SE545831C2 - Method for Producing Steel - Google Patents
Method for Producing SteelInfo
- Publication number
- SE545831C2 SE545831C2 SE2151144A SE2151144A SE545831C2 SE 545831 C2 SE545831 C2 SE 545831C2 SE 2151144 A SE2151144 A SE 2151144A SE 2151144 A SE2151144 A SE 2151144A SE 545831 C2 SE545831 C2 SE 545831C2
- Authority
- SE
- Sweden
- Prior art keywords
- stream
- predetermined amount
- steel
- iron ore
- vessel
- Prior art date
Links
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 86
- 239000010959 steel Substances 0.000 title claims abstract description 86
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 184
- 229910052742 iron Inorganic materials 0.000 claims abstract description 67
- 238000000034 method Methods 0.000 claims abstract description 45
- 238000005255 carburizing Methods 0.000 claims abstract description 32
- 229910002091 carbon monoxide Inorganic materials 0.000 claims abstract description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 31
- 229910052799 carbon Inorganic materials 0.000 claims description 31
- 230000015572 biosynthetic process Effects 0.000 claims description 13
- 239000002699 waste material Substances 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 11
- 229920002430 Fibre-reinforced plastic Polymers 0.000 claims description 8
- 125000004429 atom Chemical group 0.000 claims description 7
- 125000004432 carbon atom Chemical group C* 0.000 claims description 7
- 239000011151 fibre-reinforced plastic Substances 0.000 claims description 4
- 239000003365 glass fiber Substances 0.000 claims description 4
- 239000010813 municipal solid waste Substances 0.000 claims description 4
- 239000010801 sewage sludge Substances 0.000 claims description 4
- 229910052739 hydrogen Inorganic materials 0.000 claims description 3
- 229910002092 carbon dioxide Inorganic materials 0.000 description 41
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 36
- 238000004140 cleaning Methods 0.000 description 20
- 229910001868 water Inorganic materials 0.000 description 20
- 239000000463 material Substances 0.000 description 14
- 238000002309 gasification Methods 0.000 description 13
- 238000011084 recovery Methods 0.000 description 12
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 9
- 238000006243 chemical reaction Methods 0.000 description 9
- 239000001301 oxygen Substances 0.000 description 9
- 229910052760 oxygen Inorganic materials 0.000 description 9
- 239000007788 liquid Substances 0.000 description 8
- SZVJSHCCFOBDDC-UHFFFAOYSA-N ferrosoferric oxide Chemical compound O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 description 7
- 239000007789 gas Substances 0.000 description 7
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 7
- 238000001179 sorption measurement Methods 0.000 description 7
- 239000000571 coke Substances 0.000 description 5
- 229910010272 inorganic material Inorganic materials 0.000 description 5
- 239000011147 inorganic material Substances 0.000 description 5
- 239000001569 carbon dioxide Substances 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 238000000197 pyrolysis Methods 0.000 description 4
- 239000002893 slag Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 238000009835 boiling Methods 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- 238000007796 conventional method Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 235000013980 iron oxide Nutrition 0.000 description 3
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 241000272470 Circus Species 0.000 description 2
- 229910001567 cementite Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- -1 copper (Cu) Chemical class 0.000 description 2
- 239000011368 organic material Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 241000549548 Fraxinus uhdei Species 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910052595 hematite Inorganic materials 0.000 description 1
- 239000011019 hematite Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- LIKBJVNGSGBSGK-UHFFFAOYSA-N iron(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Fe+3].[Fe+3] LIKBJVNGSGBSGK-UHFFFAOYSA-N 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229910017464 nitrogen compound Inorganic materials 0.000 description 1
- 150000002830 nitrogen compounds Chemical class 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 238000011946 reduction process Methods 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
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
- C22B5/00—General methods of reducing to metals
- C22B5/02—Dry methods smelting of sulfides or formation of mattes
- C22B5/12—Dry methods smelting of sulfides or formation of mattes by 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
- C21B13/0073—Selection or treatment of the reducing gases
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/72—Other features
- C10J3/723—Controlling or regulating the gasification process
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/002—Removal of contaminants
- C10K1/003—Removal of contaminants of acid contaminants, e.g. acid gas removal
- C10K1/005—Carbon dioxide
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K1/00—Purifying combustible gases containing carbon monoxide
- C10K1/04—Purifying combustible gases containing carbon monoxide by cooling to condense non-gaseous materials
- C10K1/046—Reducing the tar content
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10K3/00—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
- C10K3/02—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment
- C10K3/04—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment reducing the carbon monoxide content, e.g. water-gas shift [WGS]
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/004—Making spongy iron or liquid steel, by direct processes in a continuous way by reduction from ores
-
- 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
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/20—Carburising
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/16—Integration of gasification processes with another plant or parts within the plant
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J2300/00—Details of gasification processes
- C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
- C10J2300/1861—Heat exchange between at least two process streams
- C10J2300/1892—Heat exchange between at least two process streams with one stream being water/steam
-
- 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
- C21B2100/66—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
Abstract
Method for producing steel, which comprises the steps of: providing a predetermined amount of iron ore to a vessel, reducing said iron ore to a predetermined amount of Fe, and carburizing said predetermined amount of Fe in order to produce steel. The steps of reducing and carburizing is performed using a main stream of CO and H2 being divided into at least two streams. In a first stream, H2 is removed from the stream and is fed to the vessel (9) for reducing said iron ore. A second stream comprising CO is fed to the vessel for carburizing said predetermined amount of Fe for producing steel with a predetermined content of C. The disclosure is also related to a system for producing steel according to the method.
