GB2086431A - Continuous reduction of fine iron-containing material by coal - Google Patents

Continuous reduction of fine iron-containing material by coal Download PDF

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Publication number
GB2086431A
GB2086431A GB8127681A GB8127681A GB2086431A GB 2086431 A GB2086431 A GB 2086431A GB 8127681 A GB8127681 A GB 8127681A GB 8127681 A GB8127681 A GB 8127681A GB 2086431 A GB2086431 A GB 2086431A
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United Kingdom
Prior art keywords
coal
hot
bath
temperature
mixing
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Granted
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GB8127681A
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GB2086431B (en
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Arcelor Luxembourg SA
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Arbed SA
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Publication date
Priority claimed from LU82766A external-priority patent/LU82766A1/en
Priority claimed from LU82826A external-priority patent/LU82826A1/en
Application filed by Arbed SA filed Critical Arbed SA
Publication of GB2086431A publication Critical patent/GB2086431A/en
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Publication of GB2086431B publication Critical patent/GB2086431B/en
Expired legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/0046Making spongy iron or liquid steel, by direct processes making metallised agglomerates or iron oxide
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/0006Making spongy iron or liquid steel, by direct processes obtaining iron or steel in a molten state

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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)
  • Carbon Steel Or Casting Steel Manufacturing (AREA)

Abstract

Fine-particled iron-containing material (e.g. iron ore) and ground hard coal, in a ratio of 2:1 to 5:1, are heated in separate flow reactors with the aid of hot gas. The hot material and hot coal are mixed, the resulting mixture having a temperature between 470 and 530 DEG C. The mixture is hot briquetted and the hot briquettes are introduced into a medium, e.g. in a converter or a rotary kiln, in which they are exposed to sufficiently high temperature to cause iron oxide to be reduced and carbon monoxide to be formed, and burning the carbon monoxide by supplying oxygen.

