US20040154436A1 - Method for producing granular metal - Google Patents

Method for producing granular metal Download PDF

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Publication number
US20040154436A1
US20040154436A1 US10/480,256 US48025603A US2004154436A1 US 20040154436 A1 US20040154436 A1 US 20040154436A1 US 48025603 A US48025603 A US 48025603A US 2004154436 A1 US2004154436 A1 US 2004154436A1
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iron
metal
cohesion
nuggets
slag
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Shuzo Ito
Osamu Tsuge
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Kobe Steel Ltd
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Kobe Steel Ltd
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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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/0046—Making spongy iron or liquid steel, by direct processes making metallised agglomerates or iron oxide
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/008—Use of special additives or fluxing agents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C22B1/242—Binding; Briquetting ; Granulating with binders
    • C22B1/244—Binding; Briquetting ; Granulating with binders organic
    • C22B1/245—Binding; Briquetting ; Granulating with binders organic with carbonaceous material for the production of coked agglomerates
    • 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
    • C22B5/10—Dry methods smelting of sulfides or formation of mattes by solid carbonaceous reducing agents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/02—Working-up flue dust
    • 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
    • C22B23/00—Obtaining nickel or cobalt
    • 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
    • C22B34/00—Obtaining refractory metals
    • C22B34/30—Obtaining chromium, molybdenum or tungsten
    • C22B34/32—Obtaining chromium
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • the present invention relates to methods for manufacturing metal nuggets.
  • the present invention relates to an improved method for manufacturing high-purity metal nuggets such as iron nuggets that have a large diameter and superior transportation and handling qualities, the method including heating a mixture of a metal-oxide-containing substance and a carbonaceous reductant to reduce the metal oxide, in which an auxiliary material for increasing the fluidity of and promoting the cohesion of molten by-product slag is added to the material.
  • the improved method achieves a high yield and high productivity.
  • This specification mainly describes a method for manufacturing iron nuggets to which the present invention is most effectively applied.
  • the present invention is not limited to the manufacturing of iron nuggets.
  • the present invention can also be effectively applied to the manufacture of ferrochromium or ferronickel by heating and reducing chromium-containing ore or nickel-containing ore, for example.
  • the term “nuggets” does not necessarily mean those spherical in shape and includes those having an elliptical shape, an oval shape, and slightly deformed shapes thereof.
  • An example of a known method for manufacturing metallic iron by heating and reducing an iron oxide source is a direct iron-making process for obtaining reduced iron by directly reducing iron ore or iron oxide pellets using a carbonaceous material or a reducing gas.
  • a shaft furnace process such as the Midrex process is known in the art.
  • a reducing gas made from natural gas or the like is blown from a tuyere at the lower portion of the shaft furnace so as to obtain reduced iron by reducing iron oxide using the reducing power of the reducing gas.
  • the reduced iron made by the processes described above may be directly used as an iron source for an electric furnace or may be subjected to briquetting or the like before it is used as the iron source.
  • the reduced iron made by the above processes is drawing much attention as an agent to decrease the ratio of metal impurities in the scrap, since the resulting reduced iron has a low content of metals other than iron.
  • a reducing melt process such as a direct iron ore smelting (DIOS) reduction process, for making reduced iron by directly heating and reducing iron ore is also known in the art.
  • DIOS direct iron ore smelting
  • the iron ore is pre-reduced to approximately 50 percent by mass (hereinafter denoted as “%”) or less of the metallic iron, and the pre-reduced iron is then allowed to directly react with carbon in an iron bath to make reduced metallic iron.
  • % percent by mass
  • this process requires two stages, i.e., a pre-reduction and a final reduction in an iron bath, the operation is complicated.
  • the reduced iron made mainly by a solid-phase reduction is heated, and the melting point of the reduced iron was decreased by carburization of the reduced iron so as to promote melting.
  • the productivity of the metallic iron can be improved while avoiding the problem of significant refractory wear caused by the molten iron oxide (FeO).
  • the inventors have conducted research to overcome these problems and found that iron nuggets having a relatively large size can be made when a carbonaceous reductant having a high fixed carbon content is used in the process that includes the step of reducing the metal oxide in a solid state included in a material containing a carbonaceous reductant and an iron-oxide-containing substance by means of reducing melt in a furnace and the step of further heating the resulting metallic iron so as to melt the metallic iron while allowing the metallic iron to separate from by-product slag and form nuggets by cohesion. Based on this finding, a patent application has been filed.
