US20010052273A1 - Iron production method of operation in a rotary hearth furnace and improved furnace apparatus - Google Patents
Iron production method of operation in a rotary hearth furnace and improved furnace apparatus Download PDFInfo
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- US20010052273A1 US20010052273A1 US09/266,989 US26698999A US2001052273A1 US 20010052273 A1 US20010052273 A1 US 20010052273A1 US 26698999 A US26698999 A US 26698999A US 2001052273 A1 US2001052273 A1 US 2001052273A1
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/10—Making spongy iron or liquid steel, by direct processes in hearth-type furnaces
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/10—Making spongy iron or liquid steel, by direct processes in hearth-type furnaces
- C21B13/105—Rotary hearth-type furnaces
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- 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
The present invention is an apparatus and method for the direct reduction of iron oxide utilizing a rotary hearth furnace to form a high purity carbon-containing iron metal button. The hearth layer may be a refractory or a vitreous hearth layer of iron oxide, carbon, and silica compounds. Additionally, coating materials may be introduced onto the refractory or vitreous hearth layer before iron oxide ore and carbon materials are added, with the coating materials preventing attack of the molten iron on the hearth layer. The coating materials may include compounds of carbon, iron oxide, silicon oxide, magnesium oxide, and/or aluminum oxide. The coating materials may be placed as a solid or a slurry on the hearth layer and heated, which provides a protective layer onto which the iron oxide ores and carbon materials are placed. The iron oxide is reduced and forms molten globules of high purity iron and residual carbon, which remain separate from the hearth layer. An improved apparatus includes a cooling plate that is placed in close proximity with the refractory or vitreous hearth layer, cooling the molten globules to form iron metal buttons that are removed from the hearth layer. The improvements due to the present apparatus and method of operation provide high purity iron and carbon solid buttons, which are separate from slag particulates, and discharged without significant loss of iron product to the interior surfaces of the furnace.
Description
- This application claims the benefit of U.S. Provisional Application No. 60/108,045, filed on Nov. 12, 1998.
- This invention relates to an apparatus and method for operation of an ore processing furnace for improved processing of iron oxide reduction. More particularly, this invention relates to the method of operation of a furnace for production of high purity iron and an improved furnace apparatus for iron reduction.
- In 1987, Midrex received U.S. Pat. No. 4,701,214, that taught reduction in a rotary hearth furnace and a method of operation which required less energy and a smaller smelting furnace by introducing reductant gases and fuel into the rotary hearth furnace.
- All major steelmaking processes require the input of iron bearing materials as process feedstocks. For a steelmaking method utilizing a basic oxygen furnace, the iron bearing materials are usually blast furnace hot metal and steel scrap. A broadly used iron source is a product known as Direct Reduced Iron (“DRI”) which is produced by the solid state reduction of iron ore without the formation of liquid iron. DRI and/or steal scrap are also used for steelmaking utilizing the electric arc furnace.
- Improvements are sought within the industry for furnace modifications and improved methods of operation that provide for efficient production of high purity iron with low carbon (<5%) material in which iron oxides are efficiently reduced into purified iron on a hearth surface while slag components are separated from purified iron at increased temperatures.
- In 1998, Midrex International received U.S. Pat. No. 5,730,775, that teaches an improved method known by the trade name or trademark of FASTMET™, and apparatus for producing direct reduced iron from dry iron oxide and carbon compacts that are layered no more than two layers deep onto a rotary hearth, and are metallized by heating the compacts to temperatures of approximately 1316° to 1427° C., for a short time period. For a general understanding of the recent art, U.S. Pat. No. 5,730,775 is herein incorporated by reference.
- In the direct reduction of iron oxide in furnaces, this invention improves the utilization of a rotary hearth furnace using a method for producing high purity iron product from iron oxide feed material containing carbon compounds, including the steps of providing a rotary hearth furnace having a hearth layer which consists of a refractory layer or a vitreous hearth layer formed by placing iron oxide, carbon, and silica compounds on the sub-hearth layer; heating the iron oxide, carbon, and silica compounds forming a vitreous hearth layer; placing coating materials on the hearth surface to form a coated hearth layer; feeding iron oxide material into the furnace and onto the coated hearth layer; heating the iron oxide material on the coated hearth layer; reducing the iron oxide materials on the coated hearth layer; forming liquid iron and carbon globules on the coated hearth layer, with separated slag materials; cooling the iron and carbon globules with a cooling surface, creating a solid button of iron and carbon product; and discharging iron and carbon product and slag material from the furnace. An improved apparatus includes a rotary hearth furnace having a cooling plate that is placed in close proximity with the hearth layer or refractory surface, the cooling plate cools the iron globules to form solid high purity iron and low carbon buttons that are removed from the vitreous hearth layer. The improvements due to the present apparatus and method of operation are providing high purity iron and low carbon buttons which are separated from the slag particulates, discharging the buttons from the furnace without significant loss of high purity iron in the hearth furnace, and generating iron buttons with iron content of approximately 95% or greater, and carbon content of approximately 5% or less in the discharged buttons of iron material.
