WO2005001362A1 - High temperature process - Google Patents
High temperature process Download PDFInfo
- Publication number
- WO2005001362A1 WO2005001362A1 PCT/AU2004/000837 AU2004000837W WO2005001362A1 WO 2005001362 A1 WO2005001362 A1 WO 2005001362A1 AU 2004000837 W AU2004000837 W AU 2004000837W WO 2005001362 A1 WO2005001362 A1 WO 2005001362A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- gas
- thermal exchange
- exchange means
- final product
- process according
- Prior art date
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D17/00—Arrangements for using waste heat; Arrangements for using, or disposing of, waste gases
- F27D17/001—Extraction of waste gases, collection of fumes and hoods used therefor
-
- 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
- C22B23/02—Obtaining nickel or cobalt by dry processes
- C22B23/021—Obtaining nickel or cobalt by dry processes by reduction in solid state, e.g. by segregation processes
-
- 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
- C22B5/12—Dry methods smelting of sulfides or formation of mattes by gases
Definitions
- the present invention relates to a process in which a starting material is converted into a final product by reaction of a gas at elevated temperature.
- the process is particularly concerned with using the thermal energy of the final product to raise the temperature of the gas prior to the reaction of the gas with the starting material.
- the intention here is to enhance the thermal efficiency of the system.
- the invention also relates to an apparatus suitable for carrying out the process.
- the present invention will be described with particular reference to the reduction of nickel oxide by reaction with hydrogen at elevated temperature to form nickel metal. However, it is to be appreciated that the principle underlying the invention is more generally applicable and may be employed with other reaction systems that rely on the same basic tenets.
- Hydrogen which is used in the cooling process is used upstream in the furnace for the reduction reaction.
- this hydrogen exits the cooling system at a temperature of about 150°C, it is necessary to increase the temperature of it significantly before it is delivered to the furnace, and here heaters may be used to pre-heat the hydrogen.
- the temperature of the hydrogen may be increased using heat energy from the furnace, resulting in a drop in temperature of the furnace. Additional energy is invariably also supplied to the furnace to counteract the chilling effect caused by introduction of hydrogen at a temperature relatively lower than the operating temperature of the furnace. This leads to an increase in the cost of constructing a reduction reactor due to the need to employ additional equipment (heaters for the hydrogen) and in operating the reactor due to higher energy demands.
- the present invention seeks to overcome these disadvantages by using the ⁇ nal energy of the final product to heat the gas reactant (hydrogen in the case illustrated) to a temperature higher than that achieved using the conventional technique described above.
- the invention also seeks to provide an apparatus which includes specific structural components to achieve this end. These structural components may add to the overall cost of the apparatus but this expense would be at least off-set by the savings in energy and/or the reduction in other furnace hardware associated with the invention.
- the present invention provides a process for converting a starting material into a final product by reaction of the starting material with a gas in a furnace at elevated temperature followed by cooling of the final product using a cooler, wherein, prior to introduction of the gas into the furnace the temperature of the gas is elevated by use of a thermal exchange means which is provided between the furnace and the cooler and which facilitates the transfer of thermal energy associated with the final product to the gas.
- the thermal exchange means Central to the present invention is the use of a thermal exchange means to transfer thermal energy from the final product to the gas used to effect conversion of the starting material.
- the thermal exchange means is intended to absorb radiant heat from the final product and convey this heat to the gas by convection and conduction.
- the thermal exchange means may be configured and positioned to maximise heat transfer to the gas.
- the conversion of starting material to final product takes place at elevated temperature.
- the resultant final product exits the furnace at elevated temperature.
- the present invention resides in using thermal energy associated with the final product to heat the gas which is used in the conversion reaction. This heat transfer takes place upstream of the cooler which is used to cool the final product.
- the gas being heated by use of the thermal exchange means is the same gas as used to effect conversion of the starting material to the final product in the furnace. Contacting the final product with this gas therefore also prevents any reverse reaction that would otherwise lead to reformation of the starting material.
- the conversion is the reduction of nickel oxide using hydrogen
- the use of hydrogen in the thermal exchange means maintains a reducing atmosphere that prevents oxidation of the nickel product.