  • CaCO 3 may be added to the material for the purpose of adjusting the basicity of slag component when the gangue content in the material, and particularly in the iron oxide source, is high, when the SiO 2 content in the material is high, or when desulfurization is required due to the carbonaceous reductant having a high sulfur content. In these cases, the amount of by-product slag increases, and the degradation of the cohesion property of the slag is inevitable, which is a problem.
  • the cohesion property of the by-product slag may also decrease even when the gangue content in the material is low, depending on the types of the iron oxide source, the slag components, and slag composition. An improvement as to this point is also desired.
  • An object of the present invention is to establish a process for making high-purity metal nuggets, the process comprising heating and reducing a material containing metal oxide such as iron oxide and a carbonaceous reductant such as coke, and further heating so as to melt the metal and to allow the by-product slag to undergo cohesion while separating the slag from the metal, the process that can improve the cohesion property of the by-product slag produced during cohesion and separation of the molten slag, increases the purity of the resulting granular metal produced by heating and reducing, makes large metal nuggets having a uniform size, and reliably enhances the yield of the end product of the metal nuggets regardless of the type and amount of the gangue component, which varies according to the type of the metal oxide source.
  • a method for making metal nuggets according to the present invention overcomes these problems.
  • the method includes heating a material containing a metal-oxide-containing substance and a carbonaceous reductant to reduce metal oxide in the material, and subsequently further heating the produced metal to melt the metal while allowing the metal to separate from by-product slag and to form granular iron, and is characterized in mixing a cohesion accelerator for the by-product slag in the above material.
  • the content of the cohesion accelerator in the material is preferably in the range of 0.2 to 2.5 mass %, and more preferably in the range of 0.4 to 2.0 mass %.
  • the above-described material is preferably a mixture of powders of the metal-oxide-containing substance, the carbonaceous reductant, and the cohesion accelerator.
  • the mixture to be used is preferably uniform. More preferably, a mixture formed into pellets, briquettes, or the like, or press-formed into a compact is preferably used.
  • calcium fluoride (CaF 2 ), boron oxide (B 2 O 5 ), sodium carbonate (Na 2 CO 3 ), or sodium oxide (Na 2 O) is used as the cohesion accelerator.
  • CaF 2 calcium fluoride
  • B 2 O 5 boron oxide
  • Na 2 CO 3 sodium carbonate
  • Na 2 O sodium oxide
  • fluorite which contains CaF 2 as the primary component is particularly preferable as the cohesion accelerator in overall view of the cost and the cohesion acceleration effects.
  • the material is preferably heated and reduced continuously using a moving bed furnace or a rotary hearth furnace.
  • a layer of a carbonaceous material may be bed on the hearth in advance, and then the material may be fed to be heated and reduced on the hearth.
  • the atmosphere adjacent to the materials on the hearth can be always kept at a high reducing potential, and thus the reoxidation of the reduced iron due to oxidative exhaust gas (such as carbonic acid gas and steam) from a burner, which is used to heat the furnace, can be reliably prevented.
  • oxidative exhaust gas such as carbonic acid gas and steam
  • metal nuggets can be manufactured by using iron oxide as the metal oxide and effectively using at least one of iron ore, steel-making dust, steel-making waste materials, and metal scrap as the metal-oxide-containing substance.
  • iron oxide dust generated during the production of the stainless-steel ingots
  • iron oxide source such as iron ore and mill scale.
  • valuable metals such as Ni, Cr, and Mo contained in the dust can be captured by the iron nuggets and thus be recovered effectively.
  • FIG. 1 includes photographs of products showing the state immediately after reducing melt according to an example and a comparative example.
  • FIG. 2 includes photographs that show the appearance of metallic iron nuggets prepared by the example and the comparative example.
  • FIG. 3 includes photographs of products showing the state immediately after reducing melt according to another example and another comparative example.
  • FIG. 4 includes photographs that show the appearance of metallic iron nuggets prepared by yet another example and yet another comparative example.
  • FIG. 5 is a graph showing the cumulative mass distributions, by size, of the metal nuggets prepared by a comparative example and an example.