- The principal object of the present invention is to provide a method of achieving efficient production of high purity iron having concentrations of carbon of 1% to 5% therein at elevated temperatures in a rotary hearth furnace with separation of slag components from the purified iron on the hearth surface at high temperatures.
- Another object of the invention is to provide a method of achieving efficient reduction of iron oxide at elevated temperatures in a processing and reducing furnace.
- An additional object of the invention is to provide an improved furnace apparatus for providing high purity iron and cooling the high purity iron on the hearth layer surface to facilitate separation of slag components within the furnace.
- The objects of the invention are met by a method for producing direct reduced purified iron at elevated temperatures within a furnace, including the step of providing a rotary hearth furnace having a sub-hearth layer, and introducing conditioning materials of iron oxide, carbon, and silica compounds with heating of conditioning materials to form a vitreous layer onto which agglomerates of iron oxide containing carbon are placed. The step of heating the conditioning materials proceeds the step of reducing by heating the agglomerated iron oxide and carbon, at a specified temperature, and reducing the iron oxide. The molten globules of purified iron are separated from slag components on the hearth layer surface within the furnace. A cooling step follows the separating step, where globules of purified iron are cooled within the furnace by placing a cooling apparatus in close proximity to the hearth layer, with the resulting step of solidification of purified iron within the furnace, and the remaining step of discharging the purified iron from the furnace free of solidified slag, which may be discharged separately from the furnace.
- The objects of the invention are also met by an apparatus for producing direct reduced iron at elevated temperatures within a rotary hearth furnace having a non-reactive hearth surface made by the placement of coating materials and agglomerates of iron oxide and carbon onto the surface of the hearth layer. The hearth layer may include a vitreous layer of iron oxide and silica compounds formed before the agglomerates of iron oxide and carbon are placed onto the vitreous or the refractory layer. The coating materials and agglomerates of iron oxide and carbon are heated to a specified temperature. The iron oxide is reduced followed by separation into globules of purified iron from the slag components and coating materials on the hearth layer. The purified iron is solidified by passage of the liquid iron globules in close proximity to a means for cooling above the hearth layer consisting of exposure to cooled apparatus placed close to the hearth layer or refractory surface. After passage past the means for cooling on the hearth layer or refractory surface, the purified and solidified iron and low carbon buttons are removed from the hearth layer for collection outside of the rotary hearth furnace separate from slag particulates formed within the furnace.
- The foregoing and other objects will become more readily apparent by referring to the following detailed description and the appended drawings in which:
- FIG. 1 is a top view of a rotary hearth furnace for the reduction of iron oxide and production of molten iron globules that utilizes a hearth layer surface and a means for cooling purified iron and low carbon globules within the furnace;
- FIG. 2 is a top view of the spray introduction of coating material onto a hearth surface, forming a coated hearth layer, with iron oxide and carbon agglomerates placed on the coated hearth layer, specific to the present invention;
- FIG. 3 is a top view of a solid placement of coating material onto a hearth layer surface, forming a coated hearth layer, with iron oxide and carbon agglomerates placed on the coated hearth layer, specific to the present invention;
- FIG. 4 is an isometric view of a plurality of coating materials sprayed onto and forming a coated hearth layer surface, onto which iron oxide and carbon agglomerates are placed and leveled, specific to the present invention;
- FIG. 5 is an isometric view of a plurality of solid coating materials containing a plurality of layers placed onto and forming a coated surface, onto which iron oxide and carbon agglomerates are placed and leveled, specific to the present invention;
- FIG. 6 is an isometric side view of the liquid purified iron and low carbon globules on the hearth layer surface, separate from slag particles, specific to the present invention;
- FIG. 7 is an isometric side view of a means for cooling the liquid purified iron and low carbon globules, with the means for cooling placed in close proximity to the hearth layer surface, specific to the present invention; and
- FIG. 8 is an isometric view of a discharge mechanism for removing purified iron and low carbon buttons from the hearth layer surface, specific to the present invention.
