AND APPARATUS FOR PRODUCING METALLIC IRON PARTICLES (71) We, MIDREX CORPORATION, a corporation of Delaware, United States of America, of One NCNB Plaza, Charlotte, North Carolina 28280, United States of America, do hereby declare the invention, for which we play that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to a method and apparatus for reducing a metal oxide.
The recent high cost of scrap as a feed material for steelmaking funaces has caused steelmakers to turn elsewhere for their raw materials. One recently attractive raw material is reduced iron in the form of sponge iron, iron particles, pellets, briquets, and the like, which has been produced by the direct reduction of iron oxides or iron ores. Such materials will hereinafter be referred to collectively as metallized pellets. These metallized pellets are well suited as feed material, particularly to an electric arc steelmaking furnace. As a result, there have been a number of processes developed for their production. To be an attractive feed material, the pellets should be at least 85 per cent reduced, and preferably over 90 per cent reduced.
U.S. Patent 3,375,099 discloses a direct reduction process in which iron ores are reduced in a shaft furnace by contact with hot reducing gases generated by the incomplete combustion of a mobile fuel, such as natural gas, with oxygen. The spent reducing gases, which are also known as top gases or off gases, are withdrawn from the shaft furnace, cooled and reintroduced at the bottom of the furnaces as cooling gases to cool the product. The cooling gas is then allowed to flow upwardly through the shaft furnace, thus creating a closed circuit. It is also known that cooling of spent top gas enhances its reducing capacity. U.S.
Patent 3,748,120 teaches an improved method for reducing iron oxide to metallized iron, in which a reducing gas is catalytically reformed from a mixture of a gaseous hydrocarbon and spent reducing gas from the reduction process.
There is a continuing need in designing process plant for simplification in order to achieve a beneficial reduction in capital cost, and a decrease in maintenance costs.
According to the present invention, there is provided apparatus for reducing a metal oxide, comprising: (a) a generally vertical shaft furnace within which can be established a vertically descending bed of metal oxide, said furnace having a gas outlet above a reducing gas inlet, with at least a portion of said bed being positioned intermediate said inlet and said outlet and forming a reduction zone therebetween; (b) a single gas cooler-scrubber for gas removed from said furnace, said cooler scrubber being connected to said gas outlet; (c) an inlet for introducing a cooling gas to said furnace below said reduction zone; (d) a conduit connecting the cooler scrubber and the cooling gas inlet;; (e) a cooling gas outlet for removing spent cooling gas from said furnace above said cooling gas inlet, the portion of said furnace between said cooling gas inlet and said cooling gas outlet forming a cooling zone; (f) a second conduit connecting said cooling gas outlet with an inlet to the cooling means; and (g) a pump connected in both a first circuit which includes the cooling gas outlet, the cooler-scrubber and the cooling gas inlet, and in a second circuit which includes the top gas outlet, the cooler-scrubber, a re former, and the reducing gas inlet.
Also according to the invention, there is provided a method of reducing a metal oxide which comprises: (a) establishing a gravitational flow of particulate metal oxide material by char ging the particulate metal oxide material to the upper portion of a generally vertical furnace having an upper reducing zone and a lower cooling zone, and removing the metallized product from the bottom of the furnace; (b) introducing a reducing gas to the gravitational flow of material at a tempera ture sufficient to promote a reducing re action between said reducing gas and said material at a first inlet intermediate the ends of the furnace; (c) causing said reducing gas to move countercurrent through the gravitational flow of material, react with and reduce a sub stantial portion of the metal oxide and form a top gas;; (d) removing said top gas from the upper portion of the furnace; (e) cooling said top gas in a cooler scrubber; (f) introducing a cooling gas into a second inlet near the lower end of said furnace; (g) removing a portion of said cooling gas from said furnace at a location intermediate said first and second inlets; (h) cooling the removed portion by feed ing it through said cooler-scrubber; (i) introducing part of the cooled removed portion to said second inlet to form a re circulating circuit which includes the cooling zone; and (j) adding top gas to the recirculating circuit so that said top gas passes through the cooler-scrubber and is thereby cooled prior to entering the cooling zone.
The invention will be better understood from the following non-limiting description of an example thereof given with reference to the accompanying drawing which is a schematic drawing of an apparatus for reducing a metal oxide.
A direct reduction process has been developed for producing high quality metallized pellets with an extremely high degree of thermal efficiency.
The process employs a vertical shaft type furnace having a reducing zone in the upper region of the furnace and a cooling zone in the lower region of the furnace. Hot reducing gas from any external source is introduced to the reducing zone. For the purpose of overall process description, the reducing gas utilized herein consists principally of CO and H, produced by the continuous catalytic reforming of a hydrocarbon such as natural gas, petroleum distillates, methane, ethane, propane, butane, or other readily vaporizable hydrocarbon. The continuous catalytic reforming is accomplished in a reforming furnace which employs an indirectly-heated catalyst bed. The metallized pellets are cooled by recirculating a cooling gas through a cooling gas circuit in the cooling zone of the reduction furnace. Top gas from the reduction furnace is admitted to this circuit.
The process is extremely well suited for the production of iron-and-steel-making grade metallized pellets. It will therefore be so described.
The metallized product, which is at least 85 per cent reduced and preferably at least 90 per cent reduced is produced in a generally vertical shaft furnace having an upper reducing zone and a lower cooling zone. A gravitational flow of metal oxide material or burden is established by charging particulate metal oxide material to the upper portion of the furnace and removing the metallized product from the bottom of the furnace. A hot reducing gas having CO and H2 as reductant components is introduced to the flow of material through a bustle pipe and tuyere inlet system intermediate the ends of the furnace, flows countercurrent through the material, reducing a substantial portion of the metal oxide, and forms a top gas. The top gas is removed from the upper portion of the furnace, cooled, and divided into two portions.The first portion is introduced to a cooling gas circuit which introduces cooling gas to the cooling zone through an inlet near the lower end of the furnace. The cooling gas flows upwardly and a portion of it is removed at the top of the cooling zone, scrubbed and cooled, and recirculated in a closed loop. Cooled top gas (make-up gas) may be added to the removed cooling gas and the mixture may be directed to the furnace through the cooling gas inlet.
