NL2026572B1 - Process and system for melting agglomerates - Google Patents

Process and system for melting agglomerates Download PDF

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Publication number
NL2026572B1
NL2026572B1 NL2026572A NL2026572A NL2026572B1 NL 2026572 B1 NL2026572 B1 NL 2026572B1 NL 2026572 A NL2026572 A NL 2026572A NL 2026572 A NL2026572 A NL 2026572A NL 2026572 B1 NL2026572 B1 NL 2026572B1
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NL
Netherlands
Prior art keywords
furnace
gas
melting furnace
melting
carbon monoxide
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Application number
NL2026572A
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Dutch (nl)
Inventor
Petrus Greyling Frederik
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Petrus Greyling Frederik
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Filing date
Publication date
Application filed by Petrus Greyling Frederik filed Critical Petrus Greyling Frederik
Priority to NL2026572A priority Critical patent/NL2026572B1/en
Priority to PCT/IB2021/058118 priority patent/WO2022069972A1/en
Priority to CA3192559A priority patent/CA3192559A1/en
Priority to ZA2021/06539A priority patent/ZA202106539B/en
Application granted granted Critical
Publication of NL2026572B1 publication Critical patent/NL2026572B1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B19/00—Combinations of furnaces of kinds not covered by a single preceding main group
    • F27B19/04—Combinations of furnaces of kinds not covered by a single preceding main group arranged for associated working
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D17/00—Arrangements for using waste heat; Arrangements for using, or disposing of, waste gases
    • F27D17/001—Extraction of waste gases, collection of fumes and hoods used therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D99/00—Subject matter not provided for in other groups of this subclass
    • F27D99/0001—Heating elements or systems
    • F27D99/0033—Heating elements or systems using burners

Abstract

The invention pertains to a process and system for melting agglomerates in a melting furnace by utilising a carbon monoxide (CO) off-gas of a reduction furnace as a fuel gas. The process includes the steps of (i) feeding agglomerates which includes a metalliferous feedstock material to a melting furnace (20) to form a packed bed of agglomerates in the melting furnace (20); (ii) feeding a carbon monoxide (CO) off-gas of a reduction furnace (30) as a fuel gas to a burner (22) of the melting furnace (20); and (iii) combusting the carbon monoxide (CO) off-gas of the reduction furnace (30) in the melting furnace (20) by means of the burner (22) of the melting furnace (20), to heat and melt the agglomerates in the melting furnace (22).