- Referring now to the drawings, and more particularly to FIG. 1, a
direct reduction furnace 10 is utilized for reducing iron oxide feed material. The furnace, such as a rotary hearth furnace (RHF) 10 has dimensions of a typical hearth furnace utilized in the iron production industry with an active hearth width of approximately 1 m to approximately 7 m width, or wider. The RHF 10 has a refractory layer surface or vitreoushearth layer surface 30 that is rotatable from afeed material zone 12, through approximately two or threeburner zones reaction zone 17 and discharge zone 18 (see FIG. 1). The refractory layer surface or vitreoushearth layer surface 30 is rotatable in a repetitive manner from thedischarge zone 18 to thefeed material zone 12, and through thezones burner zones burners - The
feed material zone 12 includes anopening 24 and afeed mechanism 26 by which iron oxide andcarbon agglomerates 28, also called iron oxide “greenballs”, are charged. An initial layer of iron oxide, carbon materials, and silica (silicon oxide), may be placed on the refractory sub-hearth to form avitreous layer 30 on which theiron oxide agglomerates 28 are placed. Coatingmaterials 36 placed on the refractory layer surface or vitreoushearth layer surface 30 may include iron oxide compounds, silica compounds, and carbon compounds. The materials may be placed byspray injector 32, or bysolid material conveyor 34. Theagglomerates 28 are leveled to a preferred height above the refractory surface orhearth layer surface 30 by aleveler 29 that spans the width of thesurface 30. Theagglomerates 28 are continuously fed to theRHF 10 by thefeed mechanism 26, as thesurface 30 is rotated around theRHF 10, by a variable speed drive (not shown). Therefore the iron agglomerate retention time within theRHF 10, and within eachzone - Located in the area of the
feed material zone 12, and upstream of thefeed mechanism 26 fromfeed hopper 27 foragglomerates 28, is a means for introducing 32, 34coating materials 36 such as coal powder, silica, iron oxide compounds, graphite, and fines generated from raw iron oxide materials. At least one solid material conveyor 34 (FIGS. 3) may introduce thesecoating materials 36, andadditional coating compounds 38 in a separate layer onto the refractory layer surface or vitreoushearth layer surface 30. If thematerials materials spray injector 32. Theinjector 32 may be cooled internally to allow introduction of the coating materials as fine particulates in a liquid spray for application on the surface 30 (FIGS. 2). If thematerials RHF 10 without the liquid carrier, theconveyor 34 places thecoating materials 36, andadditional coating materials 38 as close to, and across the width of, the refractory layer or vitreous hearth layer 30 (FIGS. 3). - The
coating materials 36, may include iron oxide compounds, silica compounds, and carbon compounds. Theadditional coating compounds 38 may include any of the following compounds: iron oxide, silica, magnesium oxide (MgO), aluminum oxide (Al2O3) , and silicon oxide (SiO2), particulates generated from iron oxides reduction and melting, and carbonaceous materials. Thecoating materials 36, and compounds 38 may have a variable material size of less than 10 mm, or preferably approximately 1 mm, or less. The bulk density ofcoating materials coating materials - The refractory layer surface or vitreous
hearth layer surface 30 of the RHF, with thecoating materials 36, and compounds 38 introduced onto thesurface 30, may be heat treated at temperatures with hearth temperatures of approximately 1500° C. to approximately 1600° C. The preferred hearth temperature is approximately 1530° to approximately 1550° C. After rotation through theheating zones coating materials plate 48 having cooling liquid flowing internally, with theplate 48 positioned before thedischarge zone 18. Theplate 48 is in close proximity and spanning the width of thesurface 30, to provide a zone of cooler temperatures near thesurface 30. - The preferred combustion temperature in zone17 (see FIG. 1), is approximately 1450° C. to approximately 1600° C. The iron oxide and carbon agglomerates 28 may be maintained at a temperature range of approximately 1400° C. to approximately 1500° C. The preferred temperature to maintain the iron oxide agglomerates 28 is approximately 1410° C. to approximately 1480° C.
