US20150259759A1 - Method for heating process gases for direct reduction systems - Google Patents

Method for heating process gases for direct reduction systems Download PDF

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Publication number
US20150259759A1
US20150259759A1 US14/428,116 US201314428116A US2015259759A1 US 20150259759 A1 US20150259759 A1 US 20150259759A1 US 201314428116 A US201314428116 A US 201314428116A US 2015259759 A1 US2015259759 A1 US 2015259759A1
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Prior art keywords
gas
reduction
unit
heating
enriching
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Abandoned
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US14/428,116
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English (en)
Inventor
Hermann Wolfmeir
Thomas Bürgler
Peter Schwab
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Voestalpine Stahl GmbH
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Voestalpine Stahl GmbH
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Priority claimed from DE201210109284 external-priority patent/DE102012109284A1/de
Priority claimed from DE102013104002.0A external-priority patent/DE102013104002A1/de
Application filed by Voestalpine Stahl GmbH filed Critical Voestalpine Stahl GmbH
Assigned to VOESTALPINE STAHL GMBH reassignment VOESTALPINE STAHL GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BÜRGLER, Thomas, WOLFMEIR, Hermann, SCHWAB, PETER
Publication of US20150259759A1 publication Critical patent/US20150259759A1/en
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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
    • C21B13/0073—Selection or treatment of the reducing gases
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • 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
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/14—Multi-stage processes processes carried out in different vessels or furnaces
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B1/00—Electrolytic production of inorganic compounds or non-metals
    • C25B1/01—Products
    • C25B1/02—Hydrogen or oxygen
    • C25B1/04—Hydrogen or oxygen by electrolysis of water
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/0086—Conditioning, transformation of reduced iron ores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/36—Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/10—Reduction of greenhouse gas [GHG] emissions
    • Y02P10/122—Reduction of greenhouse gas [GHG] emissions by capturing or storing CO2
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/10—Reduction of greenhouse gas [GHG] emissions
    • Y02P10/134—Reduction of greenhouse gas [GHG] emissions by avoiding CO2, e.g. using hydrogen
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/10—Process efficiency
    • Y02P20/133—Renewable energy sources, e.g. sunlight