Description
TECHNICAL FIELD
The present disclosure relates to a method for producing steel according to claim 1 and to
a system for producing steel according to claim
BACKGROUND ART
The conventional way of producing steel from iron ore requires a large amount of carbon rich coke to melt, reduce and carburize the steel. The steel industry is therefore one of the largest CO2 polluters in the world. lt is therefore of utmost importance to reduce the CO2 ppllution from steel production. To this fact it has been suggested to instead of using coke, it is possible to use hydrogen. See for example the document GB2112019A discussing such a method where
the iron is reduced out from the iron ore.
SUMMARY OF THE INVENTION There is a need to provide steel out of the reduced iron ore.
An object of the present disclosure is to provide a method for producing steel wherein some of
the problems with prior art technologies are mitigated or at least alleviated.
The disclosure proposes a method for producing steel. The method comprises the steps of: providing a predetermined amount of iron ore to a vessel, reducing the iron ore to a predetermined amount of Fe and carburizing the predetermined amount of Fe in order to produce steel. The steps of reducing and carburizing is performed using a main stream of CO and H2 being divided into at least two streams. ln a first stream, H2 is removed from the stream and is fed to the vessel for reducing the iron ore. A second stream comprising CO is fed to the vessel for carburizing the predetermined amount of
Fe for producing steel with a predetermined content of C.
The advantage of the method is that the carbon content in the resulting steel is controlled in an accurate and reliable way by controlling the amount of CO and H2 in the first and second stream, respectively to a vessel to which iron ore is fed. No coke or methane is used upon reduction and carburization of the steel. Thus, the method provides for an environmentally friendly way of producing steel (so-called green steel) since very small amounts of C02 is formed in the vessel. Much less CO2 is formed upon production of the steel according to the
present method as compared to the conventional steel production process. ln the conventionalprocess, more than 800 kg C02/ton iron ore is produced to be compared with about 450 kg C02 per 1000 kg iron ore of the present method. ln addition, the C02 formed in the present process is not formed in the vessel, instead it is formed in the process where it is co||ected thereby preventing C02 emission to the atmosphere. Thus, the proposed method is
environmental friendly as compared With conventional steel production.
According to a further development, the amount of the second stream being fed to the vessel is controlled such that all carbon atoms from C0 of the second stream are
bonded to Fe atoms when carburizing the predetermined amount of Fe.
The advantage is that a reliable and accurate way of producing steel with a predetermined
content of C is provided.
According to a further development, the predetermined amount of Fe is carburized
according the following formula, 3Fe+C0+H2=>Fe3C+H
The carbon content in the steel is in the range of 0.0002 % to 10 %, preferably in the range of 0.002 % to 6.5 %, most preferably in the range of 0.02 to 2.5 %.
The advantage is that the carbon content of the steel is controlled.
According to a further development, the main stream of CO and H2 originates from
syngas.
The advantage is that by using syngas upon producing steel according the present method very small amounts of C02 is formed in the vessel as compared to conventional steel production where coke for reducing and carburizing. By using syngas, the predetermined
content of C in the steel is reliably and accurately controlled.
According to a further development, the syngas is extracted from waste, such as auto shredder residue, ASR, carbon fibre reinforced plastics, glass fibre reinforced plastics,
sewage sludge, and/or municipal solid waste, MSW.