  • a component that promotes cohesion of the by-product molten slag produced during the step of heating and reducing the metal oxide source is added to the material, and the resulting mixture is further heated after reduction to promote the separation of the by-product slag from the molten metal so as to form relatively large metal nuggets having a uniform size and a high purity at high productivity and high recovery rate.
  • the present invention is described below using a process for making metallic iron nuggets from iron oxide, which is a representative example of a metal oxide, as an example.
  • the present invention uses the same processes for making high-purity metallic iron nuggets or blocks disclosed in publications such as U.S. Pat. No. 6,036,744, and Japanese Unexamined Patent Application Publications Nos. 09-256017, 2000-144224, and 11-131119, the processes comprising preparing a mixture of powders of a carbonaceous reductant and a iron-oxide-containing substance, forming the mixture into blocks if necessary, heating and reducing the mixture on a rotary hearth, and further heating the mixture so as to separate the molten metallic iron from the by-product slag by utilizing the difference in the specific gravities thereof.
  • the present invention is an improved method based on these processes.
  • CaCO 3 or the like is added, if necessary, to the material which essentially contains a powder of an iron-oxide-containing substance and a carbonaceous reductant in order to adjust the basicity or to perform desulfurization.
  • a cohesion accelerator preferably containing at least one of calcium fluoride (CaF 2 ), boron oxide (B 2 O 5 ), sodium carbonate (Na 2 CO 3 ) and sodium oxide (Na 2 O) is added to the material in order to promote the cohesion of the molten slag.
  • the above powder material mixture containing the cohesion accelerator may be directly fed to a furnace such as a rotary hearth furnace.
  • the powder material is formed into pellets using a pelletizing plant of a pan type, a drum type, or the like, press-formed into briquettes, or lightly pressed-formed into a compact before it is fed to the furnace so as to efficiently promote heat conduction and accelerate reductive reaction inside the material mixture.
  • a two-stage heating process is preferably performed.
  • the two-stage heating process includes: reducing the material chiefly by means of solid reduction while maintaining the furnace temperature at a temperature in the range of 1,200 to 1,500° C., and more preferably, 1,200 to 1,400° C.; and then reducing the remaining iron oxide at an increased furnace temperature in the range of 1,400 to 1,500° C. while allowing the generated metallic iron (reduced iron) to melt and to form granular iron. Under these conditions, iron nuggets can be reliably produced at a high yield.
  • the time normally taken for this process is approximately 8 to 13 minutes. The solid reduction, melting, and cohesion of iron oxide can be completed in such a short time.
  • the molten metallic iron forms granular iron and grows larger. Since the granular iron grow while excluding the by-product molten slag, the resulting molten iron nuggets contain substantially no slag and thus exhibit a high Fe purity. When these molten iron nuggets are cooled, solidified, and separated from the slag using a screen or by magnetic separation, metallic iron nuggets exhibiting a high Fe purity can be obtained.
  • the cohesion of the by-product slag can be promoted, and the problem of inhibiting cohesion of the molten metallic iron produced during the melting step after reduction can be avoided by adding a cohesion accelerator to the substance containing a metal oxide source and a carbonaceous reductant, even in the instances below:
  • the melting point of the by-product slag produced during the melting stage decreases while the fluidity of the slag dramatically increases.
  • the molten slag does not inhibit or obstruct the cohesion of the dispersed molten metallic iron.
  • the molten metallic iron can efficiently undergo cohesion while excluding the by-product slag and thus forms relatively large nuggets.
  • the cohesion property of the molten metallic iron can be increased, and iron nuggets having a high iron purity, a large diameter, and improved transportation and handling qualities can be efficiently manufactured while achieving a high yield even when an iron oxide source having a low cohesion property is used or when a low-grade iron-oxide-containing material and a low-grade carbonaceous reductant are used.
  • micro metallic iron particles, slag, and the mixtures of metallic iron nuggets and slag that pass through the clearance of a discharger such as a screw or a scraper and the hearth surface do not return again to the heating zone of the furnace.
  • the micro metallic iron particles, slag, and the mixtures of metallic iron nuggets and slag can be prevented from being pressed into a hearth protecting layer, hearth refractories, or a bedding layer on the hearth.
  • any type of cohesion accelerator can be suitably used in the present invention as long as the above-described effects and advantages can be achieved.
  • a cohesion accelerator that enters the reduced metal and decreases the purity of, for example, reduced iron should be avoided.