- The means for heating the
surface 30, andcoating materials 36, andadditional compounds 38 thereon, may include either fuel burners or other devices for heating aRHF 10, located in the furnace enclosure of theburner zones - After the
coating materials 36 and/orcoating compounds 38 are introduced onsurface 30, the placement of iron oxide andcarbon agglomerates 28 and carbon onto the upper layers ofsurface carbon agglomerates 28 and other feed materials byfeed mechanism 26, or other standard continuous or intermittent belt, or spiral conveyor of agglomerate sized materials (FIG. 1). - The iron oxide and
carbon agglomerates 28 are heated and moved from thefirst zone 14, to asecond zone 16, or a third zone if needed (not shown), on therotatable layer 30. The reducing of iron oxide agglomerates 28 occurs in theburner zones device 48, at temperatures as specified above. During the reducing phase, thecoating materials hearth layer 30. The coating compounds 38 provide a barrier to the highly reactive and purified liquid iron released by the iron oxide agglomerates 28, forcing the liquid iron to remain on the coated layer of thehearth layer 30. - The optimal intermediate phase of molten metal that is created in the method of operation of a RHF is the formation of
liquid globules 41 of molten metal carbon and iron having approximately 95% iron and approximately 5% carbon in solution. The preferred intermediate phase of molten metal carbon and iron is approximately 95.5% to 97.5% iron and approximately 2.5% to 4.5% carbon inliquid globules 41 on thehearth surface 30. - A specific benefit of the coating compounds38 introduced onto the
surface 30, includes the creation of physically separatedliquid globules 41 of iron/carbon, formed as the iron oxide andcarbon agglomerates 28 reduce, melt and separate into iron/carbon globules 41 and separate slag and gangue regimes (not shown). The iron/carbon globules 41 form within theagglomerates 28 or outside the agglomerates on thehearth layer surface 30, and form molten purified iron/carbon globules 41 withinburner zones reaction zone 17. Themolten globules 41 of iron/carbon remain isolated from the slag and gangue regimes on thehearth layer surface 30, and theglobules 41 are not absorbed into thehearth layer surface 30 due to prior coating of thesurface 30. Therefore, solidifiedbuttons 42 of highly purified solid iron product (greater than 95% iron), may be recovered from thedischarge zone 18, without contamination by other gangue particulate or slag materials on thehearth surface 30, or on other interior surfaces of theRHF 10. - The coated layer of
materials 36, andcoating compounds 38 may be rejuvenated by the periodic or continuous introduction ofadditional coating materials RHF 10 when themolten iron buttons 42 are discharged, and before the iron oxide andcarbon agglomerates 28 are placed onto thehearth layer surface 30. - Reduced and purified iron material in the form of
iron buttons 42 containing low concentrations of carbon are removed from thedischarge zone 18 by a means for removing materials from a rotatable surface by a standard discharge mechanism, such as adischarge conveyor 50, such as a continuous or intermittent belt, screw, or spiral conveyor, located above the surface 30 (FIG. 8). The purifiediron metal buttons 42, after separation by cooling from residual slag, is of a higher purity and a higher carbon content than that produced by prior hearth furnace technologies such as FASTMET™. - In an alternative operation of the
RHF 10, a vitreous iron oxide andsilica layer 36, andconditioning material layer 38 may have been previously formed ashearth layer 30. The vitreous iron oxide andsilica hearth layer 30 assists with inhibiting the attack of the iron globules 41 on the hearth layer. - In an alternative embodiment,
coating materials 38 such as iron oxide, silica, magnesium oxide (MgO), aluminum oxide (Al2O3), and silicon oxide (SiO2), coal powder, and carbon particulates generated from iron oxides reduction and melting, may be added to thesurface 30. After rotation through theheating zones plate 48 having cooling liquid flowing internally, with theplate 48 positioned before thedischarge zone 18. Theplate 48 is in close proximity and spanning the width of thehearth layer surface 30, to provide a zone of cooler temperatures near the surface of the hearth layer. - In another alternate embodiment,
carbonaceous coating material 38, may be placed on thehearth layer surface 30 to form a separate carbon layer (not shown). Thecarbonaceous material 38 serves as a non-reactive sacrificial carbon layer which promotes formation of molten iron globules 41 (see FIG. 6), and solidifiediron buttons 42 without theglobules 41 or thebuttons 42 attacking into thehearth layer 30. By keeping theglobules 41 or thebuttons 42 separated from the slag particulates and thehearth layer 30, high purity iron of approximately 95% content, and residual carbon of approximately 5% may be produced. - From the foregoing, it is readily apparent that we have invented an apparatus and method of operation for efficiently producing increased volumes and a higher purity of solid iron and low carbon product from rotary hearth furnaces without significant increases in costs, processing time, or excessive furnace temperatures. The invention achieves significantly higher quality of purified solid iron and low carbon product by adding the specified coating materials to form either a
protective hearth layer 30 of iron oxide, silica, aluminum, MgO or silicate compounds, and/or carbon compounds on thehearth layer surface 30. The layers of materials of varyingcompositions - The observed improvements due to the described invention are due to the conditions that at normal furnace temperatures the coating materials may form a
protective layer 38 attached onto or on a refractory orvitreous layer 30, thereby preventing the purified solid iron and low carbon product from coating the surface of the refractory layer orvitreous hearth layer 30. Such a coating or bonding condition makes it difficult to remove or discharge the purified solid iron and low carbon product from the furnace. The present invention, as claimed below, solves this problem of loss of purified iron and low carbon product within theRHF 10. - The invention has been described in detail, with reference to certain preferred embodiments, in order to enable the reader to practice the invention without undue experimentation. It is to be understood that the foregoing description and specific embodiments are merely illustrative of modes of the invention and the principles thereof, and that various modifications and additions may be made to the apparatus by those skilled in the art, without departing from the spirit and scope of this invention.