The advantage is that the energy bound in the waste is recovered. Furthermore, landfill which typically is the endpoint of many types of waste is reduced. Materials, such as metals, from the waste may be separated and recycled after formation of the syngas. By using waste for
extraction of syngas, the method is very cost efficient.
According to a further development, the syngas is formed by allowing the waste to be
heated to a temperature of at least 3000 °C.
3 The advantage is that syngas may be extracted from waste without the need of separating different parts of the waste, such as cabling and car upholstery of auto shredder residue, prior
to recycling the different parts.
According to a further development, heat generated at the formation of syngas is used upon the steps of reducing and carburizing, such as for heating the vessel prior to or
upon reducing the iron ore and/or carburizing of the Fe.
The advantage is that heat generated upon the formation of the syngas may be recovered upon production of the steel, such as for heating the vessel. The heat may
also be recovered and used for heating other arrangements, such as buildings.
According to a further development, the syngas is subject to at least one cleaning step
prior to forming the main stream of CO and H
The advantage is that by cleaning the syngas, syngas having a high purity is formed. Thereby,
the control of the predetermined amount of C in the steel becomes very reliable and accurate.
According to a further development, the step of reducing the iron ore to a predetermined
amount of Fe, takes place according to the following formulas, 3Fe2O3 + H2 => 2Fe3O4 + H20,
Fe3O4 + H2 => 3FeO + H20, and
FeO + H2 => Fe + H2O.
The advantage by using H2 for reducing of the iron ore is that only Fe and H20 is formed. Thus, the proposed method is very environmentally friendly as compared to conventional methods for producing steel in which a large amount of C02 is formed upon reduction of the
iron ore.
According to a further development, in the first stream the H2 is removed from the stream
according to the following formula, CO + H2O => H2 + CO
The advantage is that a high yield of H2 is removed from the first stream of H2 and CO in a very
efficient way.
According to a further development, the method further comprises a step of separating the
CO2 and H2 and collecting the CO2 in a sealed container.This provides for improved handling of the C02 formed by the proposed method as compared to conventional production of steel where C02 is formed in the vessel. The advantage is that
C02 formed upon removing of H2 in the first stream, is co||ected in a sea|ed container thereby preventing emission of C02 to the atmosphere. The separated C02 may be subject to carbon
capture and utilization, CCU, where the C02 is recycled.
According to a further development, in the step of providing a predetermined amount of iron ore to a vessel also a predetermined amount of scrap iron is provided to the
vesseL
This provides for that scrap iron is recycled and is used in the process for producing steel. By the use of scrap iron, a smaller amount of iron ore is used, thereby the process becomes more
energy efficient and cost efficient.
The disclosure further proposes a system for producing steel according to the method. The system comprises at least one vessel. The vessel comprises an inlet for iron ore, an inlet for H2 and one inlet for C0 + H2 and an outlet for produced steel with a
predetermined carbon content.
The system is able to produce steel according to the proposed method. Thus, the system provides for production of steel having all the above-mentioned advantages. ln addition, the system may be modular comprising a number of units, thus the system may be designed and
redesigned depending on the needs of the steel producer.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 schematically illustrates an example of a system for producing steel according to
the method of the present disclosure.
Fig. 2 illustrates the method according to the present disclosure.
DETAILED DESCRIPTION The present disclosure relates to a method for producing steel.
Fig. 1 schematically illustrates an example of a system 100 for producing steel
according to the method of the present disclosure.The system 100 may be modular and comprises a number of different units which will be described more in detail below. The modularity of the system 100 may facilitate design and redesign of the system 100. The system 100 may be tailor-made for example depending on type and size of a feedstock being fed into the system. Standard conduits for liquids and gases may be used for connecting the different units
of the system 100 to each other.
The system 100 comprises at least one vessel 9 comprising an inlet 15 for iron ore, an inlet 17 for H2 and one inlet 18 for CO + H2 and an outlet 16 for produced steel with a
predetermined carbon content.