  • a cohesion accelerator which combines with slag components and readily separates from the metallic iron is preferably selected.
  • the cohesion accelerators include calcium fluoride (CaF 2 ), boron oxide (B 2 O 5 ), sodium carbonate (Na 2 CO 3 ) and sodium oxide (Na 2 O). These components may be used alone or in combination, if necessary.
  • CaF 2 and more particularly, fluorite containing CaF 2 as the primary component, is particularly preferable in view of cost and cohesion acceleration effects.
  • sodium carbonate (Na 2 CO 3 ) and sodium oxide (Na 2 O) are preferable when coal powder or coke powder is used as the carbonaceous reductant, since sodium carbonate and sodium oxide capture the sulfur component derived from these carbonaceous reductants. As a result, the sulfur content in the resulting metal nuggets can be reduced.
  • the content of the cohesion accelerator is preferably in the range of 0.2 to 2.5%, and more preferably, 0.4 to 2.0%, of the material.
  • the content of the cohesion accelerator based on the slag component in the material is preferably in the range of 1 to 11%, and more preferably, 3 to 8%.
  • metal oxide used as a metal source no limit is imposed as to the type of metal oxide used as a metal source.
  • nickel-containing ore, chromium-containing ore, recycled scrap containing nickel or chromium, or the like may be used.
  • the most common source of iron oxide when making iron nuggets is iron ore, but steel-making scrap and waste materials, such as steel-making dust, produced during the iron-making process in an iron-making plant, and recycled scrap may also be used as the iron source.
  • steel-making scrap and waste materials such as steel-making dust, produced during the iron-making process in an iron-making plant, and recycled scrap may also be used as the iron source.
  • These materials can be used either alone or in combination, if necessary.
  • stainless-steel dust produced when making stainless-steel ingots in an electric furnace or the like contains large amounts of nonferrous valuable metals such as Ni, Cr, and Mo.
  • the slag component content in the material mixture should be as low as is feasibly possible.
  • the slag component content in the material mixture is preferably controlled so as to limit the amount of the slag to approximately 500 kg per ton of the metal nuggets.
  • CaO or CaCO 3 which adjust the basicity of the by-product slag as shown in the examples below, may be added to the material depending on the type of metal-oxide-containing substance and the composition of the slag component contained in the carbonaceous reductant. It is within the technical scope of the present invention to use CaO or CaCO 3 during the operation.
  • magnetite iron ore having a high gangue content and more specifically, a high SiO 2 content of 5.0% or more, was used as an iron oxide source.
  • the chemical composition of the ore is shown in Table 1.
  • Case A the basicity was not adjusted.
  • Cases B and C an adequate amount of CaCO 3 was used to adjust the basicity of the slag (CaO/SiO 2 ) to approximately 1.15.
  • Case D an adequate amount of CaCO 3 was used to adjust the basicity of the slag (CaO/SiO 2 ) to 1.3 or more.
  • Cases C and D were the examples implementing the present invention, and contained a small amount of fluorite (CaF 2 ) to enhance the fluidity of the by-product slag.
  • the designed amounts of slag were 127.8 kg/ton (iron nugget) in Case A, 215.7 kg/ton (iron nugget) in Case B, 212.7 kg/ton (iron nugget) in Case C, and 233.8 kg/ton (iron nugget) in Case D.
  • the recovery rate of the metallic iron nuggets is the ratio of the mass of the resulting metallic iron nuggets actually produced to the theoretical mass of the metallic iron nuggets calculated based on the analytical value of the total Fe content in the material pellets.
  • the recovery rate of the metallic iron nuggets to the mass of the iron contained in the material pellets was evaluated from two aspects: (1) the mass ratio of the metallic iron nuggets that have a mass of approximately 0.2 gram or more per nugget; and (2) the mass ratio of the metallic iron nuggets that have a mass of 1.0 gram or more per nugget.
  • Case A was compared with Case B.
  • Case B in which the amount of the by-product slag was increased due to the addition of 8% of CaCO 3 , clearly demonstrated a tendency of an increase in the production rate of metallic iron nuggets having a small diameter.
  • the recovery rates of the metallic iron nuggets of (1) 0.2 g or more and (2) 1.0 gram or more were clearly low. Particularly the recovery rate of the metallic iron nuggets having a mass of 1.0 g or more decreased by 12% or more.
