WO2011002465A1 - Utilisation d'un four à induction en canal pour traiter un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie à partir de différents matériaux d'alimentation - Google Patents

Utilisation d'un four à induction en canal pour traiter un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie à partir de différents matériaux d'alimentation Download PDF

Info

Publication number
WO2011002465A1
WO2011002465A1 PCT/US2009/049561 US2009049561W WO2011002465A1 WO 2011002465 A1 WO2011002465 A1 WO 2011002465A1 US 2009049561 W US2009049561 W US 2009049561W WO 2011002465 A1 WO2011002465 A1 WO 2011002465A1
Authority
WO
WIPO (PCT)
Prior art keywords
product
molten metal
induction furnace
waste material
slag
Prior art date
Application number
PCT/US2009/049561
Other languages
English (en)
Inventor
James A. Bratina
Thomas Edward Roberts
Original Assignee
Heritage Environmental Services, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Heritage Environmental Services, Llc filed Critical Heritage Environmental Services, Llc
Priority to PCT/US2009/049561 priority Critical patent/WO2011002465A1/fr
Publication of WO2011002465A1 publication Critical patent/WO2011002465A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B14/00—Crucible or pot furnaces
    • F27B14/06—Crucible or pot furnaces heated electrically, e.g. induction crucible furnaces with or without any other source of heat
    • F27B14/061—Induction furnaces
    • F27B14/065—Channel type
    • 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
    • C21B13/0046—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
    • C21B13/008—Use of special additives or fluxing agents
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B14/00—Crucible or pot furnaces
    • F27B14/02—Crucible or pot furnaces with tilting or rocking arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B14/00—Crucible or pot furnaces
    • F27B14/06—Crucible or pot furnaces heated electrically, e.g. induction crucible furnaces with or without any other source of heat
    • F27B14/061—Induction furnaces
    • 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
    • F27D17/003—Extraction of waste gases, collection of fumes and hoods used therefor of waste gases emanating from an electric arc furnace
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2200/00—Recycling of non-gaseous waste material
    • 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
    • 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
    • Y02P10/25—Process efficiency

Definitions

  • the present invention relates to the methods for processing various materials to retain one or more product(s) from such materials. More particularly, the present invention relates to methods and process for processing various materials in an induction furnace to obtain at least one of a metal product, a slag product and a volatile product.
  • EAF electric arc furnace
  • BOF basic oxygen furnace
  • EAF dust and BOF sludge/dust contain significant quantities of iron that make these materials valuable for use directly in steel making processes as a substitute for other iron containing materials such as scrap steel, hot metal, sinter dust, and other iron oxides present at steel making facilities.
  • EAF dust also contains significant quantities of zinc which makes it valuable as a feed for zinc manufacturing processes.
  • BOF sludge/dust contains smaller quantities of zinc, but the zinc present can be recovered for reuse as a zinc product.
  • EAF dust is also subject to stabilization processes followed by landfill disposal.
  • a small quantity of BOF sludge/dust is returned to the BOF steel making process in some locations arid some is recycled in other manners, but a large volume is disposed as a waste material in landfills.
  • U. S. Patent No. 6,831,939 to Bratina and Fehsenfeld discloses an expansion of the Zoppi patent that involves operating an induction furnace to both produce hot metal and a pig iron product and to process iron and volatile metal containing materials to recover iron value and concentrate metals which are volatile at the operating temperature of the induction furnace.
  • the process relies upon mixing feeding both metal oxides and reduction material into the induction furnace. The efficiency of the process is limited by the induction furnace that is used.
  • U.S. Patent Application Publication No. 2007/0062330 to Bratina et al. is directed to methods and processes of configuring and operating an induction furnace to process waste materials while producing metal products and recovering iron and volatile metals in a manner that is energy efficient and provides improved separation of volatile metals and improved control of slag viscosity.
  • U.S. Patent Application Publication No. 2007/0157761 to Bratina is directed to a method for the production of an iron product from ore containing iron which involves the use of an induction furnace.
  • the present invention is based upon tests that were conducted using a channel induction furnace similar to that disclosed in U.S. Patent Application Publication No. 2007/0062330 to Bratina et al. During the course of such tests a number of new unexpected discoveries were realized.
  • the present invention is directed to the use of an induction furnace to process various waste materials, including metal and non-metal wastes in such a manner so as to produce and/or retain one or more product(s) from such waste materials.