The cooling gas loop recirculating circuit is integrated with the spent top gas cleaning and recycling circuit to drastically reduce the amount of piping and number of pumps required in the system as well as to eliminate the separate cooling zone scrubber-cooler and compressor which are present in the systems disclosed in Figures 1 and 2 of our Patent Aplication No. 20315/76 (Serial No.
1,595,574). Spent top gas exits furnace 10 through gas take-off pipe 130, flows to scrubber-cooler 132 wherein the gas is cooled and dust particles are removed. A first portion of the gas exiting scrubber-cooler 132 is directed to blower 134 through pipe 136. This portion of the spent top gas is further divided, a portion which acts as cooling gas passing through pipe 138 and a second portion sometimes known as process gas, recycle gas or reforming oxidant passing through pipe 140 to reformer 54.
Cooling gas outlet pipe 145 connects cooling gas outlet 42 to scrubber-cooler 132. This may be done by connection with spent top gas take-off pipe 130.
The second portion of gas exiting scrubbercooler 132 passes through pipe 147 to burner 56 of reformer furnace 54 where it is burned as fuel to heat the reformer. Natural gas from source 152 can be added to the cooling gas in pipe 138 through pipe 154 which has flow control valve 156 therein.
The direct reduction process with upflow reforming as claimed in Patent Application No. 20315/76 (Serial No. 1,595,574) may be employed in conjunction with the present invention.
The improved process for the direct reduction of metal oxides to metallized particles disclosed herein can be operated with a greater thermal efficiency than heretofore possible.
In the particular embodiment disclosed here in, the effective final cooling of the burdens accomplished independently of the amount of upflow gas by means of the cooling loop re circulating circuit as described above. The flow rate of cooled, hydrocarbon enriched, top gas admitted to the cooling circuit may be con trolled, relative to the burden flow rate, to ensure the upflow gas being fully preheated and reformed to upgrade its reducing potential.
The introduction of cooled gas into the cooling loop recirculating circuit can be at any point in the loop as an alternative to the arrangement illustrated.
The removed and cooled top gas exiting from cooler-scrubber 132 is, in the illustrated embodiment, divided into a first and a second portion, and the second portion is mixed with a gaseous hydrocarbon to form the fuel mixture to heat the catalyst.
The rate of flow of the cooking gas intro duced to the second inlet via line 138 may be controlled to maintain the temperature of the portion of the cooling gas being removed from the furnace at between 800 and 1100 F, and preferably at about 1000 F.
Carbon dioxide may be removed from at least a portion of the cooled top gas prior to introducing said gas to the recirculating circuit 145, 132, 136, 134, 138, thereby upgrading the reducing potential of said top gas.
WHAT WE CLAIM IS: - 1. Apparatus for reducing a metal oxide, comprising: (a) a generally vertical shaft furnace with in which can be established a vertically descending bed of metal oxide, said furnace having a gas outlet above a reducing gas inlet, with at least a portion of said bed being positioned intermediate said inlet and said outlet and forming a reduction zone therebetween; (b) a single gas cooler-scrubber for gas removed from said furnace, said cooler scrubber being connected to said gas outlet; (c) an inlet for introducing a cooling gas to said furnace below said reduction zone; (d) a conduit connecting the cooler scrubber and the cooling gas inlet;; (e) a cooling gas outlet for removing spent cooling gas from said furnace above said cooling gas inlet, the portion of said furnace between said cooling gas inlet and said cool ing gas outlet forming a cooling zone; (f) a second conduit connecting said cool ing gas outlet with an inlet to the cooling means; and (g) a pump connected in both a first circuit which includes the cooling gas outlet, the cooler-scrubber and the cooling gas inlet, and in a second circuit which includes the top gas outlet, the cooler-scrubber, a re former, and the reducing gas inlet.
2. Apparatus according to claim 1 further comprising means beneath said shaft furnace for removing metallized material.
3. Apparatus according to claim 1 or 2 in which the reformer is a furnace containing an indirectly-heated catalyst bed.
4. Apparatus according to claim 1, 2 or 3 further comprising a third conduit between said first conduit and the fuel inlet of a burner of said reformer for delivering inter alia spent top gas to said burner as fuel to heat the reformer.
5. Apparatus according to any preceding claim further comprising a source of gaseous hydrocarbon communicating with a conduit extending between the outlet of the coolerscrubber and an inlet of the reformer.
6. Apparatus according to any preceding claim in which a further conduit provides communication between said thirst conduit and said reducing gas inlet whereby spent top gas can be introduced to said furnace through the reducing gas inlet as a portion of the reducing gas mixture.
7. A method of reducing a metal oxide which comprises: (a) establishing a gravitational flow of particulate metal oxide material by charging the particulate metal oxide material to the upper portion of a generally vertical furnace having an upper reducing zone and a lower cooling zone, and removing the metallized product from the bottom of the furnace; (b) introducing a reducing gas to the gravitational flow of material at a tempera ture sufficient to promote a reducing re action between said reducing gas and said material at a first inlet intermediate the ends of the furnace; (c) causing said reducing gas to move countercurrent through the gravitational flow of material, react with and reduce a substantial portion of the metal oxide and form a top gas; (d) removing said top gas from the upper portion of the furnace; (e) cooling said top gas in a cooler scrubber; ; (f) introducing a cooling gas into a second inlet near the lower end of said furnace; (g) removing a portion of said cooling gas from said furnace at a location intermediate said first and second inlets; (h) cooling the removed portion by feed ing it through said cooler-scrubber; (i) introducing part of the cooled removed
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (19)