- the gas used in the thermal exchange means provides cooling of the final product under conditions that will prevent reformation of the starting material.
- Hydrogen is also used during annealing of steel and stainless steel continuous strip to prevent oxidation that would otherwise occur. Cooling of the final product by use of the thermal exchange means will also reduce the load on the cooler to which the final product is subsequently delivered.
- the present invention may be applied to a variety of chemical conversions in which a starting material is reacted with a gas at elevated temperature to yield a final product which is also at elevated temperature.
- the conversion may be a reduction in which a metal oxide is reacted with a reducing gas, to yield the metal.
- One such conversion is that of nickel oxide to nickel using hydrogen. This usually takes place at a temperature of about 800 to about 1200°C, for example, about 900 to about 1000°C.
- the starting material and final product are both solids, although this is not essential.
- the invention is especially useful in processes that require the same gas for effecting the chemical reaction and for contributing to cooling of the final product.
- hydrogen is often used as process gas and coolant.
- the invention may also be useful for processes in which impurities are removed from a starting material by reaction with a gas at elevated temperature. For example, hydrogen may be used to remove sulphur from metal (e.g. nickel) briquettes.
- the present invention relies on the existence of a final product at elevated temperature in order to heat the gas used for the necessary chemical conversion. It follows from this that the present invention is not useful on start-up. However, the chemical conversions to which the present invention is applicable tend to be run continuously on an industrial scale. Thus, once start-up has been effected the process of the present invention may also be run continuously. Typically, when the process of the invention is up and running, all of the gas delivered to the furnace will have been heated in accordance with the present invention without requiring the addition of energy from an external source.
- thermo exchange means which is used to transfer heat energy of the final product to the gas before the gas is introduced into the furnace where the required chemical conversion takes place.
- the thermal exchange means is configured to optimise the amount of heat energy transferred from the final product to the gas. This will enhance the overall thermal efficiency of the system.
- the final product will cool at a slower rate than the gas temperature increases because the final product has a greater thermal mass.
- Heat transfer to the gas may also be optimised by providing the thermal exchange means immediately adjacent the furnace. This is because it is preferred from the viewpoint of maximising radiant heat transfer that the temperature of the final product be as high as possible as it is introduced into the thermal exchange means from the furnace. If the temperature of the final product cools to any significant degree before entering the thermal exchange means, the effectiveness of radiant heat transfer to the gas via the thermal exchange means will be diminished. This effect can be minimised by positioning the thermal exchange means immediately adjacent the furnace so that the final product from the furnace undergoes minimal cooling before being processed by the thermal exchange means. This principle can be applied to optimise the amount of heat transferred from the final product to the gas. It is also desirable to use a gas having high conductivity and specific heat, such as hydrogen, although this will obviously depend upon the chemical conversion being undertaken.
- the thermal exchange means comprises a series of individual baffle plates which are parallel to each other and inclined at an angle of from 30 to 60°, preferably 45°, to the horizontal.
- the plates are inclined in the direction of intended gas flow.
- the number, size, geometry, inclination and spacing of the plates are intended to cause turbulence in the gas thereby optimising heat transfer by ensuring intimate contact between incoming gas and the surfaces of the plates.
- the flow of incoming gas will contact a large surface area of the plates before exiting the thermal exchange means.
- the spacing between the baffle plates should be adjusted to ensure suitable upflow of gas between adjacent plates. If the spacing is too small, increased flow resistance occurs which reduces upflow.
- the material from which they are made preferably has high thermal conductivity.
- the conductivity of the plates is not particularly relevant (nor is their weight or thickness.)
- the plates are made of steel (such as stainless steel) and are blackened to maximise radiant heat transfer. This blackening may be done by techniques known in the art, such as chemical oxidation. However, here it will be necessary to take into account the conversion that is to take place in the furnace.
- the material from which the plates are formed should have sufficient structural integrity at the temperatures likely to be encountered in operation.
- the baffle plates are located in close proximity to the (hot) final product.