  • Case B large amounts of micro particles of metallic iron adhered onto the surface of the by-product slag, and those metallic iron nuggets that existed separately from the slag enclosed slag particles. Thus, the separation of the metallic iron nuggets from the slag was difficult.
  • Case B when Case B was compared with Case C, although the amount of the by-product slag was increased in both Case C and Case B, Case C demonstrated that the cohesion of the molten metallic iron could be dramatically improved by adding CaF 2 .
  • the yields of both metallic iron nuggets having a mass of 0.2 g or more per nugget and metallic iron nuggets having a mass of 1.0 g or more per nugget were dramatically improved.
  • the recovery rate was improved by 20 to 26% compared to Case B, achieving the recovery rate exceeding 100%. The recovery rate exceeded 100% because the total iron content of the input material was used as the denominator and the amount of crude iron that partially contains recovered carbon, silicon, or the like, was included in the numerator when calculating the recovery yield.
  • FIG. 1 Photographs showing the appearance of the metallic iron nuggets and the slag in Cases B and C are shown in FIG. 1. Photographs that show the size distribution of the metallic iron nuggets in Cases B and C are shown in FIG. 2. Note that the photographs showing the appearance of the metallic iron nuggets and the slag show the state of the produced metallic iron nuggets and the slag in a tray after reducing melt.
  • Tables 4 and 5 below show the results of the chemical analysis of the produced metallic iron nuggets and slag. Since the metallic iron nuggets did not substantially contain heavy metals other than the main gangue components such as SiO 2 in the ore, only five primary elements are shown in these tables. TABLE 4 Results of Chemical Analysis of Metallic iron nuggets (mass %) C Si Mn P S Case A 3.23 0.32 0.09 0.040 0.127 (Comparative Example) Case B 3.41 0.20 0.13 0.036 0.078 (Comparative Example) Case C 3.74 0.21 0.18 0.037 0.059 (Example) Case D 4.01 0.17 0.23 0.034 0.033 (Example)
  • Cases C and D in which 7.0 to 8.5% of CaCO 3 and 1.0% of CaF 2 as a cohesion accelerator were used, maintained a high recovery yield of the metallic iron nuggets while achieving a low sulfur content in the metallic iron nuggets.
  • Case D high-quality metallic iron nuggets having a distinctively low sulfur content of 0.033% were obtained.
  • iron ore having a poor cohesion property i.e., hematite ore
  • the experiments of reducing melt were conducted as in Example 1 above.
  • FIGS. 3 and 4 include photographs showing the appearances of the state of the products immediately after the reducing melt (FIG. 3) on an aluminum board tray and the recovered metallic iron nuggets (FIG. 4) obtained in Case F which implements the present invention and uses CaF 2 as the cohesion accelerator.
  • FIGS. 3 and 4 also include photographs showing the appearances of the state of the products immediately after the reducing melt (FIG. 3) on an aluminum board tray and the recovered metallic iron nuggets (FIG. 4) obtained in Case E which is a comparative example that does not use CaF 2 .
  • TABLE 6 Chemical Composition of Hematite Ore (mass %) T.Fe FeO Fe 2 O 3 SiO 2 Al 2 O 3 CaO MgO Other Total 68.01 0.1 97.13 1.08 0.47 0.08 0.06 1.13 100
  • FIG. 5 shows a cumulative mass distribution of the metallic iron nuggets obtained in Example 3 above and Comparative Example. In determining the cumulative mass distribution, the recovered metallic iron nuggets were classified by a screen, and the number was added from those having the largest size to those having the smallest size. The figure also shows the cumulative mass percentage of the metallic iron nuggets that have a mass of 0.2 g or more and 1.0 g or more.
  • Stainless-steel dust and mill scale having the compositions described below were used as an iron oxide source.
  • T. Fe 25.7%, M. Fe: 1.54%, SiO 2 : 6.0%, Al 2 O 3 : 0.54%, CaO: 3.66%, MgO: 1.3%, M. Ni: 0.27%, NiO: 7.91%, M. Cr: 0.15%, Cr 2 O 3 : 16.07%, M. Mn: 0.23%, MnO: 6.44%, MoO: 6.44%, ZnO: 5.53%, and C: 0.56%.
  • Both stainless-steel dust and mill scale produced when making stainless-steel ingots using an electric furnace were used as an iron oxide source at compound ratios shown in Table 9 below.
