Title of Invention
Method and apparatus for granulating molten metal.
Technical Field The present invention relates to a method and an apparatus for granulating molten metals and alloys, particularly silicon and alloys having a high content of silicon such as ferrosilicon.
Background Technology
From US patent No. 3,888,956 it is known a method for granulating molten metals, particularly molten iron, where the molten metal is caused to fall against a planar, fixed, unmoveable arranged disk, whereby the molten metal by its own kinetic energy split up is crushed against the disk to irregularly formed droplets which droplets move outwardly and fall down in a bath of cooling liquid below the disk. By this known method it is possible to produce metal granules, but the method has a number of drawbacks and disadvantages. It is thus not possible to regulate particle size and particle size distribution to any extent, as the droplets that form when the metal stream hits the disk will range from very small droplets to big droplets. By production of for instance granules of ferroalloy melts such as FeCr, FeSi, SiMn and others, a large part of granules or particles having a particle size less then 5 mm are formed. By production of ferrosilicon granules the part of particles having a particle size of less than 5 mm in typically in the range of 22 - 35 % of granulated melt and the mean particle size is about 7 mm. For ferrosilicon, particles having a size of below 5 mm are not wanted. Further, particles having a particle size below 1 mm are particularly harmful as such particles will be suspended in the bath of cooling liquid and necessitate a continuous cleaning of the cooling liquid.
The method according to US patent No. 3,888,956 has further shown to be exposed to explosions particularly when granulating silicon and alloys having a high content of silicon and a low content of easily oxidising alloying elements such as Ca and AI. The reason that explosions occur is that all particles have not got a shell of solidified alloy before they hit the cooling liquid
bath and that the film of water vapour that forms around each particle in the cooling bath may collapse and result in vapour explosions. Larger and minor explosions therefor occur by use of the method according to the US patent. The granulating plant must therefor be installed in separate building where the high probability for explosion is take care of.
From EP-A-372918 it is known a method for atomising metal melts. By this method it is used an inert gas at a very high velocity to split the metal stream into very small droplets and final cooling of the atomised droplets takes place in an inert gas atmosphere. This method will only give satisfactory particle size for a product with particles less then 2 mm and will give a major size of particles less then 0,1 mm and is therefor not suitable for products having a particle size of more then 1 mm.
From WO 97/09145 it is known that metal droplets can be formed directly in water and thereafter being solidified and cooled in a water stream in a downwardly slooping flume. By this method it is produced granules of larger size, typically 5 to 40 mm. The method has however, the drawback that the risk of vapour explosions is high as the surface of the liquid metals comes in direct contact with water.
Description of invention
By the present invention one has now arrived at a method for granulation of metal melts where the drawbacks of the existing methods have been overcome both in the ability to produce granules with very low amount of particles below 1 mm and strongly reducing the risk of vapour explosions.
The present invention thus relates to a method for granulating metal melts, particularly silicon and alloys having a high silicon content, where a continuous stream of molten metal by means of at least one low pressure gas stream is divided into metal droplets, which gas stream gives the metal droplets a forward and upward movement and where the metal droplets are collected in a flume with flowing water where the droplets are cooled and thereafter transported to a collecting unit.
According to a preferred embodiment, the metal stream is divided into metal droplets by means at three gas streams arranged at different vertical levels, where the upper gas stream introduces disturbance in the continuous metal stream, where the middle gas stream divides the metal stream into metal droplets and where the lower gas stream provides a forward and upward movement to the metal droplets before the metal droplets hit the flowing water in the flume.
The gas stream or gas streams preferably have a pressure of less than 1 bar overpressure.
By regulating the amount, velocity and direction of the gas stream or the gas streams in relation to the metal stream, the metal stream is divided into droplets having a size within a selected interval, for instance between 1 and 12 mm and where the part of particles outside the selected interval is very small.
Due to the fact that the particles are given an upward and forward movement, the particles will get a solid film on their surfaces before the particles hit the water. Further the low pressure gas stream will spread the particles before they hit the water in the flume. The risk for explosions is thereby substantially reduced compared to the conventional methods.