The system 100 may further comprise a water-gas-shift unit 7, a pressure swing adsorption (PSA) unit 8, at least one valve 14a, 14b and a control unit 10. The system may further comprise a cleaning unit 6, a heat recovery unit 4, a container for inorganic material 5, a gasification unit 2, a container for slug collection 3, an oxygen generator 12, a chopper/shredder unit 1, a container for collecting C02 11, and/or a
pump system
As illustrated in Fig. 1, the system may comprise a chopper/shredder unit 1 to which a feedstock, i.e. a raw material, is provided. The chopper/shredder unit 1 is arranged for chopping/shredding the feedstock into a desired size. The system may comprise a plurality of chopper/shredder units 1. The size and type of the chopper/shredder unit 1 chosen may depend on the size and type of feedstock the system is arranged to process. ln a further example, the feedstock is provided in a desired size and/or shape prior to entering the system 100 and a chopper/shredder unit 1 is not needed. ln such case, the feedstock may be directly fed into a gasification unit 2, which will be
described in detail below.
The feedstock may comprise waste, such as auto shredder residue, ASR, carbon fibre reinforced plastics, glass fibre reinforced plastics, sewage sludge and/or municipal solid waste, MSW. The feedstock may comprise other types of organic materials and/or inorganic materials, such as metals. Typically, the feedstock comprises a mix of organic and inorganic materials. ln one example, the feedstock comprises very large objects, such as wind blades from wind turbines and hulls from plastic boats. ln another example, the feedstock comprises parts from car interiors, such as car
upholstery, car dashboards and cablings.The system may comprise a gasification unit 2. The system 100 may further comprise a feeding unit (not shown) for feeding the feedstock into a gasification unit 2. The
feeding unit may for example be a screw arrangement.
The gasification unit 2 may comprise a pyrolysis zone and a plasma zone. The pyrolysis zone may be arranged for combusting of the feedstock in presence of a predetermined amount of oxygen. The oxygen may be provided from an oxygen generator 12. The oxygen generator 12 may comprise a pressure swing adsorption (PSA) unit and a compressor. The amount of oxygen provided may be controlled manually or automatically by means of a valve (not shown). The amount of oxygen provided and the temperature upon combustion may depend on the desired degree of combustion of the feedstock. The temperature upon combustion of the feedstock, i.e. in the pyrolysis zone, may be in the range of about 600 to 900 °C. The combusted feedstock, i.e. ash, may then be provided to the plasma zone of the gasification unit 2. The plasma zone of the gasification unit 2 may be heated to a temperature of at least 3000 °C. The plasma zone may comprise a light arc in which the formation into plasma of the combusted feedstock takes place. Due to the very high temperature, the chemical bonds of the compounds of the combusted feedstock are broken and the compounds may be decomposed into a plasma. 0xygen may be provided by the oxygen generator to the plasma zone in order to form CO of carbon being released upon the formation of plasma. The plasma formed in the gasification unit 2 comprises syngas. By providing pure oxygen instead of air, it is avoided that the resulting syngas
comprises unnecessarily high amounts nitrogen or nitrogen compounds.
Syngas, also known as synthesis gas, is a gas mixture comprising primarily of H2 and CO. Depending on the process in which the syngas is formed, such as the material of the feedstock and temperatures in the pyrolysis zone and the plasma zones of the gasification unit 2. The syngas may also comprise small amounts of other gases, such as H20, C02, N2 and CH4. As an example, cooled syngas may comprise about 5 % N2 and about 5 % C02. Before being cooled, the syngas may also comprise up to 25 % of H
Upon formation of the syngas, there may also be some residual materials formed in the gasification unit 2, such as inorganic materials, which is condensed before the gas is leaving the plasma zone or is not fully decomposed into plasma. These materials may be collected in a slag collection unit 3. The materials collected in the slag collection unit 3 are typically materials having a relatively high boiling point. Examples
of such materials are metals, such as copper (Cu), and silicon (Si). The materialscollected in the slag collection unit 3 may be recycled and reused in manufacturing
industry.
The system 100 may comprise more than one gasification unit 2 in order to ensure a
high utilization of material of the feedstock.
The system 100 may further comprise a heat recovery unit 4. The heat recovery unitis arranged to cool the syngas being formed in the gasification unit
ln the heat recovery unit 4, the syngas may be cooled by a working fluid, such as water. The working f|uid may be arranged to circu|ate in a closed system 19 by means of a pump system 13. The heating f|uid may be circulated to different units of the system 100, thereby heating and/or cooling different units of the system 100. ln one example (shown in Fig. 1), the closed system may be arranged to circu|ate the working liquid from the heat recovery unit 4 to a water-gas-shift unit 7, to a vessel 9 and back to the heat recovery unit 4. Typically, heat is generated in the recovery unitand/or in the water-gas-shift unit
As will be discussed more in detail below, heat generated in the heat recovery unit 4 and/or in the water-gas-shift unit 7 may be used to heat the vessel 9 upon reducing and carburizing. For example, the heat may be used for pre-heating of the iron ore in the vessel 9. Alternatively, the heat generated in the recovery unit 4 and/or in the
water-gas-shift unit 7 may be used for heating other arrangements.
