US20190055616A1 - Method for producing metal from metal oxide by carbothermic reduction and holed cake used therefor - Google Patents

Method for producing metal from metal oxide by carbothermic reduction and holed cake used therefor Download PDF

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Publication number
US20190055616A1
US20190055616A1 US15/851,394 US201715851394A US2019055616A1 US 20190055616 A1 US20190055616 A1 US 20190055616A1 US 201715851394 A US201715851394 A US 201715851394A US 2019055616 A1 US2019055616 A1 US 2019055616A1
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United States
Prior art keywords
oxide
holed
cake
metal oxide
metal
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Abandoned
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US15/851,394
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English (en)
Inventor
Tsung-Yen Huang
Feng-Yi Lin
Shih-Hsien Liu
Wei-Kao Lu
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China Steel Corp
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China Steel Corp
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Assigned to CHINA STEEL CORPORATION reassignment CHINA STEEL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LIN, FENG-YI, HUANG, TSUNG-YEN, LIU, SHIH-HSIEN, LU, WEI-KAO
Publication of US20190055616A1 publication Critical patent/US20190055616A1/en
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B5/00—Making pig-iron in the blast furnace
    • C21B5/007—Conditions of the cokes or characterised by the cokes used
    • 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
    • C21B13/0046—Making spongy iron or liquid steel, by direct processes making metallised agglomerates or iron oxide
    • C21B13/0053—On a massing grate
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/006—Starting from ores containing non ferrous metallic oxides
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/0066—Preliminary conditioning of the solid carbonaceous reductant
    • 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
    • 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
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B15/00—Other processes for the manufacture of iron from iron compounds
    • 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