Definitions

  • the invention relates to a method for heating process gases for direct reduction systems.
  • Sponge irons in the form of HDRI, CDRI, and HBI usually undergo further processing in electric furnaces, which is extraordinarily energy-intensive.
  • the direct reduction is carried out using hydrogen and carbon monoxide from natural gas (methane) and possibly synthesis gas as well as coke oven gas.
  • methane natural gas
  • synthesis gas possibly synthesis gas
  • coke oven gas possibly synthesis gas
  • Fe 2 O 3 +6CO(H 2 ) 2Fe+3CO 2 (H 2 O)+3 CO(H 2 ).
  • This method also emits CO 2 .
  • DE 198 53 747 C1 has disclosed a combined process for the direct reduction of fine ores in which the reduction is to be carried out with hydrogen or another reduction gas in a horizontal turbulence layer.
  • WO 2011/018124 has disclosed methods and systems for producing storable and transportable carbon-based energy sources using carbon dioxide and using regenerative electrical energy and fossil fuels.
  • a percentage of regeneratively produced methanol is prepared together with a percentage of methanol that is produced by means of non-regenerative electrical energy and/or by means of direct reduction and/or by means of partial oxidation and/or reforming.
  • this gas is in turn enriched with natural gas in order to supply fresh reduction gas.
  • the gas, which the gas purification has cooled from approximately 105° C., is heated again to approximately 700 to 1100° C. and then a partial oxidation with oxygen is performed.
  • the additionally used fossil fuel namely natural gas, is used to heat the process gases and to heat the reformer.
  • One object of the invention is to create a method for heating process gases for direct reduction systems with which the heating of process gases can be better and more flexibly adapted to and optimized for an overall process that is adapted to the energy demand and to the available energy.
  • Another object of the invention is to reduce CO 2 emissions.
  • the heating of the reduction gases and of the reformer is changed to an electrical heating.
  • the electrical energy can be produced from renewable resources, thus replacing fossil fuels.
  • the invention has the advantage that electrical current can be considered to be 100% energy so that it can be completely converted into high temperature heat.
  • the direct convertibility of electrical energy into heat permits the addition of a high degree of flexibility, particularly also with regard to the use of current peaks that are inexpensively available on the market.
  • renewable energy sources such as hydroelectric, wind power, or solar energy does not cause any CO 2 emissions when it is produced.
  • FIG. 1 shows as an example the HYL Energiron method according to the prior art, with a natural gas-powered process gas heating;
  • FIG. 2 shows the HYL Energiron method according to the invention, with an electrically-powered process gas heating
  • FIG. 3 is a very schematic depiction of the MIDREX method
  • FIG. 4 is a very schematic depiction of an expensive and complex CO 2 -optimized MIDREX method according to the prior art, with a CO 2 -removal unit (e.g. VPSA—vacuum-pressure swing adsorption).
  • VPSA vacuum-pressure swing adsorption
  • the HYL method is shown by way of example in FIG. 2 on the basis of a capacity of two million metric tons of direct reduced iron (DRI) per year, including an electric arc furnace (EAF).
  • the process gas from the shaft in which the iron ore is reduced is first conveyed through a water separation and then through a CO 2 separation.
  • the circulating gas volume flow in this case is approximately 500,000 m 3 per hour.
  • Approximately 72,000 m 3 of natural gas per hour is added to this gas flow, 56,000 m 3 of which is used for the reduction and approximately 16,000 m 3 of which is diverted for heating the process gas from 105 to 970° C.
  • oxygen is added to the heated process gas and this is then fed back into the reduction shaft.
  • the reduction gas is likewise taken from the shaft and conveyed through a water separation and a CO 2 separation. Thanks to the electrical heating of the process gas heating, it is only necessary to add a quantity of approximately 56,000 m 3 of natural gas per hour, which is split with oxygen into CO and hydrogen in accordance with the above-mentioned formulas.
  • the table in FIG. 2 shows that this achieves a 21% reduction in CO 2 per ton of reduced iron.
  • the process can be used in an exactly controllable and flexible way.
  • FIG. 3 shows the MIDREX method in which the exhaust gas is likewise withdrawn in the reduction shaft and divided into a process gas flow and a heating gas flow.
  • the process gas flow is conveyed through a process gas compressor until natural gas is added to it—particularly in a system that is likewise designed for 2 million metric tons of reduced iron per year—in a quantity of approximately 63,000 m 3 of natural gas per hour.
  • This process gas passes through a heat exchanger, in which it is preheated by the exhaust gases from the reformer to 600° C. and then passes through the reformer and in so doing, is heated to 980° C. and is conveyed back to the shaft as process gas, which is enriched with additional natural gas and oxygen.
  • the heating gas is likewise taken from the shaft furnace, enriched with natural gas, and conveyed into the reformer together with preheated combustion air.
  • the total required quantity of natural gas is approximately 68,200 m 3 per hour; by heating the reformer electrically, it is possible to compensate for approximately 5,100 m 3 of exhaust gas per hour with 52 Megawatts of electric power. As a result of this, it is possible on the one hand to achieve a 7.5% reduction of CO 2 per metric ton of reduced iron ore. In addition, this process can also be controlled in a more flexible, precise fashion thanks to the electric heating.
  • the invention has the advantage of achieving a simple and quickly implementable option for replacing fossil fuels with electrical power from renewable energies. CO 2 emissions from direct reduction systems are also reduced.
  • the invention also makes it possible to successfully operate direct reduction systems in an effective and flexible way. In particular, in a steel production that is adapted to the availability of regenerative energies with an electrically-powered preheating of process gas, particularly one with heating based on renewable energies, it is possible to achieve an improvement and reciprocal adaptation.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Combustion & Propulsion (AREA)
  • Electrolytic Production Of Non-Metals, Compounds, Apparatuses Therefor (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
  • Manufacture Of Iron (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Environmental & Geological Engineering (AREA)
  • Geology (AREA)
  • Geochemistry & Mineralogy (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Hydrogen, Water And Hydrids (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Furnace Details (AREA)
US14/428,116 2012-09-14 2013-09-10 Method for heating process gases for direct reduction systems Abandoned US20150259759A1 (en)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
DE102012108631 2012-09-14
DE102012108631.1 2012-09-14
DE102012109284.2 2012-09-28
DE201210109284 DE102012109284A1 (de) 2012-09-14 2012-09-28 Verfahren zum Erzeugen von Stahl und Verfahren zum Speichern diskontinuierlich anfallender Energie
DE102013104002.0 2013-04-19
DE102013104002.0A DE102013104002A1 (de) 2013-04-19 2013-04-19 Verfahren zum Aufheizen von Prozessgasen für Direktreduktionsanlagen
PCT/EP2013/068743 WO2014040997A1 (de) 2012-09-14 2013-09-10 Verfahren zum aufheizen von prozessgasen für direktreduktionsanlagen

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US20150259759A1 true US20150259759A1 (en) 2015-09-17

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US14/428,206 Abandoned US20150259760A1 (en) 2012-09-14 2013-09-10 Method for producing steel
US14/428,280 Abandoned US20150329931A1 (en) 2012-09-14 2013-09-10 Method for storing discontinuously produced energy
US14/428,116 Abandoned US20150259759A1 (en) 2012-09-14 2013-09-10 Method for heating process gases for direct reduction systems

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US14/428,206 Abandoned US20150259760A1 (en) 2012-09-14 2013-09-10 Method for producing steel
US14/428,280 Abandoned US20150329931A1 (en) 2012-09-14 2013-09-10 Method for storing discontinuously produced energy

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US (3) US20150259760A1 (es)
EP (3) EP2895631B1 (es)
JP (3) JP2015534604A (es)
KR (3) KR20150063075A (es)
CN (3) CN104662177A (es)
ES (2) ES2689779T3 (es)
FI (1) FI2895630T3 (es)
WO (3) WO2014040989A2 (es)

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