Upon cooling of the syngas, condensed inorganic materials may be collected in a container 5. The materials collected in the container 5 is typically materials having a boiling point which is lower than the boiling point of the materials being collected in the slag collection unit 3. Examples of materials being collected in the container 5 is aluminum and cadmium. The materials collected in the container 5 may be recycled
and reused in manufacturing industry.
The system may further comprise a cleaning unit 6. The cleaning unit 6 is arranged for cleaning and purifying of the syngas. ln one example, the syngas may be led from the
heat recovery unit 4 to the cleaning unit 6 by means of a fan device (not shown).
The cleaning unit 6 may comprise filters and/or a cleaning liquid which is circulated in the cleaning unit 6 by means of a pump system. ln one example, the syngas is firstly led through one or more filters in order to purify the syngas from undesired
compounds. Secondly, the syngas is “showered” by the cleaning liquid. The cleaning
liquid may typically be water. ln this step, H20 and water-soluble compounds may beseparated from the syngas. The syngas may be repeatedly circulated within the
cleaning unit 6 until the syngas has reached a desired purity.
The system 100 may comprise a plurality of cleaning units 6 arranged after one another. ln one example, the plurality of cleaning units 6 may comprise different types of filters and/or cleaning liquids. The syngas resulting from the cleaning unit 6 typically comprises H2 and CO in the ratio of 1:1. ln addition, the syngas may comprise small
amounts of CO2, N2 and traces of CH
The syngas resulting from the cleaning unit 6 may, but need not, be compressed by a
compressor (not shown).
The system 100 may further comprise at least one valve 14a, 14b. ln one example, the at least one valve 14a may be arranged for controlling the amount of H2 and CO being divided into the first stream and at least one valve 14b is arranged for controlling
the amount of H2 and CO being divided into the second stream. ln one example, the at least one valve 14a, 14b is manually controlled by an operator.
ln yet an example, the system may comprise a control unit 10 which may be arranged
to control the at least one valve 14a, 14b automatically.
The control unit 10 may be arranged to control the at least one valve based on a predetermined carbon content of the steel. ln one example, the control unit 10 may be arranged to divide the main stream into 30 % to the second stream and the remaining 70 % to the first stream.
The main stream of syngas may have been formed in the gasification unit 2 and may, as described above, have been subject to cooling in the heat recovery unit 4 and/or cleaning in the cleaning unit 6. ln a first stream, H2 is removed from the stream and is fed to the vessel (9) for reducing said iron ore. The second stream comprising of CO
and H2 is fed to the vessel 9 for carburizing the predetermined mount of Fe.
The system 100 may further comprise a water-gas-shift unit 7, to which the first stream of CO and H2 (syngas) is fed. The water-gas-shift unit 7 is arranged for removing CO from the first stream. ln the water-gas-shift unit 7, water steam is provided, wherein CO from the syngas reacts with water, thereby forming CO2 and H2. The water-gas-shift unit 7 may be a commercial available water-gas-shift unit. As discussed above, the water-gas-shift unit 7 may generate heat which may be
arranged to heat the working liquid in the closed loopThe system 100 may further comprise a pressure swing adsorption, PSA, unit 8. Pressure swing adsorption is a well-known technique used to separate some gas species from a mixture of gases. ln the system 100, the pressure swing adsorption unit 8 is arranged for separating C02 and H2. The resulting H2 being separated by the
swing adsorption unit 8 has a high purity, typically in the range of 99.999 %.
The C02 being separated in the PSA unit 8 may preferably be liquefied and be stored in a sealed container 11. The separated C02 may be subject to carbon capture and utilization, CCU. CCU is a process where carbon dioxide is captured and is recyc|ed for further usage. The aim of CCU is to convert the captured carbon dioxide into e.g. plastics, concrete or biofue| in a controlled way, thereby preventing the C02 from reaching the atmosphere. Alternatively, the C02 may be subject to carbon capture and storage, CCS, wherein the C02 may be permanently stored in an underground
geo|ogica| formation, thereby preventing the C02 from reaching the atmosphere.