Definitions

  • the disclosure relates to a method for producing metal, more particular to a high-efficiency method for producing metal from metal oxide by carbothermic reduction and a holed cake used therefor.
  • blast furnace is the most popular commercial ironmaking process, in which the raw materials are mainly including sinter, pellet, lump ore and coke, and the product is hot metal which is the source to the following steelmaking process.
  • the BF process requires high quality of the raw materials and the raw materials requires to be pretreated to qualified properties.
  • Coke is made from coking coal by coking process; fine ore needs to be sintered into agglomeration. Therefore, the ironmaking process via BF is relatively long.
  • coking and sintering process consumes a lot of energy and cause severe pollution. The capital using in the prevention of pollution is particularly high. Furthermore, the most important thing is that it is very difficult to further reduce the emission of carbon dioxide (CO 2 ).
  • Rotary hearth furnace (RHF) process is one of commercial ironmaking process by the means of carbothermic reduction.
  • the metal oxide mixing with carbonaceous material is pelletized into pellets. 1 or 2 layers of pellets are charged on the hearth of RHF for reduction. After the pellets are heated, the pellets are induced to the reduction reaction. Finally, the direct reduced iron (DRI) will be obtained.
  • DRI direct reduced iron
  • the metal iron conversion rate and yield of metal iron of DRI is not high enough. It is because the combustion gas content high CO 2 and H 2 O which is easy to re-oxidize the reduced iron.
  • FIG. 1 illustrates the radiation heat receiving behavior of the conventional multi-layer pellet bed in (a) the initial stage of the reduction reaction and (b) under the stage of the reduction reaction.
  • increasing the layers of pellet bed and increasing furnace temperature at the same time is helpful to prevent the re-oxidization of iron and to increase the yield of metal iron.
  • This is well known and is disclosed.
  • the packing in multi-layer pellet bed is not the perfect method. It is because that some of pellets in the middle and bottom layers of bed cannot directly receive the heat radiation. Even through the top layer pellet would be shrinking after reduction, the pellets on the top layers still shelter the path of radiation transferring into the middle and bottom layer pellets. As shown in FIG.
  • the pellets of the first and second layers can receive the radiation heat directly, but the pellets of the n th layer are shielded by the upper pellets and cannot receive the radiation heat directly, resulting in a slow reaction rate. Therefore, the pellets of the n th layer cannot receive the radiation, until the upper pellets are heated, reduced, and sintered to shrink.
  • the path of radiation is locally opened, and the radiation is gradually transferred from the upper layer to the next layer of pellets. As the pellets receive the heat, the pellets start reducing, sintering and shrinking.
  • the reduction behaviors of the pellets of different raw materials or at different operation temperatures in the furnace are various. As shown in FIG. 1( b ) , the pellets of the n th layer may swell up or may collapse into powdering. On the other hand, as the reducing conditions are not well controlled, the pellets may even get into softening and melting during the reduction reaction. Once the above phenomena occur at the upper pellets, the radiation path leading to the bottom layer will be blocked, causing the radiation fail to be passed to the next layer of pellets, so the reduction reaction cannot be induced, and a high metal reduction rate cannot be achieved.
  • a high-efficiency method for producing metal from metal oxide by carbothermic reduction includes step in which a holed cake is provided, which has a composition comprising a metal oxide, a carbonaceous reducing agent, and a binder, and the holed cake has a plurality of holes. The method continues with step in which the holed cake is placed in a high-temperature furnace for carbothermic reduction, to reduce the metal oxide in the holed cake into a metal.
  • a holed cake has a composition comprising a metal oxide, a carbonaceous reducing agent, and a binder, and the holed cake has a plurality of holes.
  • FIG. 1 illustrates the radiation heat receiving behavior of the conventional multi-layer pellet bed in (a) the initial stage of the reduction reaction and (b) under the stage of the reduction reaction.
  • FIG. 2 shows a flow diagram of a high-efficiency method for producing a metal from a metal oxide by carbothermic reduction according to the present disclosure.
  • FIG. 3 shows a schematic structural view of a holed cake according to the present disclosure.
  • FIG. 2 shows a flow diagram of a high-efficiency method for producing a metal from a metal oxide by carbothermic reduction according to the present disclosure.
  • FIG. 3 shows a schematic structural view of a holed cake according to the present disclosure. Referring to Step S 21 shown in FIG. 2 , and FIG. 3 , a holed cake 30 is provided, which has a composition comprising a metal oxide, a carbonaceous reducing agent, and a binder.
  • the content of the metal oxide is 70 to 90 wt % inclusive, and preferably the metal oxide is iron oxide, nickel oxide, copper oxide, lead oxide, manganese oxide, tin oxide, potassium oxide, sodium oxide, zinc oxide, or a combination of at least two of the foregoing.
  • the metal oxide is powdered to improve the metal conversion rate.
  • the metal oxide is a mineral containing the metal oxide.
  • the content of the carbonaceous reducing agent is 10 to 30 wt % inclusive, and preferably the carbonaceous reducing agent is carbon black, activated carbon, coal, coke, graphite, charcoal, or a combination of at least two of the foregoing.
  • the carbonaceous reducing agent is powdered to improve the utilization rate of reducing agent.
  • the binder is added in an amount of 0.1 to 6% based on the total weight of the metal oxide and the carbonaceous reducing agent.
  • the holed cake 30 is prepared by the following steps: the metal oxide, the carbonaceous reducing agent and the binder are uniformly mixed to form a mixture; and then the mixture is disposed in a mold to form the holed cake 30 .
  • the holed cake 30 has a thickness T ranging from 30 to 150 mm.
  • the holed cake 30 has a first surface 30 A, a second surface 30 B, and a plurality of holes 30 H.
  • the second surface 30 B is opposite to the first surface 30 A.