  • a carbonaceous reductant (coal powder), a binder (wheat powder), and 1.5 percent by mass of CaF 2 as a cohesion accelerator were added to this iron oxide source to prepare a mixture powder.
  • This mixture powder was formed into pellets having a diameter of approximately 16 to 20 mm.
  • the reducing melt experiment was performed in a box furnace as in Example 4 above using 350 g (approximately 40) of each type of material pellets.
  • the amount of the slag produced as the by-product, and the state of the iron nuggets and the by-product slag were examined. Note that in this experiment, 1.5 percent by mass of CaF 2 was used as a cohesion accelerator in all of the cases.
  • the purpose of the experiment was to examine the effects of the compound ratio of the electric-furnace dust as the iron source on the amount of the by-product slag.
  • the amount of slag has a large influence on the stable operation of the process.
  • the amount of the by-product slag increases as the compound ratio of the electric-furnace dust in the material increases. As a result, the slag may completely cover the iron nuggets and obstruct the cohesion of micro iron particles.
  • the dissolution of the hearth refractories may be further accelerated by the increased amount of the molten slag.
  • the ratio of the electric-furnace dust was varied to approximately 25 mass %, 30 mass %, 40 mass %, and 50 mass % in Cases 1, 2, 3, and 4, respectively, so as to examine the state of the iron nuggets generated by reducing melt and the by-product slag.
  • the amount of slag in each of these cases is also shown in Table 9.
  • T. Fe 23.5%, M. Fe: 15.7%, SiO 2 : 8.2%, Al 2 O 3 : 2.7%, CaO: 14.2%, MgO: 3.6%, M. Ni: 0.8%, NiO: 3.9%, M. Cr: 0.3%, Cr 2 O 3 : 10.8%, M. Mn: 0.6%, MnO: 3.2%, MoO: 1.1%, ZnO: 9.6%, and C: 0.9%.
  • T. Fe 75.1%, M. Fe: 0.07%, SiO 2 : 0.01%, Al 2 O 3 : 0.07%, CaO: 0.02%, MgO: 0.01%, MnO: 0.29%.
  • Composition of Material Pellets (mass %) Amount of by- Stainless- product slag steel Mill (kg/ton of dust scale Coal Binder CaF 2 iron nuggets) Case 1 23.59 55.05 18.38 1.48 1.5 217.2 Case 2 31.53 47.3 18.19 1.48 1.5 315.4 Case 3 40.18 40.18 16.66 1.48 1.5 487.8 Case 4 48.14 32.09 16.79 1.48 1.5 613.7
  • the amount of the by-product slag clearly increased as the amount of the stainless-steel dust increased.
  • the amount of by-product slag was not significantly large compared to the amount of iron nuggets, and the iron nuggets after heat-reduction was sufficiently distinguishable from the by-product slag on the alumina tray. The separation of the iron nuggets from the by-product slag was also easy.
  • the amount of the by-product slag was significantly large compared with the produced iron nuggets, and substantially all of the iron nuggets were covered with the by-product slag.
  • the stainless-steel dust and the mill scale were used at a ratio of 50:50 as an iron oxide source.
  • This ratio is substantially considered to be the limit of the ratio that allows effective separation of the iron nuggets from the by-product slag while preventing the deterioration of the hearth refractories.
  • the amount of the by-product slag relative to a ton of the iron nuggets produced was approximately 500 kg.
  • the separation of the molten metal, produced by reducing melt, from the by-product slag can be accelerated by adding a cohesion accelerator such as fluorite (CaF 2 ) to the material as an auxiliary material, the cohesion accelerator having an effect of improving the fluidity of the by-product molten metal.