The system further comprises at least one vessel 9. The vessel 9 comprises an inlet for iron ore 15, an inlet for H2 17, and one inlet for C0 + H2 18 and an outlet for
produced steel 16 with a predetermined carbon content.
The vessel 9 is arranged for reducing iron ore (iron oxides) and for carburization of iron into steel. The vessel 9 may be a commercial available MlDREX® shaft furnace. lron ore is provided to an inlet 15, which typically is arranged at the top of the vessel 9. The iron ore descends downwards in the vessel 9 due to gravity wherein the iron ore is reduced to a predetermined amount of Fe and a predetermined amount of Fe is
carburized in order to produce steel.
As mentioned above, the resulting H2 being removed from the first stream is fed into the vessel 9 for reducing the iron ore. The H2 is fed to the vessel via the inlet 17. A second stream comprising C0 and H2 is fed to the vessel 9 for carburizing the predetermined mount of Fe. The second stream is fed to the vessel via inlet 18. Upon reducing the iron ore and carburizing the predetermined amount of Fe, the vessel 9 may be heated to a temperature of about 1500 °C. Details regarding the reduction of iron ore and carburization of Fe are discussed in detail with reference to the method below. As shown in Fig. 1, the resulting steel is output from the outlet 16, which
typically is arranged at the lower end of the vessel
As mentioned above, and being illustrated in Fig. 1, the heat circulating in a closed loop 19 from the heat recovery unit 4 and/or the water-gas-shift unit 7 may be used for
heating the vessel 9, upon the steps of reducing and carburizing. ln one example, the
working liquid in the closed loop 19 may be used for heating the vessel 9 prior to or
upon reducing the iron ore and/or carburizing of the Fe.
The system described above may be used for the method of producing steel
according to the present disclosure. Fig. 2 schematically i||ustrated the method according to the present disclosure.
The method for producing steel comprises a step of providing a predetermined amount of iron ore to a vessel 9. lron ores comprises rocks and minerals from which metallic iron may be extracted. The iron ore typically comprises different types of iron oxides, such as magnetite (Fe3O4), hematite (FezOs) and FeO (wüstite). By “predetermined amount” is meant the amount of iron ore from which it is desired to extract iron. ln the step of providing a predetermined amount of iron ore to a vessel also a predetermined amount of scrap iron may be provided to the vessel 9. By scrap
iron is meant for example parts of steel from scrapped vehicles.
The method further comprises a step of reducing said iron ore to a predetermined amount of Fe. ln the step of reducing the iron ore, oxygen is removed from the iron ore. By reduction is meant the gain of electrons or decrease in the oxidation state of an atom, an ion or of certain atoms in a molecule. As will be discussed more in detail below, H2 is used for reducing the iron ore in the method of the present disclosure. By “predetermined amount” is meant the amount of iron which is desired to be carburized
in order to produce steel.
The method further comprises a step of carburizing said predetermined amount of Fe in order to produce steel. By carburizing is meant that Fe or steel absorbs carbon while the Fe is heated in the presence of a high carbon content material. The reason for carburizing the iron is to provide steel with desired properties, such as a desired hardness of the steel. Thus, by controlling the carbon content in the resulting steel, the
hardness of the resulting steel is controlled.
The steps of reducing and carburizing is performed using a main stream of CO and
H2. The main stream of CO and H2 may be syngas.
The syngas may be extracted from waste, such as auto shredder residue, ASR, carbon fibre reinforced plastics, glass fibre reinforced plastics, sewage sludge, and/or municipal solid waste, MSW. The formation of syngas from waste was discussed in
detail above with reference to the system.The main stream of CO and H2 is divided into at least two streams. ln a first stream, H2 is removed from the stream and is fed to the vessel 9 for reducing said iron ore. A second stream is fed to the vessel 9 for carburizing the predetermined amount of Fe for producing steel with a predetermined amount of C. The ratio of CO to H2 is
typically 1:1 in the main stream as well as in the first and second streams.
As described with reference to the system above, the amount of the main stream of CO and H2 being divided into the at least two streams is controlled by the control unit 10. Alternatively, the amount of the main stream of CO and H2 being divided into the at least two streams is manually controlled by at least one valve 14a, 14b. The ratio of the first and the second stream is controlled based on the amount of carbon from the
CO needed in order to produce steel with a predetermined content of C.