  • the present invention provides a method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which involves:
  • the at least one waste material to react in the channel induction furnace to produce at least one of a molten metal product that passes into the molten metal bath, a vapor phase metal product that passes into the headspace of the channel induction furnace and a slag product that floats as a layer on the molten metal bath,
  • the at least one waste material consists of a source of at least one of:
  • the present invention further provides a method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which involves:
  • the at least one waste material to react in the channel induction furnace to produce at least one of a molten metal product that passes into the molten metal bath, a vapor phase metal product that passes into the headspace of the channel induction furnace and a slag product that floats as a layer on the molten metal bath,
  • the at least one waste material is formed into one of a briquette and a pellet using a binder selected from the group consisting of waste paint, cola syrup, soft drink syrup and mixtures thereof.
  • Figure 1 depicts a prior art system that uses an induction furnace to both produce hot metal (or pig iron) and to recover iron value from iron and volatile metal containing materials, including EAF dust while concentrating volatile metals such as zinc, lead, cadmium, etc.
  • Figure 2 is a front view of a channel induction furnace used according to one
  • Figure 3 is a top view of the channel induction furnace of Fig. 2.
  • Figure 4 is a side view of the channel induction furnace of Fig. 2.
  • Figure 5 is a schematic drawing of the channel induction furnace of Figs. 2-4 which is provided to illustrate how the process of the present invention works according to one embodiment.
  • Figure 6 is a schematic illustration of how feed materials react in the channel induction furnace according to the present invention.
  • the present invention is generally directed to methods and apparatus that involve the use of an induction furnace for processing various metal and/or non-metal waste materials while producing one or more products.
  • Reference herein to waste and waste materials is not intended to limit the present invention which is capable of processing a variety of materials that contain various volatile metals, non-volatile metals, and non-metal components, including, ores, scrap materials, stock materials, machining wastes, industrial wastes, etc.
  • the present invention involves a method of configuring and operating an induction furnace for the processing various metal and/or non-metal waste materials and producing one or more products in a manner that is energy efficient and provides improved separation of components from the metal and non-metal waste materials.
  • the waste materials can be added as various feed streams into the induction furnace. Waste materials that can be processed according to the present invention are exemplified by those listed in Table 1 below.
  • the configuration of the induction furnace used according to the present invention allows for: 1) controlling the gas temperature in the headspace of the furnace by controlling the flow of excess air into the furnace; 2) controlling the combustion of carbon monoxide in the gas headspace to provide additional heat in the headspace while allowing the gas headspace to remain in a reducing state to prevent volatile metals such as zinc from being oxidized; 3) controlling the chemistry of slag formed in the process with additions of slagging agents (which can be waste materials) to product a fluid slag material that can be easily removed from the furnace and used as a slag conditioner for the steel making industry, an aggregate for forming pavements, a construction article such as pavers or blocks, etc.; 4) providing a feed location at the opposite end of the gas and slag removal locations to allow for a plug flow type reactor that provides an extended reaction time for the process, allowing for more complete separation of the various feed materials in the process; and 5) providing a channel type induction furnace that allows a more energy efficient furnace to be used with thicker
  • the improved energy and separation efficiency of the present invention serves to provide for a system that will be capable of processing a wide variety of feed materials, including waste materials, in a more cost effective manner than previous processes.
  • the apparatus used for the present invention includes a channel type induction furnace as its main component that has an inductor at the bottom or other suitable lower portion of the furnace body.
  • This feature allows the furnace to be designed in a more energy efficient manner by incorporating a thicker layer of refractory in the main body (drum portion) of the furnace. This thicker refractor also provides for longer period of time between the need for refractory replacement. While the use of an induction furnace of this type is not unique per se, the use of such an induction furnace for processing various metal and non-metal materials and producing one or more products according to the present invention is unique as evidenced by the specific features and operating methods described herein.
  • the use of a channel type induction furnace also allows additional improvements to be made in the form of energy efficiency.
  • the body of the furnace is a horizontal drum that can be enclosed to thereby allow the flow of air into the process to be restricted and controlled.
  • the restriction of air flow into the drum limits the quantity of air that is heated in the furnace and removed by the gas control system on the furnace, thus reducing the heat lose to the air that is normal for typical induction furnace operation.
  • the amount of air that enters the furnace can be controlled so as to burn a portion of the carbon monoxide generated by feed materials added into the furnace and/or to combust materials such as organic materials or components.
  • the burning of carbon monoxide in the headspace of the furnace and/or organics can provide additional heat in the gas headspace of the furnace thereby allowing the furnace to operate with a higher temperature in the headspaced than is normal for operation.
  • the high temperature of the gas headspace achieved by the process of the present invention which can range from about 1,300 0 C to about 1,500 0 C, eliminates or greatly reduces heat loss from the surface of the furnace bath and thereby allows the slag on the surface of the bath to be maintained at a higher temperature.
  • the flow of air into the furnace can also be controlled as desired to limit the air to a level at which carbon monoxide formed as a result of the metal oxidation reduction process in the system will not be completely oxidized.