  • a cohesion accelerator such as fluorite (CaF 2 )
  • the cohesion accelerator having an effect of improving the fluidity of the by-product molten metal.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Manufacture Of Iron (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Physical Vapour Deposition (AREA)
US10/480,256 2001-06-18 2002-06-13 Method for producing granular metal Abandoned US20040154436A1 (en)

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JP2001183932 2001-06-18
JP2002007854A JP4669189B2 (ja) 2001-06-18 2002-01-16 粒状金属鉄の製法
JP2002-7854 2002-01-16
PCT/JP2002/005872 WO2002103064A1 (fr) 2001-06-18 2002-06-13 Procede de fabrication de grenaille

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US20040028919A1 (en) * 2002-08-09 2004-02-12 Mitsushi Yamamoto Surface protective film for transparent conductive substrate, and transparent conductive substrate with surface protective film
US20040168550A1 (en) * 2001-07-24 2004-09-02 Osamu Tsuge Method for accelerating separation of granular metallic iron from slag
US20060150772A1 (en) * 2004-12-07 2006-07-13 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US20060169103A1 (en) * 2003-03-20 2006-08-03 Kabushiki Kaisha Kobe Seiko Sho Process for producing particulate iron metal
US20060278041A1 (en) * 2003-04-09 2006-12-14 Takao Harada Method for producing improved coal for use in metallurgy, and method for producing reduced metal and slag containing oxidized nonferrous metal
US20070209480A1 (en) * 2006-03-13 2007-09-13 Michigan Technological University Production of iron using environmentally-benign renewable or recycled reducing agents
US20090175753A1 (en) * 2004-12-07 2009-07-09 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US20090229414A1 (en) * 2006-10-04 2009-09-17 Nu-Iron Technology, Llc System and method for producing metallic iron
US20100171072A1 (en) * 2007-06-27 2010-07-08 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Method for manufacturing granular metallic iron
EP2500441A1 (en) * 2006-07-26 2012-09-19 Nu-Iron Technology, LLC Metallic iron nuggets
WO2012149635A1 (en) * 2011-05-04 2012-11-08 Wei-Kao Lu Process of the production and refining of low-carbon dri (direct reduced iron)
US20130055853A1 (en) * 2010-05-06 2013-03-07 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Method for producing metallic iron
RU2497953C2 (ru) * 2011-12-07 2013-11-10 Владимир Евгеньевич Черных Способ получения гранулированного металлического железа
US10155996B2 (en) 2013-09-11 2018-12-18 Primetals Technologies Austria GmbH Method and device for manufacturing granulates
US10364480B2 (en) * 2014-10-06 2019-07-30 Sumitomo Metal Mining Co., Ltd. Method for smelting nickel oxide ore

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US8021460B2 (en) 2006-07-26 2011-09-20 Nu-Iron Technology, Llc System and method for producing metallic iron nodules
JP5194111B2 (ja) * 2007-05-11 2013-05-08 ポスコ ニッケル含有溶鉄の製造方法
JP5096811B2 (ja) * 2007-06-27 2012-12-12 株式会社神戸製鋼所 粒状金属鉄の製造方法
JP5210555B2 (ja) * 2007-06-27 2013-06-12 株式会社神戸製鋼所 粒状金属鉄の製造方法
JP5096810B2 (ja) * 2007-06-27 2012-12-12 株式会社神戸製鋼所 粒状金属鉄の製造方法
AU2011211415B2 (en) * 2007-06-27 2012-04-12 Kabushiki Kaisha Kobe Seiko Sho Method for manufacturing granular metallic iron
JP4603626B2 (ja) * 2008-03-31 2010-12-22 新日本製鐵株式会社 還元鉄の製造方法
JP5420935B2 (ja) * 2008-04-09 2014-02-19 株式会社神戸製鋼所 粒状金属鉄の製造方法
JP2010111941A (ja) * 2008-10-07 2010-05-20 Kobe Steel Ltd フェロバナジウムの製造方法
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US8287621B2 (en) 2010-12-22 2012-10-16 Nu-Iron Technology, Llc Use of bimodal carbon distribution in compacts for producing metallic iron nodules
JP5671426B2 (ja) * 2011-08-03 2015-02-18 株式会社神戸製鋼所 粒状金属鉄の製造方法
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Cited By (31)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040168550A1 (en) * 2001-07-24 2004-09-02 Osamu Tsuge Method for accelerating separation of granular metallic iron from slag
US20040028919A1 (en) * 2002-08-09 2004-02-12 Mitsushi Yamamoto Surface protective film for transparent conductive substrate, and transparent conductive substrate with surface protective film
US20060169103A1 (en) * 2003-03-20 2006-08-03 Kabushiki Kaisha Kobe Seiko Sho Process for producing particulate iron metal