The amount of the second stream being fed to the vessel may be controlled such that all carbon atoms from CO of the second stream are bonded to Fe atoms when carburizing the predetermined amount of Fe. lf there is an excess of CO and/or carbon atoms in the second stream not all of the carbon atoms may be bonded to Fe. Thus, an excess of CO may result in an undesired high carbon content of the steel
and/or formation of undesired CO2 in the vessel.
The amount of compressed H2 and CO (syngas) needed for reducing and carburizing 1000 kg of iron ore (Fe2O3) is in the range of 10-50 kg, depending on the amount of the desired carbon content in the resulting steel. ln one example, 25 kg H2 and CO
(syngas) results in a carbon content in the steel of about 1 %.
The remaining portion of the main stream may then be provided into the first stream. Alternatively, also the amount of the main stream being divided into the second stream is controlled. The amount of H2 and CO (syngas) in the first stream needs to be high enough to produce an amount of resulting H2 needed to reduce the carbon ore into a predetermined amount of Fe in the vessel. However, an excess of H2 in the vessel upon reducing of the iron ore as well as upon carburization does not affect the carbon content in the steel. Thus, an excess of H2 in the vessel does not adversely
affect the production of the steel.
ln a first stream, H2 is removed from the stream and is fed to the vessel 9 for reducing said iron ore. The H2 may be removed from the stream by means of a water-gas-shift unit as described with reference to the system above. The H2 may be removed
according to the following formula,
CO + H2O => H2 + COAs described above, the CO2 may be separated from the H2 by means of a pressure
swing adsorption unit, PSA unit, and may be collected in a sealed container.
The step of reducing the iron ore to a predetermined amount of Fe may take place
according to the following formulas,
3Fe2O3 + H2 => 2Fe3O4 + H2O Exothermic reaction
FesO4 + H2 => 3FeO + H2O, and Endothermic reaction
FeO + H2 => Fe + H20 Endothermic reaction
Thus, upon the step of reducing the iron ore, a predetermined amount of Fe is formed. As will be described more in detail below, the resulting predetermined amount of Fe is carburized in order to produce steel. As noted above, H2O formed during the reducing of iron ore. The H2O vaporizes due to the high temperature in the vessel. Typically the vaporized H2O is may be led out via a chimney (not shown) which is arranged on the
vessel. The heat from the vaporized H2O may also be recovered and used for heating
purposes.
The second stream is fed to the vessel for carburizing said predetermined amount of
Fe for producing steel with a predetermined content of C.
The amount of the second stream being fed to the vessel is controlled such that all carbon atoms from CO of the second stream are bonded to Fe atoms when carburizing said predetermined amount of Fe. As described above with reference to the system, the control of the amount of the main stream being divided into the first stream and the second stream may be performed by the control unit. An excess of CO may result in an undesired high C content in the steel and/or undesired formation of
CO2 in the vessel. The predetermined amount of Fe may be carburized according the following formula, 3Fe + CO + H2 => Fe3C + H2O.
The carbon content in the steel may be in the range of 0.0002 % to 10 %, preferably in the range of 0.002 % to 6.5 %, most preferably in the range of 0.02 to 2.5 %.
The amount of H2 and CO of the first and second stream, respectively, is determined depending on the desired properties of the resulting steel, such as the desired hardness of the resulting steel. The properties of the steel depends on the amount of
carbon bonded to the Fe atoms in the steel. An increased amount of CO provided tothe predetermined amount of Fe, thus results in an increased percentage of carbon in the steel. Typically, the amount of CO and H2 that is needed for the desired carbon content in the steel is provided for the carburizing (second stream) and then the remaining amount of CO and H2 is divided into the first stream in which the H2 is removed from the stream and fed to the vessel. The amount of CO needed in order to carburize the iron depends on the amount of iron ore provided to the vessel. ln one example, 70 % of the CO and H2 is provided in the first stream and 30 % of the CO and H2 is provided in the second stream. By this method, all carbon atoms in the steel
originates from CO.
Conventional method for production of steel for comparison
Production of steel typically results in formation of large amounts of carbon dioxide. The conventional reduction process of iron ore (iron oxides) typically takes place by carbon
monoxide from coke according to the following chemical reactions below:
3Fe2 Og + CO => 2Fe3O4 + CO2 Exothermic reaction
Fe3O4 + CO => 3FeO + CO2 Endothermic reaction
FeO + CO => Fe + CO2 Exothermic reaction Further, conventional carburization of iron takes place according to the following reaction: 3Fe + 2CO => FegC + CO2 Exothermic reaction
As seen above, carbon dioxide is formed during both the reduction and carburization steps
upon the conventional method for producing steel.