Claims (34)
1. A method for producing solid iron and carbon product from iron oxide material containing carbon compounds, comprising the steps of:
(a) providing a rotary hearth furnace, having a hearth layer surface;
(b) feeding iron oxide and carbon materials onto said hearth layer surface;
(c) heating said iron oxide and carbon materials;
(d) reducing said iron oxide and carbon materials;
(e) forming liquid iron and carbon globules and slag particulates on said hearth layer surface, said globules separating from said slag particulates;
(f) cooling said liquid iron and carbon globules with a cooling surface, creating solid iron and carbon buttons;
(g) discharging solid iron and carbon buttons from said furnace; and
(h) removing slag particulates from said furnace.
2. The method of , wherein said step of providing a rotary hearth furnace further comprises applying iron oxide, carbon, and silica compounds to said hearth layer surface, forming a vitreous layer on said hearth layer surface.
claim 1
3. The method of , wherein said step of providing a rotary hearth furnace further comprises introducing coating materials on said hearth layer surface, said coating materials selected from the group consisting essentially of magnesium oxide compounds, silicon oxide compounds, aluminum oxide compounds, iron oxide compounds, and carbon compounds.
claim 1
4. The method of wherein said heating step further comprise heating said iron oxide and carbon materials with a plurality of radiant heat sources at temperatures of at least 1450° C. to about 1600° C. inside said furnace.
claim 1
5. The method of wherein said reducing step further comprises reducing said iron oxide and carbon materials with a plurality of radiant heat sources at temperatures of at least 1450° C. to about 1540° C. inside said furnace.
claim 1
6. The method of wherein said reducing step further comprises heating said materials with a plurality of radiant heat sources at temperatures of at least 1400° C. to about 1500° C. at said hearth layer surface.
claim 1
7. The method of wherein said reducing step further comprises heating said iron oxide and carbon materials with a plurality of radiant heat sources at temperatures of at least 1410° C. to about 1480° C. at said hearth layer surface.
claim 1
8. The method of wherein said feeding step further comprises introducing said iron oxide and carbon materials onto said vitreous layer having iron oxide, carbon, and silica compounds.
claim 2
9. The method of wherein said cooling step further comprises providing a cooling surface near said hearth layer surface, said surface cooling said liquid iron and carbon globules, creating a solid button of iron and carbon on said hearth surface before said discharging step.
claim 1
10. An apparatus for direct reduction of iron oxide material to a solid iron and carbon product, comprising:
(a) a furnace, said furnace having an interior hearth layer of refractory material;
(b) means for introducing a mixture of coating materials onto said hearth layer;
(c) means for placing iron oxide and carbon materials onto said hearth layer or said refractory layer;
(d) means for heating said hearth layer, said coating materials, and said iron oxide and carbon materials;
(e) means for reducing said iron oxide and carbon materials with the formation of liquid iron and carbon globules and slag particulates, said globules separate from said slag particulates;
(f) means for cooling said liquid iron and carbon globules on said hearth layer with the formation of a solid iron and carbon button;
(g) means for removing said solid iron and carbon button from said furnace; and
(h) means for removing said slag particulates from said furnace.