  • the holes 30 H can or cannot in communication with the first surface 30 A and the second surface 30 B.
  • the cross section of the holes 30 H is circular. Or, in another embodiment, the cross section of the holes 30 H is polygonal.
  • each of the holes 30 H has a diameter d, and a to-be-reduced material portion 30 M is present between two adjacent holes 30 H, wherein the to-be-reduced material portion 30 M has a thickness t.
  • each of the holes 30 H has a center C, and a distance G exists between the centers C of two adjacent holes 30 H.
  • the thickness t of the to-be-reduced material portion 30 M is less than the distance G, such that the to-be-reduced material portion 30 M can be heated evenly.
  • the holed cake 30 is placed in a high-temperature furnace for carbothermic reduction, whereby the metal oxide in the holed cake 30 is reduced into a metal.
  • the holes 30 H of the holed cake 30 face a heat source of the high temperature furnace (not shown), to allow the radiation heat to be uniformly transmitted to the holes 30 H.
  • a reaction temperature of the carbothermic reduction is 900 to 1600° C. inclusive; and for the purpose of improving the metal conversion rate and the metal yield, the reaction temperature of the carbothermic reduction is preferably 1000 to 1550° C. inclusive.
  • a reaction time of the carbothermic reduction is 30 to 80 min inclusive, and preferably 35 to 45 min inclusive.
  • the holed cake 30 having a plurality of holes 30 H is used as a raw material for carbothermic reduction, through which the problem that the bottom layer of the conventional multi-layer pellets cannot receive the radiation heat can be effectively solved, and the heat transfer rate inside the material can be increased, thereby enhancing the carbothermic reduction rate at the bottom of the hearth.
  • Table 1 which shows the source and chemical composition of the metal oxide minerals in the comparative example, and Embodiments 1 and 2 of the present disclosure.
  • Table 2 which shows the source and chemical composition of the carbonaceous reducing agent in the comparative example, and Embodiments 1 and 2 of the present disclosure.
  • the reduction reaction was carried out with a multi-layer stacked spherical material.
  • Table 3 shows the reduction reaction conditions and the characteristics of the reduced iron produced in the comparative example.
  • the content ratio of the metal oxide to the carbonaceous reducing agent in the raw material depends on the carbon/oxygen ratio (C/O).
  • C in the carbon/oxygen ratio (C/O) is calculated based on the total carbon in the reducing agent, and O in the carbon/oxygen ratio (C/O) is the total number of O atoms in the metal oxide that can be reduced by carbon.
  • the carbon/oxygen ratio (C/O) is the atomic ratio of C to O contained in the material.
  • the binder was added in an amount of 2% of the total amount of the metal oxide and the carbonaceous reducing agent.
  • the raw materials were prepared into pellets of 14 to 17 mm in diameter.
  • the pellets were laid on a hearth in a high-temperature furnace, and about 7 to 8 layers of the pellets were laid, as shown in FIG. 1 .
  • the maximum reduction reaction temperature in the high-temperature furnace was 1500° C. and the reduction reaction time was 60 min or 65 min.
  • the metal iron conversion rates for the DRI obtained from the sample Nos. P-1, P-2 and P-3 are 91.4%, 84.2% and 89.8%, respectively.
  • the yields of the metal iron are 65.2, 43.6 and 48.6 Kg-M.Fe/(h*m 2 ) respectively.
  • Embodiment 1 of the present disclosure the reduction reaction was carried out with a holed cake.
  • Table 4 shows the reduction reaction conditions and the characteristics of the reduced iron produced in Embodiment 1 of the present disclosure.
  • the three metal oxide minerals used in Embodiment 1 are the same as those in the comparative example, and the mixing ratios of the carbonaceous reducing agents coal #1 and coal #2 are the same as that in the comparative example.
  • the binder is also added in an amount of 2%.
  • the holed cake has a parameter T of about 60 mm, a parameter d of about 16 mm, a parameter G of about 29 mm, and a parameter t of about 25 mm.
  • the holed cake was placed on a hearth in a high-temperature furnace.
  • the maximum reduction reaction temperature in the high-temperature furnace was 1450° C. and the reduction reaction time was 35 min.
  • the metal iron conversion rates obtained with the sample Nos. C-1, C-2 and C-3 are 90.5%, 83.2% and 95.5%, respectively.
  • the yields of the metal iron are 90.2, 62.4, and 69.6 Kg-M.Fe/(h*m 2 ) respectively.
  • Embodiment 1 it can be found through comparison of Embodiment 1 with the comparative example that when the reduction reaction is carried out with a holed cake, the reduced iron can be obtained with a comparable rate of conversion to metal iron at a low carbon/oxygen ratio (C/O), a low reduction reaction temperature, and with a short reduction reaction time, and the yield of metal iron is also increased considerably.
  • C/O carbon/oxygen ratio
  • Embodiment 2 of the present disclosure the reduction reaction was carried out with a holed cake.
  • Table 5 shows the reduction reaction conditions and the characteristics of the reduced iron produced in Embodiment 2 of the present disclosure.
  • Embodiment 2 the same raw materials are used, and the reduction reaction conditions are changed, in which the reduction reaction temperature drops from 1450° C. to 1350° C., and the reduction reaction time is prolonged from 35 min to 45 min, as compared with Embodiment 1 of the present disclosure.
  • the metal iron conversion rate is high for the sample No. C-1 and slightly low for sample Nos. C-5 and C-6; however, the reduced ion still has a high metal conversion rate, compared with Embodiment 1 of the present disclosure.
  • the yield of the metal iron is low compared with Embodiment 1 of the present disclosure. The reason is that the reduction reaction time is prolonged, causing the yield of the metal iron to decrease. However, although the yield of the metal iron in Embodiment 2 of the present disclosure is lower than that in Embodiment 1 of the present disclosure, it is still higher than that in the comparative example.
  • the reduction reaction is carried out with a holed cake, through which both a high metal iron conversion rate and a high yield of the metal iron are achieved. Moreover, the usage of the carbonaceous reducing agent is correspondingly reduced. Most importantly, the reduction reaction temperature is reduced from 1500 to 1350° C., which is an important breakthrough in the ironmaking technology.