Description

SPECIFICATION Continuous reduction of iron-containing material The present invention relates to a process for the continuous reduction of iron-containing material, in particular of fine-particled iron ore.
Fine-particled iron ore is available in large quantities and at relatively low prices. This is because the cheap transportation of ores through pipelines requires thattheorns exist in a finely ground state with an average particle size of about 50 microns.
This, in turn, means that the ores transported inexpensively have to be reconverted into a shape per mitting further metallurgical processing, which means that the ores must be pelletized prior to the further processing. Pelletization is a relatively expensive matter, as the pellets have to be fired, so the benefits obtained by cheap transportation are lost again owing to the inevitably necessary conversion of the ores into pellets.
There has been no lack of attempts to reduce ores continuously, attention being paid mainly to coarse-particled to lumpy ores, as the continuous reduction of very fine-particled iron ores is problematic, regardless of whether the reduction is to be carried out in the solid phase or into the liquid phase.
Direct reduction processes which are carried out in the solid phase and, for example, in rotary kilns have been known for a long time. Thus, British Patent No.
1,358,780 describes a process in which iron ore is reduced by blowing in natural gas beneath the ore charge. The exhaust gases formed in the process are mixed with air and burned over the ore bed. The iron carriers are lump ore, ore pellets, and optionally also sintered pellets. The nature of the direct reduction processes carried out in rotary kilns requires that both the iron carriers and the reducing agents, if not reducing gases, be present in lumped form.
In fact, it is worth preventing the materials used (or materials which have already been reduced or prereduced) from being blown out of the rotary tube by the blasting action of flames and settling on the filters. Forthis reason, attention should be paid to the properties of stability at high temperatures, when selecting lumped ore for the charge.
Now lumped ore and coal having the necessary stability to high temperatures are rare and are consequently correspondingly expensive The conversion of fine-particled ores into ore pellets is also an expensive procedure, as pelletizing apparatuses can be operated only at considerable expense.
With regard to reduction into the liquid phase, we have described in our Luxembourg Patent No. 71 435 a process for the production of liquid pig iron permitting simultaneous recovery of a gaseous mixture which is used for the pre-reduction of the ore charge.
A carbon carrier is introduced by means of a carrier gas into a first zone of an iron bath, deep in it, carbon being bonded to the iron and the bath being intentionally carburized. In an adjacent zone of the bath, subjected to continuous thorough mixing, the excess carbon is oxidised off by means of an incoming oxygen blast and is converted into carbon monoxide, while the ores at least partially prereduced by the resultant reducing gases in an adjacent reaction chamber are changed into the immediate vicinity of the exothermic reaction zone and are caused to melt.
When carrying out this process, a carbon injection lance is obviously needed, entailing high expenditure. Moreover, it should be noted that in the course of the process very hot exhaust gases are formed, whose temperature is about 1450"C. If these exhaust gases are to be utilised for the pre-reduction of ore, a cooling stage must be provided. It is also advisable to remove the dust from the exhaust gases.
What is desired, therefore, is a process which permits inexpensive fine-particled iron carriers to be reduced with the aid of inexpensive solid reducing agents and which allows work to be carried out both within the scope of reduction in the solid phase and into the liquid phase and, particularly in the latter case, allows the problems arising from the high temperature of the exhaust gases to be transformed into an advantage.
The present invention provides a process in which fine-particled ores as well as ground hard (mineral) coal in a ratio of 2:1 to 5:1 are heated separately in a flow reactor with the aid of hot gas, the hot components are mixed, the temperature of the mixture lying between 470 and 530"C, and the components are then briquetted while hot, and the hot briquettes are exposed to sufficiently high temperatures, on the one hand, to cause the iron oxide to be reduced and, on the other hand, to cause CO gas to be formed, which is burnt by a deliberate supply of oxygen.
Fine ores can be mixed with softening, caking, hard coals acting as a binder and also with nonsoftening, carbon-containing substances such as low-volatile hard coals, coke breeze, fine-particled low-temperature coke, and/or petroleum coke. However, it is possible to use non-caking hard coal and to provide an addition of pitch as a binder.
In a preferred process, fine ores (as well as optionally non-softening carbon-containing substances), prior to mixing with softening caking hard coal and prior to briquetting, are brought to a temperature above the briquetting temperature, while the softening caking hard coal is broughtto a temperature below its softening point. The temperatures of the components are adjusted prior to mixing in such a way that the desired briquetting temperature turns out to be the temperature of the mixture.
Briquetting preferably takes place on a roller press operating at pressures of between 1 and 5 Kg/cm roller width.
After leaving the roller press, the ready briquettes can be kept for a prolonged period, at least 30 minutes, in the region of the press temperature and thus additionally strengthened.
In another embodiment of the process according to the invention, the pressed bodies are charged hot.
This saves the otherwise necessary cooling process, and the sensible heat of the pressed bodies is not wasted.
According to a first embodiment of the process according to the invention, the hot briquettes are charged into a conventional rotary kiln at the delivery end of which there is located at least one burner which ensures the necssary starting temperature at the beginning of the process and compensates for any temperature variations in the course of the pro cess.
Since carbon monoxide which is to be used to heat the furnace is formed during the reduction process, the rotary kiln is provided with tuyeres which permit the aimed supply of fresh air. The reduction process itself is caused predominantly by the reaction with the solid carbon. The products formed when carry ing outthe process are pure scrap metal and coke breeze. The pure scrap metal obtained can be processed metallurgically without a need for expensive sampling, analysis, and grading, as is the case when using conventional pure scrap metal.
Although the temperatures prevailing in the rotary kiln during the metallurgical processing of the briquettes lead to a certain loss of strength, the binder coal is simultaneously transformed into a stable coke framework which counteracts this loss of strength.
In the rotary kiln direct reduction process carried out here, the carbon originating from the binder is additionally used as a heat carrier and reducing agent Another embodiment of the process according to the invention involves charging the hot briquettes into a converter containing an iron bath whose carbon content is as high as possible and which is decarburised continuously by a blast of oxygen, the bath simultaneously being flushed by blowing in inert gas through the converter bottom. Owing to the high carbon content of the iron bath, the briquettes immediately enter a strongly reducing medium as they impinge upon the bath surface in general, regardless of whether and how much slag is located above the bath.In fact, it can be assumed that a proportion, if not the majority, of the metallurgical reactions take place inside the slag during the refining operation, as is revealed by the fact that metallic iron granules are invariably found in converter slags.
This explains why the oxygen jet with which the bath is supplied does not cause a disturbance in the present instances, asthe briquette carbon would be oxidised before the briquette entered the bath, but the bath is caused to bubble so intensively by the oxygen jet that the briquettes enter the turbulent layer consisting of slags and of iron, where reduction also takes place.
It can be assumed that Fe2O3 contained in the briquettes is pre-reduced with the briquette carbon according to Fe2O3 + C < FeO + CO, while the FeO in the bath passes into the metallic phase underthe effect of the bath carbon according to FeO + C < Fe +CO.
It is immaterial whether this actually applies or not, providing that sufficient carbon always enters the bath through the addition of briquettes to guarantee that the bath remains as saturated as possible with carbon, since, in the final analysis, the energy is supplied by the combustion of carbon.
The process according to the invention is suitable for the continuous production of liquid iron as, owing to the continuous charging of briquettes, carbon is continuously introduced into the bath and therefore saturates it. Fine ore is simultaneously reduced continuously into iron and supplies energy to the bath, since carbon is burnt by the blowing of oxygen.
Blowing can obviously take place intermittently, in which case the intensity and duration of the addition of oxygen depend on the temperature prevailing in the bath and on the carbon content of the bath.
These can be estimated by analysis of the exhaust gases or can be determined by taking samples.
With regard to the flushing of the bath with inert gas through the converter bottom, this measure is an important aid, as the thickness and the consis tencyofthe slag layer can be influenced by varying the intensity of lushing, as described in our Luxembourg Patent No. 81 207. In fact, intensive flushing with inert gas causes the slag foam to collapse, whereas a thick, foamy slag layer can be formed by curbing the intensity of flushing. Thin-layered, non- .
foaming slag is formed during the flushing operation; decarburisation, as well as after-combustion of the CO over the surface of the bath, is promoted.
This is of particular importance in the process according to the invention, as the zone located above the bath should not consist predominantly of oxygen, on the one hand, and high temperatures should prevail in that very place, on the other hand.
Owing to the flushing with inert gas, the conditions favourable for the addition of briquettes can consequently be created according to the invention by heating the briquettes sufficiently above the bath and not subjecting them, either above the bath or inside the slag layer, to excessive contact with oxygen, so that reduction can take place without a significant interruption.
A possible embodiment of the process according to the invention involves introducing into apparatus, in which the heating of the ore end of the coal as well as briquetting take place, the hot exhaust gases formed during decarburisation of the bath in order to utilise their sensible heat as well as their energy of combustion.
Another possible embodiment involves using the exhaust gases as heating or as reducing gases. In fact, about 75% of the exhaust gases consist of CO, the remainder being CO2 and N2.
It is important during the decarburisation process to take into consideration the fact that more or less significant quantities of sulphur can be present in the carbon-containing substances used. For this reason, slag forming agents are added, as known, in order to obtain a basic, free-flowing slag having a predominant desulphurisation effect. The slag forming agents can be introduced into the bath either individually or as constituents of the briquette.
It should also be emphasised that the process according to the invention is not only suitable for the reduction of oxidic iron carriers but that it is quite possible to use iron-containing dust or roller sinter instead of fine ore, in the interests of recycling and of environmental protection.