Description

P34788NL00/JV Title: PROCESS AND SYSTEM FOR MELTING AGGLOMERATES
FIELD OF THE INVENTION The invention pertains to a process and system for melting agglomerates. More particularly, the invention pertains to a process and system for melting agglomerates in a melting furnace by utilising a carbon monoxide (CO) off-gas as a fuel gas.
BACKGROUND TO THE INVENTION A metal is typically extracted from its ore by means of a smelting process. During a smelting process, heat together with a chemical reducing agent reduces a metal oxide in the ore to release oxygen bound to the metal. The oxygen that is released from the metal oxide binds to carbon to form a carbon monoxide (CO) off-gas. The carbon monoxide (CQ) off-gas is often burned in a flare stack and released to the atmosphere as carbon dioxide {CO:2). In such an instance, all the energy that is associated with the carbon monoxide (CO) gas is lost. Efforts have been made to use the energy that is associated with a carbon monoxide (CO) off-gas. As an example, a carbon monoxide (CO) off-gas has been used for general plant heating functions and for power generation. However, both of the aforesaid uses have a relatively low thermal efficiency and much of the energy that is associated with a carbon monoxide (CO) off-gas is still lost. A process by which a carbon monoxide (CO) off-gas is used to pre-heat an ore is also known. In this known process, a carbon monoxide (CO) off-gas is passed through ores in a kiln. The carbon monoxide (CO) off-gas pre-heats the ores in the kiln up to a temperature of around 800°C. However, this process does not use the energy that is associated with a carbon monoxide (CO) off-gas optimally. From the above it is apparent that there remains a need for the better utilisation of the energy that is associated with a carbon monoxide (CO) off-gas.
OBJECT OF THE INVENTION It is an object of the present invention to provide a process and system for melting agglomerates in a melting furnace by utilising a carbon monoxide (CO) off-gas of a reduction furnace as a fuel gas, with which the applicant believes the energy that is associated with a carbon monoxide (CO) off-gas may be better utilised than in known processes and systems, or which would provide a useful alternative use of the energy that is associated with a carbon monoxide (CO) off-gas.
SUMMARY OF THE INVENTION According to a first aspect of the present invention, there is provided a process for melting agglomerates, the process including the steps of: — feeding agglomerates which includes a metalliferous feedstock material to a melting furnace to form a packed bed of agglomerates in the melting furnace; — feeding a carbon monoxide (CO) off-gas of a reduction furnace as a fuel gas to a burner of the melting furnace; and — combusting the carbon monoxide (CO) off-gas of the reduction furnace in the melting furnace by means of the burner of the melting furnace to heat and melt the agglomerates in the melting furnace.
The agglomerate may be any one selected from the group consisting of a briquet, a pellet and an extrusion. The agglomerate may include a flux. The metalliferous feedstock material may be an ore.
The reduction furnace may be any one selected from the group consisting of a DC brush-arc furnace, an AC brush-arc furnace and a DC-arc furnace. A brush-arc furnace is an electrical furnace whose electrodes are arcing on top of the furnace contents with a short arc length, typically not longer than 100 mm.
The process may include the additional step of feeding combustion air to the burner of the melting furnace for combusting the combustion air together with the carbon monoxide (CO) off-gas of the reduction furnace in the melting furnace.
The melting furnace may be a gas-fired cupola furnace (i.e. a coke-less cupola furnace). Alternatively, the melting furnace may be a shaft furnace.
The process may include the additional step of removing particulate matter from the carbon monoxide (CO) off-gas of the reduction furnace in a wet scrubber prior to feeding it as a fuel gas to the burner of the melting furnace.
According to a second aspect of the present invention, there is provided for the use of a carbon monoxide off-gas of a reduction furnace as a fuel gas for a burner of a melting furnace.
According to a third aspect of the present invention, there is provided a system for melting agglomerates, the system including: — a melting furnace having a burner for combusting a fuel gas to heat and melt agglomerates in the melting furnace to form a liquid product; — a reduction furnace for reducing the liquid product and forming a metal liquid product, a slag and a carbon monoxide (CO) off-gas, the reduction furnace being in fluid flow communication with the melting furnace; and — a conduit for feeding the carbon monoxide (CO) off-gas of the reduction furnace to the burner of the melting furnace.
BRIEF DESCRIPTION OF THE ACCOMPANYING DIAGRAM The invention will now be described further, by way of example only, with reference to the accompanying diagram, wherein figure 1 is a schematic diagram of the system of the invention by which the process of the invention is implemented.