Claims (1)
- CLAIMS Method for producing steel (200), which comprises the steps of: providing (210) a predetermined amount of iron ore to a vesse| (9), reducing (220) said iron ore to a predetermined amount of Fe, carburizing (230) said predetermined amount of Fe in order to produce steel, wherein the steps of reducing and carburizing is performed using a main stream of CO and H2 being divided into at least two streams, wherein in a first stream H2 is removed from the stream and is fed to the vesse| (9) for reducing said iron ore, and a second stream comprising CO is fed to the vesse| (9) for carburizing said predetermined amount of Fe for producing steel with a predetermined content of C. _ The method (200) according to claim 1,wherein the amount of the second stream being fed to the vesse| is controlled such that all carbon atoms from CO of the second stream are bonded to Fe atoms when carburizing said predetermined amount of Fe. The method (200) according to claim any of the preceding claims, wherein the predetermined amount of Fe is carburized according the following formula, 3F6+CO+H2=>F63C+H2O, wherein carbon content in the steel is in the range of 0_0002 % to 10 %, preferably in the range of 0.002 % to 6.5 %, most preferably in the range of 0.02 to 2.5 %_ _ The method (200) according to any of the preceding claims, wherein the main stream of CO and H2 originates from syngas. The method (200) according to claim 4, wherein said syngas is extracted from waste, such as auto shredder residue, ASR, carbon fibre reinforced plastics, glass fibre reinforced plastics, sewage sludge, and/or municipal solid waste, MSW. _ The method (200) according to claim 5, wherein said syngas is formed by allowing the waste to be heated to a temperature of at least 3000 °C__ The method (200) according to claim 6, wherein heat generated at the formation of syngas is used upon the steps of reducing and carburizing, such as for heating the vessel prior to or upon reducing the iron ore and/or carburizing of the Fe. _ The method (200) according to claim any of claims 4 to 7, wherein the syngas is subject to at least one c|eaning step prior to forming the main stream of CO and H The method (200) according to any of the preceding claims, wherein the step of reducing the iron ore to a predetermined amount of Fe, takes place according to the following formulas, 3FG2Û3 + H2 => 2FG3Û4 + H2O, FG3Û4 + H2 => 3FGO + H2Û, and FeO + H2 => Fe + H The method (200) according to any of the preceding claims, wherein in the first stream the H2 is removed from the stream according to the following formula, CO + H2O => H2 + CO .The method (200) according to claim 10, further comprising a step of separating the CO2 and H2 and collecting the CO2 in a sealed container. 12.The method (200) according to any of the preceding claims, wherein in the step of providing (210) a predetermined amount of iron ore to a vessel (9) also a predetermined amount of scrap iron is provided to the vessel (9). 13.System (100) for producing steel comprising at least one vessel (9) comprising an inlet (15) for iron ore, an inlet for H2 (17) and one inlet for CO + H2 (18) and an outlet (16) for produced steel with a predetermined carbon content, wherein said system is arranged for producing steel according to the method of any of claims 1-12.
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US7854786B2 (en) * | 2006-01-31 | 2010-12-21 | Danieli & C. Officine Meccaniche S.P.A. | Reduction process and plant |
DE202021001452U1 (en) * | 2021-04-20 | 2021-05-26 | EAT Anlagenbau UG (haftungsbeschränkt) | Plant for the production of fluid fuels |
US20210246521A1 (en) * | 2018-06-12 | 2021-08-12 | Primetals Technologies Austria GmbH | Method for Carburization of HDRI produced in H2 based Direct Reduction Process |
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GB2112019A (en) | 1981-12-18 | 1983-07-13 | British Steel Corp | Reduction of agglomerated iron ore |
US10316376B2 (en) * | 2015-06-24 | 2019-06-11 | Midrex Technologies, Inc. | Methods and systems for increasing the carbon content of sponge iron in a reduction furnace |
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US7854786B2 (en) * | 2006-01-31 | 2010-12-21 | Danieli & C. Officine Meccaniche S.P.A. | Reduction process and plant |
US20210246521A1 (en) * | 2018-06-12 | 2021-08-12 | Primetals Technologies Austria GmbH | Method for Carburization of HDRI produced in H2 based Direct Reduction Process |
DE202021001452U1 (en) * | 2021-04-20 | 2021-05-26 | EAT Anlagenbau UG (haftungsbeschränkt) | Plant for the production of fluid fuels |
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