GB2405400A - Oxidising scrap steel with steam - Google Patents

Oxidising scrap steel with steam Download PDF

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Publication number
GB2405400A
GB2405400A GB0320152A GB0320152A GB2405400A GB 2405400 A GB2405400 A GB 2405400A GB 0320152 A GB0320152 A GB 0320152A GB 0320152 A GB0320152 A GB 0320152A GB 2405400 A GB2405400 A GB 2405400A
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GB
United Kingdom
Prior art keywords
retort
combustion
process according
carbon
oxidised
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0320152A
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GB0320152D0 (en
Inventor
Ray Smith
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Individual
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Individual
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Filing date
Publication date
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Priority to GB0320152A priority Critical patent/GB2405400A/en
Publication of GB0320152D0 publication Critical patent/GB0320152D0/en
Publication of GB2405400A publication Critical patent/GB2405400A/en
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/001—Dry processes
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/06—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents
    • C01B3/10—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents by reaction of water vapour with metals
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G49/00—Compounds of iron
    • C01G49/02—Oxides; Hydroxides
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B3/00—General features in the manufacture of pig-iron
    • C21B3/04—Recovery of by-products, e.g. slag
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/005—Preliminary treatment of scrap
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/36—Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
    • 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
    • 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
    • Y02P10/20—Recycling
    • 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
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Geology (AREA)
  • Environmental & Geological Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

Scrap steel is oxidised with steam. At the start of the process, scrap steel products are oxidised in a retort 1 in combustion with hydrogen and oxygen gas obtained from the electrolysis of water. When the combustion process reaches a first critical temperature the hydrogen supply is removed so that the combustion process is fuelled by oxygen only. At a second critical temperature the oxygen supply is replaced by dry steam. The oxidisation process yields iron oxides and hydrogen gas.