US8790420B2 (en) 2003-04-09 2014-07-29 Kobe Steel, Ltd. Method for producing reduced metal and slag containing oxidized nonferrous metal using an upgraded coal
US7799100B2 (en) 2003-04-09 2010-09-21 Kobe Steel, Ltd. Method for producing improved coal for use in metallurgy, and method for producing reduced metal and slag containing oxidized nonferrous metal
US20060278041A1 (en) * 2003-04-09 2006-12-14 Takao Harada Method for producing improved coal for use in metallurgy, and method for producing reduced metal and slag containing oxidized nonferrous metal
US7641712B2 (en) 2004-12-07 2010-01-05 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US7632335B2 (en) 2004-12-07 2009-12-15 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US8158054B2 (en) 2004-12-07 2012-04-17 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US20090175753A1 (en) * 2004-12-07 2009-07-09 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US20060150772A1 (en) * 2004-12-07 2006-07-13 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US7628839B2 (en) 2004-12-07 2009-12-08 Iwao Iwasaki Method and system for producing metallic iron nuggets
US20060150774A1 (en) * 2004-12-07 2006-07-13 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US20060150773A1 (en) * 2004-12-07 2006-07-13 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US20060150775A1 (en) * 2004-12-07 2006-07-13 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US7695544B2 (en) 2004-12-07 2010-04-13 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US20100164150A1 (en) * 2004-12-07 2010-07-01 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US8470068B2 (en) 2004-12-07 2013-06-25 Nu-Iron Technology, Llc Method and system for producing metallic iron nuggets
US7632330B2 (en) * 2006-03-13 2009-12-15 Michigan Technological University Production of iron using environmentally-benign renewable or recycled reducing agents
US20070209480A1 (en) * 2006-03-13 2007-09-13 Michigan Technological University Production of iron using environmentally-benign renewable or recycled reducing agents
EP2500441A1 (en) * 2006-07-26 2012-09-19 Nu-Iron Technology, LLC Metallic iron nuggets
US8097065B2 (en) 2006-10-04 2012-01-17 Nu-Iron Technology, Llc System and method for producing metallic iron
US8535602B2 (en) 2006-10-04 2013-09-17 Nu-Iron Technology, Llc System and method for producing metallic iron
US20090229414A1 (en) * 2006-10-04 2009-09-17 Nu-Iron Technology, Llc System and method for producing metallic iron
US20100171072A1 (en) * 2007-06-27 2010-07-08 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Method for manufacturing granular metallic iron
US20130055853A1 (en) * 2010-05-06 2013-03-07 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Method for producing metallic iron
WO2012149635A1 (en) * 2011-05-04 2012-11-08 Wei-Kao Lu Process of the production and refining of low-carbon dri (direct reduced iron)
US20140060251A1 (en) * 2011-05-04 2014-03-06 Wei-Kao Lu Process of the production and refining of low-carbon dri (direct reduced iron)
RU2497953C2 (ru) * 2011-12-07 2013-11-10 Владимир Евгеньевич Черных Способ получения гранулированного металлического железа
US10155996B2 (en) 2013-09-11 2018-12-18 Primetals Technologies Austria GmbH Method and device for manufacturing granulates
US10364480B2 (en) * 2014-10-06 2019-07-30 Sumitomo Metal Mining Co., Ltd. Method for smelting nickel oxide ore

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CA2448381A1 (en) 2002-12-27
AU2002311197B2 (en) 2008-08-28
ES2291473T3 (es) 2008-03-01
MXPA03011868A (es) 2004-06-18
EP1405924B1 (en) 2007-08-15
EP1405924A1 (en) 2004-04-07
PL199092B1 (pl) 2008-08-29
EP1405924A4 (en) 2005-03-23
PL373812A1 (en) 2005-09-19
BR0205667B1 (pt) 2011-09-06
UA74905C2 (uk) 2006-02-15
BR0205667A (pt) 2003-07-15
RU2004101052A (ru) 2005-05-20
KR20030020990A (ko) 2003-03-10
CA2448381C (en) 2013-01-15
ATE370253T1 (de) 2007-09-15
DE60221844D1 (de) 2007-09-27
RU2271395C2 (ru) 2006-03-10
CN1516744A (zh) 2004-07-28
KR100576397B1 (ko) 2006-05-03
TW533237B (en) 2003-05-21
DE60221844T2 (de) 2008-05-08
WO2002103064A1 (fr) 2002-12-27
CN1516744B (zh) 2010-04-28
JP4669189B2 (ja) 2011-04-13
JP2003073722A (ja) 2003-03-12

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