11. The apparatus of wherein the furnace is a rotary hearth furnace having a rotatable hearth surface.
claim 10
12. The apparatus of , wherein said hearth layer of refractory material further comprising a vitreous layer of iron oxide and silica compounds, said vitreous layer is placed on said layer of refractory material before said introducing means introduces said coating materials onto said hearth layer.
claim 11
13. The apparatus of wherein said means for introducing said mixture of coating material comprises a particle movement conveyor, said conveyor having the capability to introduce said coating material onto said hearth layer.
claim 10
14. The apparatus of wherein said mixture of coating materials comprises a material selected from the group consisting essentially of iron oxide compounds, silicate compounds, magnesium oxide compounds, silicon oxide compounds, aluminum oxide compounds, and carbon compounds.
claim 10
15. The apparatus of , wherein said mixture of coating materials further comprises another layer of carbonaceous material, said carbonaceous material and said mixture of coating material introduced by said introducing means into said hearth layer.
claim 13
16. The apparatus of , wherein said mixture of coating material further comprises a carbonaceous material, said carbonaceous material introduced by said introducing means onto said hearth layer before said iron oxide and carbon materials are placed onto said hearth layer.
claim 13
17. The apparatus of , wherein said means for placing said iron oxide and carbon materials comprises a conveyor, said iron oxide and carbon materials are positionable by said conveyor onto said hearth layer.
claim 10
18. The apparatus of , wherein said means for heating comprises a plurality of radiant heat sources providing heat at a temperature range of at least 1450° C. to about 1600° C., said radiant heat sources maintaining said hearth layer within said temperature range.
claim 10
19. The apparatus of , wherein said means for heating further comprises a plurality of radiant heat sources providing heat at a temperature range of at least 1400° C. to about 1600° C. at said hearth layer inside said furnace.
claim 10
20. The apparatus of , wherein said means for heating further comprises a plurality of radiant heat sources at temperatures of at least 1450° C. to about 1530° C. at said hearth layer inside said furnace.
claim 10
21. The apparatus of , wherein said means for cooling said liquid iron and carbon globules on said hearth layer further comprises a cooling surface in close proximity to said hearth layer surface, said cooling surface including a cooling plate extended over said hearth layer.
claim 10
22. The apparatus of , wherein said means for removing solid iron and carbon buttons comprises a discharge mechanism, said discharge mechanism including a conveyor to accept said solid iron and carbon buttons from said furnace.
claim 10
23. A method for producing solid iron and carbon product from iron oxide material containing carbon compounds, comprising the steps of:
(a) providing a furnace, said furnace providing a sub-hearth layer surface;
(b) introducing conditioning materials including iron oxide compounds, carbon compounds, and silica compounds onto said sub-hearth layer surface;
(c) heating said conditioning materials, forming a vitreous layer including at least iron oxide and silica compounds;
(d) placing iron oxide and carbon materials on said vitreous layer;
(e) reducing said iron oxide and carbon materials by heating;
(f) forming liquid iron and carbon globules and slag particulates on said vitreous layer, with separating of said slag particulates on said vitreous layer;
(g) cooling said liquid iron and carbon globules, forming solid iron and carbon buttons on said vitreous layer;
(h) discharging said solid iron and carbon buttons from said furnace; and
(i) removing said slag particulates from said furnace.
24. The method of , wherein said providing step further comprises providing a rotary hearth furnace having a rotatable hearth surface.
claim 23
25. The method of , wherein said step of introducing conditioning materials further comprises providing additional conditioning materials selected from the group consisting essentially of magnesium oxide compounds, silicon oxide compounds, aluminum oxide compounds, iron oxide compounds, and carbonaceous compounds.
claim 23
26. The method of , wherein said heating step further comprises heating said coating materials with a plurality of radiant heat sources providing heat at a temperature range of at least 1450° C. to about 1600° C.
claim 23
27. The method of , wherein said reducing step further comprises exposing said iron oxide and carbon materials to a plurality of radiant heat source providing heat at a temperature range of at least 1410° C. to about 1480° C. inside said furnace.
claim 23
28. The method of , wherein said cooling step of said liquid iron and carbon globules further comprises providing a cooling surface near said vitreous layer, said cooling step cooling said liquid iron and carbon globules, creating iron and carbon solid buttons on said vitreous layer.
claim 23
29. A method for producing iron product from iron oxide material containing carbon compounds, comprising the steps of:
(a) providing a furnace, said furnace providing a sub-hearth layer surface;
(b) introducing iron oxide compounds, carbon compounds, and silica compounds onto said sub-hearth layer surface;
(c) heating said compounds, forming a vitreous hearth layer including at least iron oxide and silica compounds;
(d) placing coating materials on said vitreous hearth layer, forming a coated vitreous hearth layer;
(e) placing said iron oxide and carbon materials on said coated vitreous hearth layer;
(f) reducing said iron oxide and carbon materials on said coated vitreous hearth layer;
(g) forming liquid iron and carbon globules, and slag particles on said coated vitreous hearth layer;
(h) cooling said liquid iron and carbon globules, forming solid iron and carbon buttons on said coated vitreous hearth layer separate from said slag particles;
(i) discharging said solid iron and carbon buttons from said furnace; and
(j) removing said slag particles from said furnace.