DETAILED DESCRIPTION OF THE INVENTION With reference to figure 1, a system for melting agglomerates according to the invention are generally indicated by reference numeral 10. The system 10 includes a melting furnace 20 which has a burner 22. The system 10 also includes a reduction furnace 30. A conduit 40 extends between the reduction furnace 30 and the burner 22 of the melting furnace 20 for feeding a carbon monoxide (CO) off-gas of the reduction furnace 30 as a fuel gas to the burner 22 of the melting furnace.
It will be appreciated by those skilled in the art that an off-gas is a gas which is emitted as a by-product of a chemical process.
Agglomerates (not shown) comprising of a metalliferous feedstock material and a flux are fed 5 to the melting furnace 20 to form a packed bed of agglomerates (not shown) in the melting furnace 20. The agglomerates are typically fed to the melting furnace 20 via a sluice (not shown). Process stream (I) in figure 1 indicates the step of feeding agglomerates to the melting furnace 20. The flux serves to promote the melting of the metalliferous feedstock material in the agglomerate.
An agglomerate that is fed to the melting furnace 20 typically takes the form of a briquet, a pellet or an extrusion.
The packed bed of agglomerates typically locates on top of a bed of refractory materials (not shown). The bed of refractory materials, in turn, locates on top of a water-cooled grate 24 of the melting furnace 20. A combustion chamber 26 of the melting furnace 20 locates beneath the water-cooled grid 24. The burner 22 is arranged to combust the carbon monoxide (CO) off-gas of the reduction furnace 30 together with a combustion gas in the combustion chamber 26 of the melting furnace 20. The combustion gas is fed to the burner 22 of the melting furnace 22, as indicated by process stream (II) in figure 1. An outlet (not shown) is provided at an operatively top region of the melting furnace 20 for extracting an off-gas which is formed in the melting furnace 20 from the melting furnace 20. The step of extracting an off-gas which is formed in the melting furnace 20 from the melting furnace 20 is indicated by process stream (VI) in figure 1. An off-gas which is formed in and extracted from the melting furnace 20 is typically carbon dioxide (CO2). The carbon dioxide (CO,) off-gas which is formed in and extracted from the melting furnace 20 is often passed through a bag filter 60 to remove particulate matter therefrom prior to the off-gas being released to the atmosphere.
The melting furnace 20 is in fluid flow communication with a reduction furnace 30 by means of a conduit 50. The conduit 50 typically extends between an operatively bottom region of the melting furnace 30 (e.g. a tap region and tap hole of the melting furnace 20) to the reduction furnace 30. The conduit 50 serves to convey a liquid product (not shown) which forms in the melting furnace 20 to the reduction furnace 30. The liquid product includes a liquid metalliferous feedstock material. The conduit 50 is typically a closed conduit and insulated to prevent heat losses when the liquid product is conveyed from the melting furnace 20 to the reduction furnace 30. The reduction furnace 30 may be any one of a DC brush-arc furnace, an AC brush-arc furnace or a DC-arc furnace. A brush-arc furnace is an electrical furnace whose electrodes are arcing on top of the furnace contents with a short arc length, typically not longer than 100 mm. Exemplary embodiments of a brush-arc furnace are provided in international patent application number PCT/IB2011/052428, South African patent number 2012/04751 and South African provisional patent application number 2019/07850. The contents of these three documents are incorporated herein by reference. In figure 1, the reduction furnace 30 takes the form of a brush-arc furnace having two electrodes 32a and 32b which extends from or through a roof 31 of the reduction furnace 30. The electrodes 32a and 32b are arranged to arc 33a and 33b on top of the furnace contents
34. Reductants (not shown) can be fed to the reduction furnace 30, as indicated by process stream (III) in figure 1. The furnace contents 34 comprise of a slag 34a and a liquid metal product 34b. The furnace contents 34 are formed during the reduction of the liquid metalliferous feedstock constituent of the liquid product which is conveyed from the melting furnace 20 to the reduction furnace
30. A carbon monoxide (CO) off-gas is emitted during the reduction reaction.
A tap hole (not shown) is provided in the reduction furnace 30 to convey the slag 34a out of the reduction furnace 30 as indicated by process stream (IV) in figure 1. A further tap hole {not shown) is provided in the reduction furnace 30 to convey the metal liquid product 34b out of the reduction furnace 30 as indicated by process stream (V) in figure 1.