Claims (16)

1. A process for the continuous reduction of ironcontaining material, comprising the steps of heating fine-particled iron-containing material and ground hard coal, which are in a ratio of 2:1 to 5:1, seperately in respective flow reactors with the aid of hot gas, mixing the resulting hot material and hot coal, the temperature of the resulting mixture lying between 470 and 530"C, hot briquetting the mixture at a given briquetting temperature, introducing the resulting hot briquettes into a medium in which they are exposed to sufficently high temperatures to cause iron oxide to be reduced and carbon monoxidle to be formed, and burning the carbon monoxide by supplying oxygen.
2. A process as claimed in claim 1, in which the said material comprises fine-particled iron ore.
3. A process as claimed in claim 1 or 2, in which the said coal is caking coal.
4. A process as claimed in claim 3, in which the said coal is at a temperature below its softening point, prior to mixing with the said material.
5. A process as claimed in claim 3 or4, in which the said material is at a temperature above the briquetting temperature, prior to mixing with the said coal.
6. A process as claimed in any of claims 3 to 5, further comprising, before the said material and the said coal are mixed, mixing the said material with at least one non-softening carbon-containing substance.
7. A process as claimed in claim 6, in which the said material and the said at least one substance are at a temperature above the briquetting temperature, prior to mixing with the said coal.
8. A process as claimed in claim 1 or2, in which the said coal is non-caking hard coal, the process further comprising mixing the said material with pitch as a binder, prior to mixing with said coal.
9. A process as claimed in any of claims 1 to 8, in which, prior to the formation of the said mixture, individual components of the said mixture are at respective temperatures such that, after the formation of the said mixture, the temperature of the mixture is equal to the briquetting temperature.
10. A process as claimed in any of claims 1 to 9, including charging the hot briquettes into a converter containing a bath of molten iron, decarburising the bath by an oxygen blast, optionally flushing the bath by blowing inert gas through the bottom of the converter, and collecting hot exhaust gases formed during the decarburisation of the bath.
11. A process as claimed in claim 10, further comprising controlling the intensity of the inert gas flushing during decarburisation in such a manner that the decarburisation of the bath and the burning of carbon monoxide above the bath are promoted and a thin layer of non-foaming slag is obtained on the bath.
12. A process as claimed in claim 10 or 11, further comprising utilising the hot exhaust gases in the flow reactors for heating the said material and the said coal.
13. A process as claimed in any of claims 10 to i 2, further comprising utilising the hot exhaust gases as combustion gases.
14. A process as claimed in any of claims 10 to 13, further comprising utilising the hot exhaust gases as reducing gases.
15. A process as claimed in any of claims 1 to 9, including charging the hot briquettes into a rotary kiln, the burning of the carbon monoxide serving to maintain the kiln at a high temperature.
16. A process as claimed in claim 15, in which the carbon monoxide is burnt with atmospheric oxygen.
GB8127681A 1980-09-12 1981-09-14 Continuous reduction of iron-containing material Expired GB2086431B (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
LU82766A LU82766A1 (en) 1980-09-12 1980-09-12 METHOD FOR DIRECTLY REDUCING IRONIC SUBSTANCES
LU82826A LU82826A1 (en) 1980-10-06 1980-10-06 METHOD FOR CONTINUOUSLY REDUCING IRON ORE