30. The method of , wherein said providing step further comprises providing a rotary hearth furnace having a rotatable hearth surface.
claim 29
31. The method of , wherein said step of placing coating materials further comprises selecting said coating materials from the group consisting essentially of magnesium oxide compounds, silicon oxide compounds, aluminum oxide compounds, carbonaceous compounds, and iron oxide compounds.
claim 29
32. The method of , wherein said heating step further comprises heating said compounds with a plurality of radiant heat sources providing heat at a temperature range of at least 1450° C. to about 1600° C.
claim 29
33. The method of , wherein said reducing step further comprises exposing said iron oxide and carbon material to a plurality of radiant heat source providing heat at a temperature range of at least 1410° C. to about 1480° C. inside said furnace.
claim 29
34. The method of , wherein said cooling step of said liquid iron and carbon globules further comprises providing a surface near said vitreous hearth surface, said surface cooling said liquid iron and carbon globules, creating solid iron and carbon buttons on said coated vitreous hearth layer before said discharging step.
claim 29
Priority Applications (19)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/266,989 US6413295B2 (en) | 1998-11-12 | 1999-03-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
ARP990105750A AR021245A1 (en) | 1998-11-12 | 1999-11-11 | METHOD OF OPERATION OF A ROTATING SOLAR OVEN FOR THE PRODUCTION OF IRON AND IMPROVED OVEN APPLIANCE |
PE1999001141A PE20001247A1 (en) | 1998-11-12 | 1999-11-11 | METHOD OF OPERATION OF A ROTATING SOLERA OVEN FOR THE PRODUCTION OF IRON AND IMPROVED OVEN APPARATUS |
KR10-2001-7005975A KR100417201B1 (en) | 1998-11-12 | 1999-11-12 | The method for the production of solid iron and carbon product, or iron product, and the apparatus for effectuating same |
PL99348435A PL194677B1 (en) | 1998-11-12 | 1999-11-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
ES99957306T ES2199599T3 (en) | 1998-11-12 | 1999-11-12 | PROCEDURE OF IRON PRODUCTION IN A ROTATING SOLAR OVEN AND IMPROVED OVEN. |
PCT/EP1999/008726 WO2000029628A1 (en) | 1998-11-12 | 1999-11-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
SK611-2001A SK6112001A3 (en) | 1998-11-12 | 1999-11-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
HU0105164A HUP0105164A3 (en) | 1998-11-12 | 1999-11-12 | Iron production method in a rotary hearth furnace and furnace for the method |
DE69908176T DE69908176T2 (en) | 1998-11-12 | 1999-11-12 | PRODUCTION OF IRON IN A ROTATING STOVE AND IMPROVED OVEN |
IDW00200101048A ID28563A (en) | 1998-11-12 | 1999-11-12 | METHOD OF OPERATION OF IRON PRODUCTION IN A SPINNING FIRE KITCHEN AND LIGHTWEIGHT RADAS |
CZ20011580A CZ20011580A3 (en) | 1998-11-12 | 1999-11-12 | Process for producing iron within a rotary hearth furnace and enhanced furnace equipment |
AT99957306T ATE241020T1 (en) | 1998-11-12 | 1999-11-12 | PRODUCTION OF IRON IN A ROTARY HEART FURNACE AND IMPROVED FURNACE |
EP99957306A EP1137817B1 (en) | 1998-11-12 | 1999-11-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
AU15058/00A AU760611B2 (en) | 1998-11-12 | 1999-11-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
CNB998131180A CN1289693C (en) | 1998-11-12 | 1999-11-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
CA002348940A CA2348940C (en) | 1998-11-12 | 1999-11-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