As already described, a conduit 40 extends between the reduction furnace 30 and the burner 22 of the melting furnace 20 for feeding a carbon monoxide (CO) off-gas of the reduction furnace 30 as a fuel gas to the burner 22 of the melting furnace 20. More specifically, the conduit 40 extends between an operatively top region of the reduction furnace 30 and the burner 22 of the melting furnace 20. That is, the conduit 40 has an opening in the reduction furnace 30 which locates above the contents 34 of the reduction furnace 30. As shown in figure 1, a wet scrubber 50 is provided for removing pollutants from the carbon monoxide (CO) off-gas of the reduction furnace 30. In particular, the wet scrubber 50 serves to remove particulate matter from the carbon monoxide (CO) off-gas of the reduction furnace 30 prior to feeding it as a fuel gas to the burner 22 of the melting furnace 20. In use, agglomerates (not shown) which includes a metalliferous feedstock material are fed to the melting furnace 20 via the sluice (not shown). This step is indicated by process stream (I) in figure 1. The agglomerates are fed to the melting furnace 20 to form a packed bed of agglomerates on a packed bed of refractory materials (not shown). The packed bed of refractory materials is supported on a water-cooled grate 24 of the melting furnace 20. The scrubbed carbon monoxide (CO) off-gas of the reduction furnace 30 is fed as a fuel gas to the burner 22 of the melting furnace 20 via the conduit 40. Combustion gas is also fed to the burner 22 of the melting furnace 20, as indicated by process stream (II) in figure 1. The burner 22 of the melting furnace 20 combusts the carbon monoxide (CO) off-gas of the reduction furnace 30 and the combustion gas to heat the packed bed of refractory materials in the melting furnace 20. The refractory materials, in turn, heat and melt the agglomerates in the melting furnace 20 to form a liquid product {not shown). During the combustion reaction, a carbon dioxide (CO,) off-gas is formed. The carbon dioxide (CO:z) off-gas is extracted from the melting furnace 20, as indicated by process stream (VI). The extracted carbon dioxide (COy) off-gas is passed through the bag filter 60 to remove particulate matter therefrom prior to it being released to the atmosphere. The liquid product trickles down and through the packed bed of refractory materials and water-cooled grate 24, where after it is conveyed to the reduction furnace 30 by means of the conduit 50. The liquid product locates in the reduction furnace 30 and electrical energy is continually added to the reduction furnace 30 and its contents 34 by means of the electrodes 32a and 32b. The electrodes 32a and 32b are arranged to arc 33a and 33b on top of the furnace contents 34. Reductant (not shown) is also continually added to the reduction furnace 30, as indicated by process stream (III) in figure 1. As electrical energy and reductants are continuously added to the reduction furnace 30 and its contents 34, the liquid metalliferous feedstock material constituent of the liquid product is reduced to form a liquid metal product 34b and a slag 34a. The liquid metal product 34b is tapped periodically or continuously from the reduction furnace 30 via a tap hole (not shown), as indicated by process stream (V) in figure 1. The slag 34a is tapped periodically or continuously from the reduction furnace 30 via tap hole (not shown), as indicated by process stream (IV) in figure 1.
During the reduction of the liquid metalliferous feedstock material constituent of the liquid product, an off-gas consisting of mainly carbon monoxide (CO) is emitted. The carbon monoxide (CO) off-gas is extracted from the reduction furnace 30 via the conduit 40 and fed to the wet scrubber 50. Pollutants and particulate material are removed from the carbon monoxide (CO) off-gas of the reduction furnace 30 in the wet scrubber 50. The scrubbed carbon monoxide (CQO) off-gas of the reduction furnace 30 is then fed as a fuel gas to the burner 22 of the melting furnace 20.
It will be appreciated by those skilled in the art that the carbon monoxide (CQO) off-gas of the reduction furnace 30 can form a constituent fuel gas of a fuel gas which is fed to the burner 22 of the melting furnace 30. The process and system of the present invention provides for the energy efficient use of energy that is associated with a carbon monoxide (CO) off-gas of reduction furnace. By using the carbon monoxide (CO) off-gas of a reduction furnace as a fuel gas for a burner of a melting furnace, the applicant has found that the processing capacity of the reduction furnace can be doubled. Alternatively, by using the carbon monoxide (CO) off-gas of a reduction furnace as a fuel gas for a burner of a melting furnace, the applicant has found that the electric energy requirements of the reduction furnace can be reduced substantially. It will be appreciated by those skilled in the art that the invention is not limited to the precise details as described herein and that many variations are possible without departing from the scope of the invention. As such, the present invention extends to all functionally equivalent processes, methods and uses that are within its scope. The description is presented by way of example only in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show more detail than is necessary for a fundamental understanding of the invention. The words which have been used herein are words of description and illustration, rather than words of limitation.