**WARNING** start of CLMS field may overlap end of DESC **. No. 20315/76 (Serial No. 1,595,574) may be employed in conjunction with the present invention. The improved process for the direct reduction of metal oxides to metallized particles disclosed herein can be operated with a greater thermal efficiency than heretofore possible. In the particular embodiment disclosed here in, the effective final cooling of the burdens accomplished independently of the amount of upflow gas by means of the cooling loop re circulating circuit as described above. The flow rate of cooled, hydrocarbon enriched, top gas admitted to the cooling circuit may be con trolled, relative to the burden flow rate, to ensure the upflow gas being fully preheated and reformed to upgrade its reducing potential. The introduction of cooled gas into the cooling loop recirculating circuit can be at any point in the loop as an alternative to the arrangement illustrated. The removed and cooled top gas exiting from cooler-scrubber 132 is, in the illustrated embodiment, divided into a first and a second portion, and the second portion is mixed with a gaseous hydrocarbon to form the fuel mixture to heat the catalyst. The rate of flow of the cooking gas intro duced to the second inlet via line 138 may be controlled to maintain the temperature of the portion of the cooling gas being removed from the furnace at between 800 and 1100 F, and preferably at about 1000 F. Carbon dioxide may be removed from at least a portion of the cooled top gas prior to introducing said gas to the recirculating circuit 145, 132, 136, 134, 138, thereby upgrading the reducing potential of said top gas. WHAT WE CLAIM IS: -
1. Apparatus for reducing a metal oxide, comprising: (a) a generally vertical shaft furnace with in which can be established a vertically descending bed of metal oxide, said furnace having a gas outlet above a reducing gas inlet, with at least a portion of said bed being positioned intermediate said inlet and said outlet and forming a reduction zone therebetween; (b) a single gas cooler-scrubber for gas removed from said furnace, said cooler scrubber being connected to said gas outlet; (c) an inlet for introducing a cooling gas to said furnace below said reduction zone; (d) a conduit connecting the cooler scrubber and the cooling gas inlet;; (e) a cooling gas outlet for removing spent cooling gas from said furnace above said cooling gas inlet, the portion of said furnace between said cooling gas inlet and said cool ing gas outlet forming a cooling zone; (f) a second conduit connecting said cool ing gas outlet with an inlet to the cooling means; and (g) a pump connected in both a first circuit which includes the cooling gas outlet, the cooler-scrubber and the cooling gas inlet, and in a second circuit which includes the top gas outlet, the cooler-scrubber, a re former, and the reducing gas inlet.
2. Apparatus according to claim 1 further comprising means beneath said shaft furnace for removing metallized material.
3. Apparatus according to claim 1 or 2 in which the reformer is a furnace containing an indirectly-heated catalyst bed.
4. Apparatus according to claim 1, 2 or 3 further comprising a third conduit between said first conduit and the fuel inlet of a burner of said reformer for delivering inter alia spent top gas to said burner as fuel to heat the reformer.
5. Apparatus according to any preceding claim further comprising a source of gaseous hydrocarbon communicating with a conduit extending between the outlet of the coolerscrubber and an inlet of the reformer.
6. Apparatus according to any preceding claim in which a further conduit provides communication between said thirst conduit and said reducing gas inlet whereby spent top gas can be introduced to said furnace through the reducing gas inlet as a portion of the reducing gas mixture.