The present invention further relates to an apparatus for granulating metal melts, which apparatus comprises a reservoir for molten metal having means for pouring a continuous stream of molten metal from the reservoir, at least one nozzle for directing a gas stream against the metal stream, and a flume having means for providing a continuous water flow in the flume, said flume being arranged at a lower level than the gas nozzle or the gas nozzles.
According to a preferred embodiment the apparatus comprises three nozzles for directing a gas stream against the molten metal stream, which nozzles are
arranged at different vertical levels and where the gas stream can be regulated individually for each nozzle.
It has been found that by the method of the present invention it is possible to produce granules having a very low amount of particles below 1 mm. It has further been found that by the method of the present invention the risk for vapour explosions is substantially reduced wen granulating silicon and alloys having a high content of silicon. The reason being that the granules formed by the gas stream or gas streams are kept in air for a time sufficient to form a solid film of metal or alloy on the surface of each granule before the granules hits the cooling water in the flume.
Shot description of the drawings
Figure 1 shows a side elevation of an embodiment of the apparatus according to the present invention, and
Figure 2 shows a side elevation of a second embodiment of the apparatus according to the present invention.
Detailed description of the invention
On figure 1 there is shown an embodiment of the apparatus according to the present invention.
On figure 1 there is shown a reservoir 1 intended to contain molten metal. The reservoir 1 can be a tiltable ladle or the like. A metal stream 2 is poured from the reservoir 1 at a constant amount of metal per unit of time by tilting the reservoir 1 or by other conventional means. A gas nozzle 3 is arranged in such a way that a continuous gas stream hits the metal stream 2. The gas stream has such a velocity that the metal stream is divided into metal droplets 4 when the gas stream hits the metal stream and to provide a forward and upward movement to the metal droplets 4 as shown in Figure 1. A flume 5 having a small angle to the horizontal is arranged below the gas nozzle 3. The flume 5 has means (not shown) for continuous supply of water to the upper end of the flume 5. When the metal droplet hit the water in the flume 5 they
will be cooled and transported to the lower end of the flume where they are separated from the water in conventional ways such as a tank 6 equipped with a transport screw or a cell feeder 7 in the bottom for transporting the finished granules out of the tank 6.
In Figure 2 there is shown a second embodiment of the apparatus according to the invention. The apparatus shown in Figure 2 is identical to the apparatus shown in Figure 1 , except that it is arranged three gas nozzles at different vertical levels. Parts on Figure 2 corresponding to parts on Figure 1 have identical reference numerals.
In the embodiment shown in Figure 2 there are arranged three gas nozzles 10, 11 , 12. The upper gas nozzle 10 is intended to provide a gas stream against the metal stream 2 inducing disturbances to the metal stream 2, but does not divide the metal stream 2 into metal droplets. The middle gas nozzle 11 is intended to divide the metal stream 2 into metal droplets 4, while the lower gas nozzle 12 is intended to provide a gas stream which gives the metal droplets a forward and upward movement.
By regulating the gas streams from the gas nozzles 10, 11 and 12 to suitable values, it will be formed metal droplets 4 having such a retention time before they hit the water in the flume 5, that a solid film will be formed on each metal droplet.
Even if the embodiments shown in Figure 1 and Figure 2 have one, respectively three gas nozzles, it is understood that the apparatus according to the invention can have two gas nozzles or more than three gas nozzles.
By the method and apparatus according to the present invention, the possibility of explosion is substantially reduced as the metal droplets will have a solid film on the surface before they hit the water in the flume 5. There will thus not be any direct contact between liquid metal and cooling liquid.
EXAMPLE 1
Molten silicon with a purity of 98 % by weight was granulated in the apparatus shown in Figure 1. The amount of silicon poured was 150 kg/min and air was used as gas in the gas nozzle. It was obtained granules of silicon where 99 % by weight had a diameter of less then 10 mm, 55 % by weight had a diameter below 5 mm, 20 % by weight had a diameter of less then 3 mm and only 2 % by weight had a diameter less then 1 mm.
EXAMPLE 2 An alloy consisting of 75 % by weight of silicon, the reminder being iron except for minor impurities, was granulated in the apparatus shown in Figure 1. The amount of alloy poured was 60 kg/min. The particle size distribution of the produced granules was 99 % by weight less than 10 mm and 4 % by weight was than 1 mm. The mean granule size was 4 mm.