Claims (10)

-10 - CONCLUSIES-10 - CONCLUSIONS 1. Werkwijze voor het smelten van agglomeraten, waarbij de werkwijze de volgende stappen omvat: — het toevoeren van agglomeraten die een metaalhoudend uitgangsmateriaal omvatten aan een smeltoven om een gepakt bed van agglomeraten te vormen in de smeltoven; — het toevoeren van een koolmonoxide (CO) afgas van een reductieoven als brandstofgas aan een brander van de smeltoven; en — het verbranden van het koolmonoxide (CO) afgas van de reductieoven in de smeltoven door middel van de brander van de smeltoven om de agglomeraten in de smeltoven te verwarmen en te smelten.A method for melting agglomerates, the method comprising the steps of: - feeding agglomerates comprising a metal-containing raw material to a melting furnace to form a packed bed of agglomerates in the melting furnace; - supplying a carbon monoxide (CO) off-gas from a reduction furnace as fuel gas to a burner of the melting furnace; and - burning the carbon monoxide (CO) off-gas from the reduction furnace in the melting furnace by means of the burner of the melting furnace to heat and melt the agglomerates in the melting furnace. 2. Werkwijze volgens conclusie 1, waarbij de agglomeraten worden gekozen uit de groep bestaande uit een briket, een pellet en een geëxtrudeerde stof.The method of claim 1, wherein the agglomerates are selected from the group consisting of a briquette, a pellet and an extrudate. 3. Werkwijze volgens conclusie 1 of 2, waarbij de agglomeraten een flux bevatten.A method according to claim 1 or 2, wherein the agglomerates contain a flux. 4. Werkwijze volgens een van de voorgaande conclusies, waarbij het metaalhoudende uitgangsmateriaal een erts is.A method according to any one of the preceding claims, wherein the metallic feedstock is an ore. 5. Werkwijze volgens een van de voorgaande conclusies, waarbij de reductieoven een oven is die wordt gekozen uit de groep bestaande uit een gelijkstroom borstel-boogoven, een wisselstroom borstel-boogoven en een gelijkstroom boogoven.The method of any preceding claim, wherein the reduction furnace is a furnace selected from the group consisting of a DC brush-arc furnace, an AC brush-arc furnace and a DC arc furnace. 6. Werkwijze volgens een van de voorgaande conclusies, waarbij de werkwijze de aanvullende stap omvat van het toevoeren van verbrandingslucht aan de brander van de smeltoven voor het verbranden van de verbrandingslucht samen met het koolmonoxide (CO) afgas van de reductieoven in de smeltoven.A method according to any one of the preceding claims, wherein the method comprises the additional step of supplying combustion air to the burner of the melting furnace for combustion of the combustion air together with the carbon monoxide (CO) off-gas from the reduction furnace in the melting furnace. 7. Werkwijze volgens een van de voorgaande conclusies, waarbij de smeltoven een gasgestookte koepeloven of een schachtoven is.A method according to any one of the preceding claims, wherein the melting furnace is a gas-fired cupola furnace or a shaft furnace. 8. Werkwijze volgens een van de voorgaande conclusies, waarbij de werkwijze de aanvullende stap omvat van het verwijderen van deeltjesvormig materiaal uit het koolmonoxide (CO) afgas van de reductieoven, voordat het als brandstofgas aan de brander van de smeltoven wordt toegevoerd.A method according to any one of the preceding claims, wherein the method comprises the additional step of removing particulate matter from the carbon monoxide (CO) off-gas of the reduction furnace before it is supplied as fuel gas to the burner of the melting furnace. -11 --11 - 9. Gebruik van een koolmonoxide (CO) afgas van een reductieoven als brandstofgas voor een brander van een smeltoven.9. Using a carbon monoxide (CO) off-gas from a reduction furnace as fuel gas for a smelting furnace burner. 10. Systeem voor het smelten van agglomeraten, waarbij het systeem omvat: — een smeltoven met een brander voor het verbranden van een brandstofgas om agglomeraten in de smeltoven te verwarmen en te smelten om een vloeibaar product te vormen; — een reductieoven voor het reduceren van het vloeibare product en het vormen van een vloeibaar metaalproduct, een slak en een koolmonoxide (CO) afgas, waarbij de reductieoven in fluidumstroomverbinding staat met de smeltoven; en — een leiding voor het toevoeren van het koolmonoxide (CO) afgas van de reductieoven als brandstofgas aan de brander van de smeltoven.A system for melting agglomerates, the system comprising: — a melting furnace having a burner for burning a fuel gas to heat and melt agglomerates in the melting furnace to form a liquid product; a reduction furnace for reducing the liquid product and forming a liquid metal product, a slag and a carbon monoxide (CO) off gas, the reduction furnace being in fluid flow communication with the melting furnace; and - a conduit for feeding the carbon monoxide (CO) off-gas from the reduction furnace as fuel gas to the burner of the melting furnace.
NL2026572A 2020-09-29 2020-09-29 Process and system for melting agglomerates NL2026572B1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
NL2026572A NL2026572B1 (en) 2020-09-29 2020-09-29 Process and system for melting agglomerates
PCT/IB2021/058118 WO2022069972A1 (en) 2020-09-29 2021-09-07 Process and system for melting agglomerates
CA3192559A CA3192559A1 (en) 2020-09-29 2021-09-07 Process and system for melting agglomerates
ZA2021/06539A ZA202106539B (en) 2020-09-29 2021-09-07 Process and system for melting agglomerates