7. A method of reducing a metal oxide which comprises: (a) establishing a gravitational flow of particulate metal oxide material by charging the particulate metal oxide material to the upper portion of a generally vertical furnace having an upper reducing zone and a lower cooling zone, and removing the metallized product from the bottom of the furnace; (b) introducing a reducing gas to the gravitational flow of material at a tempera ture sufficient to promote a reducing re action between said reducing gas and said material at a first inlet intermediate the ends of the furnace; (c) causing said reducing gas to move countercurrent through the gravitational flow of material, react with and reduce a substantial portion of the metal oxide and form a top gas; (d) removing said top gas from the upper portion of the furnace; (e) cooling said top gas in a cooler scrubber;; (f) introducing a cooling gas into a second inlet near the lower end of said furnace; (g) removing a portion of said cooling gas from said furnace at a location intermediate said first and second inlets; (h) cooling the removed portion by feed ing it through said cooler-scrubber; (i) introducing part of the cooled removed
portion to said second inlet to form a re circulating circuit which includes the cool ing zone; and (j) adding top gas to the recirculating circuit so that said top gas passes through the cooler-scrubber and is thereby cooled prior to entering the cooling zone.
8. A method acording to claim 7 wherein said reducing gas is a reformed hydrocarbon in vapour form.
9. A method according to claim 7 or 8 wherein said hydrocarbon is selected from the group comprising natural gas, petroleum distillates, methane, ethane, propane, butane.
10. A method according to claim 8 wherein said hydrocarbon is natural gas.
11. A method according to any of claims 7-10 wherein said removed and cooled top gas is separated into a first portion and a second portion, and said second portion is introduced as a fuel into a furnace containing a tube having catalyst therein.
12. A method according to claim 7 wherein a gaseous hydrocarbon and steam are passed through a heated catalyst to form said reducing gas for introduction into said first inlet.
13. A method according to claim 11 wherein said second portion of said cooled top gas is mixed with a gaseous hydrocarbon to form the fuel mixture to heat said catalyst.
14. A method according to any of claims 7-13 further comprising mixing a second portion of said cooled top gas with said reducing gas and introducing the mixture to said first inlet whereby the resulting mixture will have the proper proportion of hot reducing gas and cooled top gas to bring the temperature of the mixture to the desired inlet temperature.
15. A method according to any of claims 7-14 wherein said particulate metal oxide material is iron oxide.
16. A method according to any of claims 7--15 further comprising controlling the rate of flow of cooling gas introduced to said second inlet to maintain the temperature of the portion of said cooling gas being removed from said furnace at between 800 and 1100 F.
17. A method according to claim 16 wherein the removed cooling gas temperature is maintained at about 1000 F.
18. A method according to claim 7 wherein said top gas contains carbon dioxide, said method further comprising after step (e) removing carbon dioxide from at least a portion of said cooled top gas prior to introducing cooled top gas to the recirculating circuit, thereby upgrading the reducing potential of said cooled top gas.
19. A method according to claim 7 further comprising adding a gaseous hydrocarbon to said cooling gas prior to introducing said cooling gas into said second inlet.
GB44831/77A 1975-11-14 1976-05-17 Method and apparatus for producing metallic iron particles Expired GB1595575A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US05/632,137 US4046557A (en) 1975-09-08 1975-11-14 Method for producing metallic iron particles

Publications (1)

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GB1595575A true GB1595575A (en) 1981-08-12

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Family Applications (1)

Application Number Title Priority Date Filing Date
GB44831/77A Expired GB1595575A (en) 1975-11-14 1976-05-17 Method and apparatus for producing metallic iron particles

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PS Patent sealed
732 Registration of transactions, instruments or events in the register (sect. 32/1977)
PE20 Patent expired after termination of 20 years

Effective date: 19960516