- the baffle plates are positioned above (and adjacent) the product as the product is transported through (and out of) the thermal exchange means, the spacing between the trailing (lower) edge of the plates and the product being as little as possible. It has been found that a significant portion of gas can pass beneath the plates in the space immediately above the product.
- the trailing edge of each plate may be provided with a flap which is easily displaced by contact with the product.
- the flap will usually be formed of the same material as the baffle plate and be attached (loosely) to the plate by a hinge permitting the flap to move relative to the baffle plate. After being displaced by product being transported the flap will swing back into a resting position.
- One function of the flaps is to encourage gas flow over the baffle plates.
- baffle plates are located adjacent the final product being transported means that, at thermal equilibrium, there is an essentially constant rate of radiant heat transfer from the product to the plates (and conductive heat transfer from the plates to the circulating gas in contact with the plates).
- the gas is passed over the plates generally in a direction counter to that of the final product as it is being transported.
- the final product is transported through the thermal exchange means on a conveyor belt.
- the trailing edge of each baffle plate will be arranged so as to be in close thermal proximity to the product as it is being transported. It is likely that the starting material enters and moves through the furnace on the same conveyor belt.
- the baffle plates will be positioned at a location within the thermal exchange means such that they are adjacent the final product as it enters the thermal exchange means and is transported through it.
- no conveyor belt is used and here the product may be transported over a series of mandrels or rollers. This would be the case for example in a continuous strip furnace. Similar considerations will then apply as described above with respect to use of a conveyor belt. It will be appreciated that the exact manner in which the final product is transported through the thermal exchange means is not especially critical provided that the intended thermal relationship between the final product and the thermal exchange means is preserved.
- the efficacy of the thermal exchange means may be enhanced by positioning the baffle plates below and adjacent the final product as it is transported.
- gas (for the conversion) entering the thermal exchange means is cooler, and thus heavier, than gas already present.
- This "fresh" gas is to flow downwards.
- Positioning the thermal exchange means below the final product being transported is likely to mean that more of this "fresh” gas will contact the thermal exchange means. It is of course possible to have thermal exchange means above and below the final product as it is transported.
- the baffle plates are corrugated to impart greater turbulence and offer increased surface area for gas contact.
- the thermal exchange means includes a suitable housing in order to ensure flow of gas over (and between) the baffle plates as required. This housing will be provided over the hot product as it is transported after exiting the furnace.
- the thermal exchange means includes an inlet for "cold” gas and an outlet for "heated” gas.
- the inlet and outlet are provided in close proximity to the hot product being transported.
- the gas outlet corresponds to the inlet for the final product, and vice versa.
- Gas delivered to the thermal exchange means gas may already have been used repeatedly (by means of recirculation and instream cooling) downstream of the thermal exchange means.
- the outlet delivers gas at an elevated temperature to the furnace.
- the gas in order to generate turbulence over the plates, is delivered under pressure. This is desirable since impingement of the gas with the final product and/or with heat exchange surfaces within the thermal exchange means may enhance the rate of heat uptake by the gas.
- the gas may be directed from a pressure chamber of the cooler downstream of the furnace (and thermal exchange means).
- gas is delivered to the thermal exchange means via an inlet provided close to the roof thereof. This has also been found to assist in creating gas turbulence in the thermal exchange means.
- a circulating fan may be provided to enhance the rate of convection heat transfer between the baffle plates and the gas.
- the thermal exchange means also includes a guide means which is provided adjacent the outlet of the thermal exchange means and which is configured to gather and funnel heated gas towards the outlet.
- this guide means takes the form of a plate which extends across the height of the thermal exchange means and which is inclined in the opposite direction to the other plates. Gas impinging upon this plate is deflected towards the outlet of the thermal exchange means. It has been found that the presence of this guide (exit) plate contributes to the overall performance of the thermal heat exchanger.
- the guide plate extends above the height of the baffle plates. The effect of this is to divert more of the upper-level flow in the thermal exchange means close to the guide plate.
- the position of the guide plate adjacent the gas outlet may also influence the velocity of gas flowing across this plate. This may cause some of the gas flowing parallel to and adjacent the final product to be diverted upwards thereby increasing the net flow over the top of the guide plate .