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NL2026572A NL2026572B1 (en) 2020-09-29 2020-09-29 Process and system for melting agglomerates

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WO (1) WO2022069972A1 (en)
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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3186830A (en) * 1963-05-20 1965-06-01 William H Moore Melting process
EP0318896A2 (en) * 1987-11-30 1989-06-07 Nkk Corporation Method for smelting reduction of iron ore and apparatus therefor
US6379422B1 (en) * 1999-08-05 2002-04-30 Technological Resources Pty. Ltd. Direct smelting process
US6685761B1 (en) * 1998-10-30 2004-02-03 Midrex International B.V. Rotterdam, Zurich Branch Method for producing beneficiated titanium oxides
EP2937429A1 (en) * 2012-12-21 2015-10-28 Posco Fixed-type electric furnace and molten steel production method
WO2017089651A1 (en) * 2015-11-24 2017-06-01 Outotec (Finland) Oy Method and apparatus for preheating and smelting manganese ore sinter

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3186830A (en) * 1963-05-20 1965-06-01 William H Moore Melting process
EP0318896A2 (en) * 1987-11-30 1989-06-07 Nkk Corporation Method for smelting reduction of iron ore and apparatus therefor
US6685761B1 (en) * 1998-10-30 2004-02-03 Midrex International B.V. Rotterdam, Zurich Branch Method for producing beneficiated titanium oxides
US6379422B1 (en) * 1999-08-05 2002-04-30 Technological Resources Pty. Ltd. Direct smelting process
EP2937429A1 (en) * 2012-12-21 2015-10-28 Posco Fixed-type electric furnace and molten steel production method
WO2017089651A1 (en) * 2015-11-24 2017-06-01 Outotec (Finland) Oy Method and apparatus for preheating and smelting manganese ore sinter

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CA3192559A1 (en) 2022-04-07
WO2022069972A1 (en) 2022-04-07
ZA202106539B (en) 2022-09-28

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