  • By keeping excess carbon monoxide in the gas headspace of the furnace the system will be operated in a reducing mode until the gases exit the furnace.
  • volatile metals released from the feed materials such as zinc, lead and cadmium (in the vapor form) are prevented from being oxidized in the furnace before they are removed. This manner of operating limits oxidized volatile metals from being deposited in the slag leaving the furnace. As a result, a cleaner slag is maintained during the process.
  • the present invention provides for the ability to make a higher quality fluid slag that is easier to remove from the induction furnace process. This is accomplished in at least three ways.
  • the air flow into the furnace can be controlled according to the present invention to produce a higher temperature gas headspace.
  • This higher temperature in the gas headspace heats the upper surface of the slag layer.
  • the higher temperature in the gas headspace which is not provided by typical operation of an induction furnace, prevents and can actually reverse normal loss of heat from the slag surface thereby, in either event, providing a higher temperature for the slag layer.
  • the fluidity of the slag is increased as compared to the manner in which an induction furnace is typically operated.
  • the chemistry of the slag layer can be adjusted to provide a more fluid slag and to provide a slag product that has various uses such as a slag conditioner for the steel making industry, an aggregate for forming pavements, a construction article such as pavers or blocks, etc. This is accomplished by adding silica, lime or some other material or known slagging agent or waste materials to improve the fluidity and quality of the slag.
  • the induction furnace used according to the present invention is provided with a feed at one end of the furnace and slag/gas removal at the opposite end.
  • This arrangement provides a reaction zone that provides an increase process retention time.
  • This increase in retention time is provided by plug flow movement of the slag on the surface of the iron bath from the feed point to the slag discharge point.
  • the retention time provides more time for volatile metals to react and leave the slag surface before the slag is removed from the furnace.
  • the removed slag therefore has a lower concentration of volatile metals and the proper chemistry for value as an aggregate for road construction applications.
  • Figure 1 depicts a prior art system that uses an induction furnace to both produce hot metal (or pig iron) and to recover iron value from iron and volatile metal containing materials, including EAF dust while concentrating volatile metals such as zinc, lead, cadmium, etc.
  • the system depicted in Fig. 1 includes a channel induction furnace 1 inside of which a charge 2 of molten material such as molten iron is depicted as only partially filling the induction furnace 1.
  • the portion or area of charge 2 at and near the upper surface of the charge 2 is relatively calm due to the use of an induction furnace which includes an inductor located at or near the bottom of the furnace through which movement of the molten bath is limited so as not to create turbulent conditions at or near the surface of the charge 2.
  • the portion or area of charge 2 at and near the upper surface of the charge 2 can thus be controlled to flow or move through the induction furnace by adding feed materials through an inlet on one side or end of the furnace and removing slag through an outlet on an opposite side or end of the furnace.
  • This manner of feeding materials into the furnace and removing slag from the furnace allows for a plug flow type reactor that provides an extended reaction time for the process as mentioned above.
  • the channel induction furnace 1 is coupled to a hood 3 through which gases and vapors in the headspace of the channel induction furnace 1 are removed.
  • the hood 3 can be coupled by an air passage 4 to a cyclone 5 in which the coarsest and heaviest components are removed and collected at 6. Complete dust removal takes place in bag house 7 which is upstream of chimney 8. Components removed at bag house 7 are collected at 9.
  • Figure 2 is a front view of a channel induction furnace used according to one embodiment of the present invention.
  • Figure 3 is a top view of the channel induction furnace of Fig. 3.
  • Figure 4 is a side view of the channel induction furnace of Fig. 2.
  • the channel induction furnace 1 in Figs. 2-4 is configured to operate in a continuous fashion to process feed materials while producing various products from materials fed into the furnace. It is also possible to operate the furnace in a batch or semi-continuous batch manner.
  • the channel induction furnace 1 is configured to remove slag in a continuous manner and is configured to have a gas outlet 10 that can be coupled to a hood 4 shown in Fig. 1. It is also possible to remove the slag in a batch or semi-continuous batch manner.
  • the channel induction furnace 1 generally includes a drum- or cylindrical-shaped chamber 11 that is surrounded and defined by a refractory material 12 that is provided as a liner.
  • a refractory material 12 that is provided as a liner.
  • An inductor 13 of conventional design is provided at a bottom portion of the drum-shaped chamber 11 and used to maintain the molten bath in the channel induction furnace 1. It is also possible to use the inductor 13 to form an initial molten bath in the channel induction furnace 1 ; however, it is generally more efficient to form the initial molten bath in some other manner and use the inductor 13 to maintain the molten bath.
  • an inlet 14 for feeding materials into the channel induction furnace 1 is provided near one side or end and an outlet 10 for removal of gases is provided at an opposite side or end as shown.
  • the channel induction furnace 1 can also be provided with an access port 15 that is generally closed during operation.