- the baffle and guide plates are usually attached to the housing at their edges. Typically, the plates are supported at one edge only. The supporting structures should be configured to minimise flow disruption and distortion on expansion of the plates. In practice, both sides of the plates may be supported.
- the gas to be used in the furnace is heated to 70-90%, more preferably 80-90% of the furnace temperature.
- the gas temperature is raised to a value which is relatively close to the operating temperature of the furnace. This greatly reduces the temperature slump that would occur in the furnace if gas were introduced unheated or at a temperature significantly lower than that of the furnace operating temperature. This also means that the chemical reaction in the furnace is likely to progress more immediately since little or no additional thermal energy needs to be supplied.
- the gas which is used in the process of the present invention will obviously vary depending upon the chemical conversion being undertaken. Mixtures of two or more suitable gases may be used. In reduction reactions, such as the conversion of nickel oxide to nickel, hydrogen, or a mixture of hydrogen and nitrogen at a volume ratio of 75:25 respectively, are typically used. Hydrogen is especially useful as it has a high specific heat and high thermal conductivity.
- the present invention also provides an apparatus suitable for carrying out the process described herein.
- the apparatus comprises a furnace provided upstream of a thermal exchange means as described, the thermal exchange means being provided upstream of a (product) cooler.
- upstream is intended to denote the relative position of these components of the apparatus, the starting material being introduced at the upstream end and the final product cooled at the downstream end.
- the furnace and thermal exchange means are in communication with each other in that the final product exiting the furnace is delivered to the thermal exchange means for heat uptake by the gas. These two components are also in communication in order to allow hot gas from the thermal exchange means to be delivered to the furnace. As noted above, the gas outlet is also the final product inlet to the thermal exchange means, and vice versa.
- the cooler receives final product which has been "processed" by the thermal exchange means. Usually, the same conveyor belt or mandrels/rollers will do this. When at least a portion of (pressurised) gas is fed from the cooler to the inlet of the thermal exchange means for the purpose of increasing turbulence, suitably arranged piping will generally be used.
- the figure shows a thermal exchange means (1) which includes a housing (2) provided over a conveyor belt (3) upon which final product is transported after leaving the furnace (not shown).
- the housing includes an inlet (4) for feed gas at relatively low temperature and an outlet (5) for delivery of heated gas to the furnace.
- the thermal exchange means (1) includes a series of baffle plates (6) which are provided at about 45° to the horizontal. These plates (6) are inclined in the direction of intended gas flow from inlet (4) to outlet (5).
- the plates (6) are in close proximity to the conveyor belt (3) and in use will be heated by hot product transported on the conveyor belt (3) (from left to right in the figure and thus counter to the direction of gas flow through the thermal exchange means (1)).
- Gas flow within the thermal exchange means (1) is turbulent resulting in gas flowing across and between the baffle plates (6).
- the thermal exchange means is also provided with a guide plate (7) which is provided at the outlet (5) end of the thermal exchange means (1).
- This guide plate (7) extends across the height of the housing (2) and is inclined in the opposite direction to the baffle plates (6). The function of the guide plate (7) is to channel hot gas towards the outlet (5).
- Thermal exchange means - dimensions and characteristics Housing: stainless steel. Length: 2640mm. Height (roof to conveyor belt): 650mm.
- Inlet/outlet dimension 150mm, provided at opposite ends of the thermal exchange means 100mm above the product on the conveyor belt. Practically, this dimension will be dependant on the product thickness, and it is desirable to minimise the distance between the product and the bottom of the plates in order to discourage laminar flow over the product as this can by-pass the plates.
- a stainless steel plate separates the thermal exchange means from the adjacent compartment of the apparatus.
- Plate spacing 125mm (measured along the horizontal). Clearance from conveyor belt: 140mm (first plate, inlet end); 150mm (remaining 12 plates).
- Nickel powder is transported on the conveyor belt at lm/min at a temperature of 980°C.
- a mixture of nitrogen and hydrogen at a volume ratio N 2 :H 2 of 25:75 was introduced at 150°C at an entry rate of 500m 3 /hr.