Description

PROCESS FOR UTILISING WASTE MATERIALS
TECHNICAL FIELD OF THE INVENTION
This invention relates to a process for utilising waste materials.
BACKGROUND
The disposal of waste materials presents an increasing problem. Land-fill sites are short and re-cycling is only suitable for a small proportion of the waste which is produced from day-to-day.
The present invention seeks to provide a new and inventive process for utilising waste materials.
SUMMARY OF THE INVENTION
The present invention provides a process for utilising waste materials in which, at the commencement of the process, scrap steel products are oxidised in a retort fuelled by hydrogen and oxygen gas which may be obtained from the electrolysis of water. As the combustion temperature increases the gaseous fuels can be replaced by dry steam. The process can be used to produce hydrogen gas and other useful fuel products. In addition, scrap steel can be converted to iron oxide for use as a raw material in the manufacture of new steel.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description and the accompanying drawings referred to therein are included by way of non-limiting example in order to illustrate how the invention may be put into practice. In the drawings: Figure 1 is a schematic diagram of apparatus for utilising waste materials in accordance with the invention; Figure 2 is a schematic diagram of an electrolytic chamber for removing carbon dioxide; Figure 3 is a schematic diagram of a waste recycling plant incorporating the apparatus; Figure 4 is a schematic diagram of another waste recycling plant; and Figure 5 is a section through part of the apparatus for utilising waste materials.
DETAILED DESCRIPTION OF THE DRAWINGS
The apparatus includes an upright fire-clay retort 1 which is filled with waste materials through a top opening 2. Solid products may be removed through the bottom of the retort. Volatile products are removed from the top of the retort through an ascension pipe 3. Inlets are provided for hydrogen gas 4, oxygen gas 5 and dry steam 6. The retort is surrounded by a boiler 8. An electrolysis tank 10 provides hydrogen and oxygen gas which are fed separately to the retort inlets 4 and 5 via holding tanks 11 and 12.
In the initial stages of the process, the retort is charged with scrap steel such as cars, refrigerators etc. To start the process water is broken down by electrolysis into hydrogen and oxygen in the tank 10. During off peak periods, when surplus electrical power is available and relatively inexpensive, a d.c. or rectified a.c. current is passed through the water to yield hydrogen gas at the cathode and oxygen gas at the anode. If sea water is used, common salt is also obtained as a by- product of the process.
The combustion of the gases in the retort 1 heats the scrap steel. When the combustion reaches a first critical temperature the supply of hydrogen gas is shut off so that the steel continues to burn on oxygen alone.
At this stage steam generated in the boiler 8 can be used to drive a turbine which generates electricity. Thus, sufficient electricity may be produced to replace the energy input to the electrolysis process so that, even at this stage in the process, there is no net consumption of energy.
When the combustion temperature reaches a second critical temperature the oxygen supply can be turned off and dry steam injected through the inlet 6. The water molecules in the steam are broken down into hydrogen and oxygen gas. The oxygen reacts with the steel forming iron oxide which can be discharged through the bottom of the retort. The hydrogen gas can also be drawn off to be used as a fuel product. Iron oxide recovered from the process can be used as a raw material for the manufacture of new steel.
Gaseous hydrogen fuel and iron oxide are the two main by-products of the process. However, other valuable by-products can also be produced by addition of other waste materials, as will shortly be described.
An economical way of generating electricity is to use a static internal combustion engine driving an electricity generator. The engine may be fuelled by air enriched with the hydrogen fuel obtained from the process, or hydrogen and oxygen.
Carbon-based household waste and sewage can be broken down into inflammable gases in a vat of hydrochloric acid.
The fire-clay retort can be fed with carbon-based household waste, vehicle tyres, plastic household waste, paper products or sewage waste. These are broken down into various inflammable gases, tars, ammonia, etc. as well as solid carbon products which may be removed from the bottom of the retort.
If dry steam is introduced into the retort during the combustion of such carbon-based materials, water gas (carbon monoxide and hydrogen) is produced. The water gas can be used as a fuel product or separated into its two constituent gases. Carbon monoxide is itself a useful gaseous fuel, being higher in calorific value than hydrogen gas.
A mixture of gaseous products are generally obtained from the ascension pipe 3. These could themselves be used to drive an electricity generator 22.
The gaseous products can also be distilled, refined and used as substitute fuels to replace petroleum, diesel or aviation fuel.
The invention therefore provides an energy-efficient process by which carbon-based waste materials can provide substitute fuels using hydrogen obtained from sea water.
It is important to note that air should be excluded from the retort during operation of the process since atmospheric nitrogen reduces the operating temperature and is detrimental to the recovery of useful fuel products.
Carbon dioxide may be a by-product of the process. This is an undesirable greenhouse gas, but it can be broken down as shown in Fig. 2 by passing reduced CO2 gas between high tension electric plates in an electrolysis chamber 24. This yields valuable oxygen gas and carbon which can be recycled. The same electrolysis chamber can be used to crack reduced steam into hydrogen and oxygen gases.
Not only carbon-based waste materials can be used. For example, is scrap glass products are added to the returt these can be broken down to silica.
The process may operate continuously, 24 hours a day, so that a high capacity storage system is necessary for holding the resulting products. A number of retorts 1 may be used to supply common holding tanks 25 for the various products, as shown in Fig. 3.
Fig. 4 shows a recycling plant which has a number of the retorts 31-33 used for oxidising different materials to yield a range of valuable products. Retort 31 is fed with scrap steel. Retorts 32 are fed with general carbon-based waste from which the carbon residues are fed to the retort 33. The resulting gaseous hydrocarbons are then fed to a refinery to yield substitute hydrocarbon fuels. The electrolysis chamber 24 breaks down CO2 gas and returns the resulting carbon to the retort 33.
The carbon monoxide produced by the process can be utilised as shown in Fig. 5. The carbon monoxide gas 50 is fed to a burner 51 where it is mixed with oxygen 52 obtained by the electrolysis process as described. The burner is incorporated into a further retort 55 for receiving scrap materials.
The retort is enclosed by a boiler 56 which incorporates a first stage heat exchanger 57. This arrangement extracts heat rather than allowing it to simply warm the environment. The boiler has a steam outlet 58 which can supply steam to drive turbines for generating electricity. The outlet from the multi-stage heat exchangers can eventually be returned to the boiler via hot water inlet 59.
It will be appreciated that the features disclosed herein may be present in any feasible combination. Whilst the above description lays emphasis on those areas which, in combination, are believed to be new, protection is claimed for any inventive combination of the features disclosed herein.
* * * * * * * *
1. A process for utilising waste materials in which scrap steel products are oxidised with steam in a retort.
2. A process according to Claim 1, in which material rich in iron oxide is removed from the bottom of the retort.
3. A process according to Claim 1 or 2, in which hydrogen gas is removed from the retort.
4. A process according to any preceding claim, in which the steel products are oxidised by a combustion process.
5. A process according to any preceding claim, in which initiation of the combustion process is fuelled by hydrogen and oxygen gases.
6. A process according to Claim 5, in which the hydrogen and oxygen gases are obtained by electrolysis of water.
7. A process according to Claim 5 or 6, in which, when the combustion process reaches a first critical temperature, the supply of hydrogen is shut off and the combustion process continues fuelled by oxygen.
8. A process according to Claim 7, in which, when the combustion process reaches a second critical temperature, the supply of oxygen is shut off and steam is fed into the retort.
9. A process according to any preceding claim, in which the retort is surrounded by a boiler which is used to supply steam to drive an electricity generator.
10. A process according to any preceding claim, in which carbon- based waste materials are fed into the retort.
1 1. A process according to Claim 10, in which carbon residues are recovered from the retort.
12. A process according to Claim 10 or 11, in which gaseous products are removed from the retort.
13. A process according to Claim 12, in which the gaseous products recovered from the retort are refined and distilled.
14. A process for utilising waste materials which is substantially as described with reference to the drawings.
* * * * * * * *

Claims (22)