Publications (2)

Publication Number Publication Date
GB2086431A true GB2086431A (en) 1982-05-12
GB2086431B GB2086431B (en) 1984-08-08

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GB8127681A Expired GB2086431B (en) 1980-09-12 1981-09-14 Continuous reduction of iron-containing material

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AU (1) AU542443B2 (en)
BE (1) BE890175A (en)
BR (1) BR8105810A (en)
CA (1) CA1180189A (en)
DE (1) DE3132766A1 (en)
FR (1) FR2490242A1 (en)
GB (1) GB2086431B (en)
IT (1) IT1189047B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5891214A (en) * 1995-05-18 1999-04-06 Technological Resources Pty. Ltd. Smelting reduction method with increased effectiveness

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3304504A1 (en) * 1983-02-10 1984-08-16 Metallgesellschaft Ag, 6000 Frankfurt METHOD FOR CONTINUOUSLY MELTING IRON SPONGE
LU86070A1 (en) * 1985-09-09 1987-04-02 Laborlux Sa METHOD FOR PROCESSING ZINC AND LEAD-CONTAINING RESIDUES FROM THE STEEL INDUSTRY WITH REGARD TO METALLURGICAL PROCESSING
DE3809616C1 (en) * 1988-03-22 1989-05-24 Laborlux S.A., Esch-Sur-Alzette, Lu
US4888376A (en) * 1988-09-26 1989-12-19 Dow Corning Corporation Curable organopolysiloxanes filled with silicon carbide powders and highly densified sintered bodies therefrom
US4962069A (en) * 1988-11-07 1990-10-09 Dow Corning Corporation Highly densified bodies from preceramic polysilazanes filled with silicon carbide powders

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE931596C (en) * 1952-01-12 1955-08-11 Ludwig Dipl-Kfm Weber Process for steel production in the converter
NL107852C (en) * 1961-12-05 1964-03-16
GB1301235A (en) * 1970-07-22 1972-12-29
US3753682A (en) * 1970-09-18 1973-08-21 Allis Chalmers Mfg Co Ported rotary kiln process for direct reduction of oxides of metallic minerals
DE2335669A1 (en) * 1973-07-13 1975-02-06 Metallgesellschaft Ag PROCESS FOR THE MANUFACTURING OF ORECAKE HOT BRIQUETTES FOR SELF-DIVIDING
LU71435A1 (en) * 1974-12-06 1976-11-11
DE2852964A1 (en) * 1978-12-07 1980-06-26 Krupp Polysius Ag METHOD AND SYSTEM FOR REDUCING ORES
LU81207A1 (en) * 1979-04-30 1980-12-16 Arbed METHOD FOR REFINING A METAL BATH CONTAINING SOLID COOLING MATERIALS

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5891214A (en) * 1995-05-18 1999-04-06 Technological Resources Pty. Ltd. Smelting reduction method with increased effectiveness

Also Published As

Publication number Publication date
CA1180189A (en) 1985-01-02
IT1189047B (en) 1988-01-28
FR2490242A1 (en) 1982-03-19
GB2086431B (en) 1984-08-08
IT8149278A0 (en) 1981-09-11
AU542443B2 (en) 1985-02-21
BR8105810A (en) 1982-06-08
DE3132766A1 (en) 1982-06-16
BE890175A (en) 1982-01-04
AU7513681A (en) 1982-03-18

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