BRPI9916605-4A BR9916605B1 (en) | 1998-11-12 | 1999-11-12 | Method for producing a solid iron and carbon product and apparatus for a method of direct reduction of iron oxide material. |
JP32329099A JP4231960B2 (en) | 1998-11-12 | 1999-11-12 | Method and apparatus for producing carbon-containing iron using hearth rotary furnace |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US10804598P | 1998-11-12 | 1998-11-12 | |
US09/266,989 US6413295B2 (en) | 1998-11-12 | 1999-03-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
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US20010052273A1 true US20010052273A1 (en) | 2001-12-20 |
US6413295B2 US6413295B2 (en) | 2002-07-02 |
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US09/266,989 Expired - Lifetime US6413295B2 (en) | 1998-11-12 | 1999-03-12 | Iron production method of operation in a rotary hearth furnace and improved furnace apparatus |
Country Status (19)
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US (1) | US6413295B2 (en) |
EP (1) | EP1137817B1 (en) |
JP (1) | JP4231960B2 (en) |
KR (1) | KR100417201B1 (en) |
CN (1) | CN1289693C (en) |
AR (1) | AR021245A1 (en) |
AT (1) | ATE241020T1 (en) |
AU (1) | AU760611B2 (en) |
BR (1) | BR9916605B1 (en) |
CA (1) | CA2348940C (en) |
CZ (1) | CZ20011580A3 (en) |
DE (1) | DE69908176T2 (en) |
ES (1) | ES2199599T3 (en) |
HU (1) | HUP0105164A3 (en) |
ID (1) | ID28563A (en) |
PE (1) | PE20001247A1 (en) |
PL (1) | PL194677B1 (en) |
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- 1999-03-12 US US09/266,989 patent/US6413295B2/en not_active Expired - Lifetime
- 1999-11-11 PE PE1999001141A patent/PE20001247A1/en not_active Application Discontinuation
- 1999-11-11 AR ARP990105750A patent/AR021245A1/en unknown
- 1999-11-12 AU AU15058/00A patent/AU760611B2/en not_active Ceased
- 1999-11-12 ES ES99957306T patent/ES2199599T3/en not_active Expired - Lifetime
- 1999-11-12 SK SK611-2001A patent/SK6112001A3/en unknown
- 1999-11-12 CZ CZ20011580A patent/CZ20011580A3/en unknown
- 1999-11-12 DE DE69908176T patent/DE69908176T2/en not_active Expired - Lifetime
- 1999-11-12 CN CNB998131180A patent/CN1289693C/en not_active Expired - Fee Related
- 1999-11-12 WO PCT/EP1999/008726 patent/WO2000029628A1/en active IP Right Grant
- 1999-11-12 KR KR10-2001-7005975A patent/KR100417201B1/en not_active IP Right Cessation
- 1999-11-12 BR BRPI9916605-4A patent/BR9916605B1/en not_active IP Right Cessation
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- 1999-11-12 AT AT99957306T patent/ATE241020T1/en not_active IP Right Cessation
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Also Published As
Publication number | Publication date |
---|---|
BR9916605A (en) | 2001-08-14 |
DE69908176T2 (en) | 2004-03-18 |
EP1137817B1 (en) | 2003-05-21 |
JP4231960B2 (en) | 2009-03-04 |
DE69908176D1 (en) | 2003-06-26 |
WO2000029628A1 (en) | 2000-05-25 |
CN1289693C (en) | 2006-12-13 |
CZ20011580A3 (en) | 2002-03-13 |
PE20001247A1 (en) | 2000-12-05 |
CN1325459A (en) | 2001-12-05 |
CA2348940C (en) | 2005-02-15 |
AU760611B2 (en) | 2003-05-22 |
EP1137817A1 (en) | 2001-10-04 |
PL194677B1 (en) | 2007-06-29 |
CA2348940A1 (en) | 2000-05-25 |
KR100417201B1 (en) | 2004-02-05 |
AU1505800A (en) | 2000-06-05 |
ID28563A (en) | 2001-05-31 |
HUP0105164A3 (en) | 2002-06-28 |
ATE241020T1 (en) | 2003-06-15 |
US6413295B2 (en) | 2002-07-02 |
JP2000144224A (en) | 2000-05-26 |
AR021245A1 (en) | 2002-07-03 |
SK6112001A3 (en) | 2002-01-07 |
HUP0105164A2 (en) | 2002-04-29 |
KR20010080423A (en) | 2001-08-22 |
BR9916605B1 (en) | 2009-01-13 |
PL348435A1 (en) | 2002-05-20 |
ES2199599T3 (en) | 2004-02-16 |
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