Amendments to the claims have been filed as follows CLAIMS
1. A process for utilising waste materials in which scrap steel products are oxidised with steam in a retort, and carbon-based waste is broken down separately to yield gaseous hydrocarbons, in which carbon dioxide byproducts are collected and broken down in an electrolysis chamber, and other the gaseous products obtained from the process are recovered for use as fuels.
2. A process according to Claim 1, in which material rich in iron oxide is removed from the bottom of the retort in which the scrap steel products are oxidised.
3. A process according to Claim 1 or 2, in which hydrogen gas is removed from the retort in which scrap steel products are oxidised.
4. A process according to any preceding claim, in which the steel products are oxidised by a combustion process.
5. A process according to Claim 4, in which initiation of the combustion process is fuelled by hydrogen and oxygen gases.
6. A process according to Claim 5, in which the hydrogen and oxygen gases for initiation of the process are obtained by electrolysis of water.
[, . . . . . . i to
7. A process according to Claim 5 or 6, in which, when the combustion process reaches a first critical temperature, the supply of hydrogen is shut off and the combustion process continues fuelled by oxygen.
8. A process according to Claim 7, in which, when the combustion process reaches a second critical temperature, the supply of oxygen is shut off and steam is fed into the retort.
9. A process according to any preceding claim, in which the retort is surrounded by a boiler which is used to supply steam to drive an electricity generator.
10. A process according to any preceding claim, in which combustion of carbon-based waste materials takes place in a retort from which carbon residues are recovered.
11. A process according to Claim 10, in which carbon residues recovered from the combustion of carbon-based waste materials are fed into a further retort with hydrogen gas obtained from the combustion of steel.
12. A process according to Claim 11, in which the gaseous hydrocarbon products are refined and distilled.
13. Apparatus for utilising waste materials which includes: - a retort in which scrap steel products are oxidised with steam, : 1 ' ' - a separate retort in which carbon-based waste are broken down to yield gaseous hydrocarbons, and: - an electrolysis chamber in which carbon dioxide by-products are broken down, I the apparatus being arranged such that the gaseous products obtained from the process are recovered for use as fuels.
14. Apparatus according to Claim 13, including means for removing material rich in iron oxide from the bottom of the retort in which the scrap steel products are oxidised.
15. Apparatus according to Claim 13 or 14, including means for removing hydrogen gas from the retort in which scrap steel products are oxidised.
16. Apparatus according to any of Claims 13 to 15, including; means for supplying hydrogen and oxygen gases to the retort in which the steel products are oxidised, to fuel a combustion process.
17. A process according to Claim 16, including means for electrolysis of water to obtain the hydrogen and oxygen gases for initiation of the combustion process.
18. A process according to any of Claims 13 to 17, in which the retort is surrounded by a boiler which is used to supply steam to drive an electricity generator. it,
i. .. . ; 1 /
19. Apparatus according to any of Claims 13 to 18, in which the retort in which combustion of carbon-based waste materials takes place: includes means for recovering carbon residues.
20. Apparatus according to Claim 19, in which carbon residues recovered from the combustion of carbon-based waste materials are fed into a further retort with hydrogen gas obtained from the combustion of steel. :
21. A process for utilising waste materials which is substantially as described with reference to the drawings.
22. Apparatus for utilising waste materials which is substantially as described with reference to the drawings.
* * * * * * * * . .. . ... . i .
GB0320152A 2003-08-28 2003-08-28 Oxidising scrap steel with steam Withdrawn GB2405400A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0320152A GB2405400A (en) 2003-08-28 2003-08-28 Oxidising scrap steel with steam

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GB0320152A GB2405400A (en) 2003-08-28 2003-08-28 Oxidising scrap steel with steam

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GB0320152D0 GB0320152D0 (en) 2003-10-01
GB2405400A true GB2405400A (en) 2005-03-02

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0056004A2 (en) * 1981-01-05 1982-07-14 Exxon Research And Engineering Company Production of carbon filaments in the presence of iron monoxide
JPS645916A (en) * 1987-06-29 1989-01-10 Nippon Seiko Kk Magnetic material
DE4226496A1 (en) * 1992-08-11 1993-01-21 Gottfried Von Dipl Czarnowski Hydrogen generation by reacting scrap iron with steam in shaft furnace - and recycling magnetite obtd. to iron and steel mfr., reducing energy consumption
JPH06157003A (en) * 1992-11-19 1994-06-03 Sumitomo Metal Ind Ltd Production of hydrogen utilizing iron
JPH08157220A (en) * 1994-11-29 1996-06-18 Nisshin Flour Milling Co Ltd Superfine iron oxide particle and its production

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0056004A2 (en) * 1981-01-05 1982-07-14 Exxon Research And Engineering Company Production of carbon filaments in the presence of iron monoxide
JPS645916A (en) * 1987-06-29 1989-01-10 Nippon Seiko Kk Magnetic material
DE4226496A1 (en) * 1992-08-11 1993-01-21 Gottfried Von Dipl Czarnowski Hydrogen generation by reacting scrap iron with steam in shaft furnace - and recycling magnetite obtd. to iron and steel mfr., reducing energy consumption
JPH06157003A (en) * 1992-11-19 1994-06-03 Sumitomo Metal Ind Ltd Production of hydrogen utilizing iron
JPH08157220A (en) * 1994-11-29 1996-06-18 Nisshin Flour Milling Co Ltd Superfine iron oxide particle and its production

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Publication number Publication date
GB0320152D0 (en) 2003-10-01

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