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US15/851,394 2017-08-18 2017-12-21 Method for producing metal from metal oxide by carbothermic reduction and holed cake used therefor Abandoned US20190055616A1 (en)

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TW106128019 2017-08-18
TW106128019A TWI687520B (zh) 2017-08-18 2017-08-18 高效能金屬氧化物碳熱還原生產金屬之方法及其使用之多孔料餅

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024170464A1 (en) 2023-02-14 2024-08-22 Tata Steel Ijmuiden B.V. Method of producing direct reduced iron

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
TWI708852B (zh) * 2019-03-14 2020-11-01 中國鋼鐵股份有限公司 含鐵碳複合球團產製直接還原鐵之方法
CN113560591B (zh) * 2021-07-21 2023-04-21 安徽光智科技有限公司 锗金属小球的制备方法

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US3922165A (en) * 1974-08-16 1975-11-25 Jaconvel Company Method for direct reduction of iron ore using sleeve-shaped briquettes
US20100218644A1 (en) * 2007-08-07 2010-09-02 Victor Black Method of Producing Metals and Alloys by Carbothermal Reduction of Metal Oxides

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CN101956037B (zh) * 2010-08-31 2012-01-04 贾会平 间接加热式还原炼铁的方法和装置
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TWI568855B (zh) * 2016-04-21 2017-02-01 中國鋼鐵股份有限公司 產生高料層碳熱還原鐵的配渣控制方法

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US3918956A (en) * 1966-11-04 1975-11-11 Jesse J Baum Reduction method
US3922165A (en) * 1974-08-16 1975-11-25 Jaconvel Company Method for direct reduction of iron ore using sleeve-shaped briquettes
US20100218644A1 (en) * 2007-08-07 2010-09-02 Victor Black Method of Producing Metals and Alloys by Carbothermal Reduction of Metal Oxides

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024170464A1 (en) 2023-02-14 2024-08-22 Tata Steel Ijmuiden B.V. Method of producing direct reduced iron

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