- the gas exit temperature was found to be about 700°C.
- the surface temperature of the nickel powder was found to decrease by on average about 150°C during transit through the thermal exchange means. It was also found that the highest gas velocity occurred at the outlet where the heated and expanded gas is forced through a relatively small exit aperture.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Furnace Details (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2004252178A AU2004252178B2 (en) | 2003-06-30 | 2004-06-29 | High temperature process |
CA2527025A CA2527025C (en) | 2003-06-30 | 2004-06-29 | Cooling a final product to heat a furnace gas |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2003903344A AU2003903344A0 (en) | 2003-06-30 | 2003-06-30 | High temperature process |
AU2003903344 | 2003-06-30 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005001362A1 true WO2005001362A1 (en) | 2005-01-06 |
Family
ID=31982979
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2004/000837 WO2005001362A1 (en) | 2003-06-30 | 2004-06-29 | High temperature process |
Country Status (4)
Country | Link |
---|---|
AU (1) | AU2003903344A0 (en) |
CA (1) | CA2527025C (en) |
WO (1) | WO2005001362A1 (en) |
ZA (1) | ZA200509641B (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8466927B2 (en) | 2007-06-15 | 2013-06-18 | Ricoh Co., Ltd. | Full framebuffer for electronic paper displays |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB191216275A (en) * | 1911-10-05 | 1913-05-29 | Albert Hiorth | Process of Extracting Iron and Steel. |
FR2373612A1 (en) * | 1976-12-13 | 1978-07-07 | Siderurgie Fse Inst Rech | Zinc recovery from steelworks dust - where hot blast furnace gas reduces zinc oxide to zinc vapour which is re:oxidised and collected |
US5730775A (en) * | 1994-12-16 | 1998-03-24 | Midrex International B.V. Rotterdam, Zurich Branch | Method for rapid reduction of iron oxide in a rotary hearth furnace |
JP2001272180A (en) * | 2000-03-27 | 2001-10-05 | Mitsubishi Heavy Ind Ltd | Heat exchanger |
US6482351B2 (en) * | 2000-07-05 | 2002-11-19 | Mitsubishi Heavy Industries, Ltd. | Apparatus for producing reduced iron |
-
2003
- 2003-06-30 AU AU2003903344A patent/AU2003903344A0/en not_active Abandoned
-
2004
- 2004-06-29 CA CA2527025A patent/CA2527025C/en not_active Expired - Lifetime
- 2004-06-29 WO PCT/AU2004/000837 patent/WO2005001362A1/en active Application Filing
-
2005
- 2005-11-29 ZA ZA200509641A patent/ZA200509641B/en unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB191216275A (en) * | 1911-10-05 | 1913-05-29 | Albert Hiorth | Process of Extracting Iron and Steel. |
FR2373612A1 (en) * | 1976-12-13 | 1978-07-07 | Siderurgie Fse Inst Rech | Zinc recovery from steelworks dust - where hot blast furnace gas reduces zinc oxide to zinc vapour which is re:oxidised and collected |
US5730775A (en) * | 1994-12-16 | 1998-03-24 | Midrex International B.V. Rotterdam, Zurich Branch | Method for rapid reduction of iron oxide in a rotary hearth furnace |
JP2001272180A (en) * | 2000-03-27 | 2001-10-05 | Mitsubishi Heavy Ind Ltd | Heat exchanger |
US6482351B2 (en) * | 2000-07-05 | 2002-11-19 | Mitsubishi Heavy Industries, Ltd. | Apparatus for producing reduced iron |
Non-Patent Citations (1)
Title |
---|
PATENT ABSTRACTS OF JAPAN * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8466927B2 (en) | 2007-06-15 | 2013-06-18 | Ricoh Co., Ltd. | Full framebuffer for electronic paper displays |
Also Published As
Publication number | Publication date |
---|---|
ZA200509641B (en) | 2006-11-29 |
CA2527025C (en) | 2012-12-04 |
AU2003903344A0 (en) | 2003-07-17 |
CA2527025A1 (en) | 2005-01-06 |
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