  • the access port 15 is shown as being centrally located at the top of the channel induction furnace 1.
  • a slag discharge 16 is provided at a side or end of the channel induction furnace 1 that is opposite of inlet 14 and at a height that is suitable for controlling a slag layer that forms on a molten bath within the channel induction furnace 1.
  • the slag discharge 16 comprises a trough or channel structure that extends from the side of the channel induction furnace 1 and is in fluid communication with the drum- or cylindrical-shaped chamber 11.
  • the slag discharge 16 can be provided with a gate or movable dam that can be used to control slag discharge.
  • the channel induction furnace 1 is also provided with a spout 17 in the front of the furnace 1 through which molten metal from the molten bath can be removed from the drum- or cylindrical-shaped chamber 11.
  • the channel induction furnace 1 is provided with a mechanism generally identified by reference number 18 which is used to rotate the drum- or cylindrical-shaped chamber 11 about its central axis in a known manner so that molten metal in the molten bath can flow out through the spout 17.
  • FIG. 5 is a schematic drawing of the channel induction furnace of Figs. 2-4 which is provided to illustrate how the process of the present invention works according to one embodiment.
  • the inductor 13 is located at the bottom of the channel induction furnace 1 where it is in communication with the drum- or cylindrical-shaped chamber 11 discussed above.
  • a feed stream 19 enters the channel induction furnace 1 through inlet 14 provided in the top of the furnace 1 near one side or end.
  • Slag conditioning material such as silica, lime, etc. can also be added to the process through inlet 14 which is at the opposite side or end of the drum- or cylindrical-shaped chamber 11 than the slag discharge 16.
  • the temperature of the feed materials increases due to the operating temperatures of the channel induction furnace and contact and exposure to the hot slag, heated gas headspace and molten charge.
  • Metals and metal components that have a high density pass through the slag layer 21 and into the underlying molten bath 22 in the bottom portion of the channel induction furnace 1.
  • the inductor 13 provides energy for the molten metal bath 22 from electrical power to keep the bath 22 at a desired operating temperature.
  • the molten material of the bath 22 is removed from the channel induction furnace 1 through a spout 17 at the front of the furnace 1.
  • Slag which has a lower density than the liquid molten bath material will float on the surface of the molten bath 22 and flow toward the slag discharge 16 at the opposite side or end of the channel induction furnace 1 from the inlet 14.
  • the slag will be kept fluid by a combination of high temperature in the gas headspace 20 and slag conditioning additives that improve the slag viscosity as discussed above.
  • the slag can be removed continuously or semi-continuously as desired by the system operation.
  • the travel time from the addition of new feed material to the discharge of its slag components can be adjusted by changing the depth or thickness of the slag layer 16 in the channel induction furnace 1 or changing the surface area of the liquid levels in the furnace through equipment design changes.
  • Gases produced from the process will be a combination of carbon monoxide, carbon dioxide, volatile metal vapors and combustion products of organic materials, depending on what types of materials are fed into the system.
  • Some air can be added to the system with the feed material stream inlet 14 and at the slag discharge 16. The oxygen in this added air can burn a portion of the carbon monoxide within the gas headspace 20 to add additional heat to the gas headspace 20 area. If too much air is added or allowed to enter at these or other points, all of the carbon monoxide present in the gas headspace 20 can be burnt followed by the burning or oxidation of a portion of any metal vapors.
  • metal vapors are allowed to burn or oxidize they will form metal oxides that could condense in the channel induction furnace 1 and into the slag layer 21. This undesired burning or oxidation of metal vapors would result in a lower percentage of volatile metal recovery and an increase in unwanted materials in the slag layer.
  • the present invention according involves operating the system with control of the air entering the furnace in order to provide the proper gas headspace 20 operating temperature and limit oxygen entering the gas headspace 20.
  • the gas stream 23 exiting the channel induction furnace 1 can be reacted with air as it leaves the furnace 1 to oxidize any volatile metals so that they can be collected in the manner taught by U. S. Patent No. 6,136,059 to Zoppi and U. S. Patent No. 6,831,939 to Bratina and Fehsenfeld. These collected volatile metal materials can be subsequently processed to recover the volatile metals according to conventional processes.
  • the slag layer 21 can be removed and consequently reduced in thickness until the surface of the underlying molten metal bath 22 approaches the height of the slag discharge 16, before which the drum- or cylindrical-shaped chamber 11 can be rotated about its central axis so that molten metal in the bath 22 can flow out through the spout 17.
  • Table 1 is a non-exhaustive list of various materials that can be fed into the system according to the present invention.
  • Batteries include: NiCd, Alkaline, Lithium Ion, Zn/Fe.
  • Table 1 is a non-exhaustive list of various materials, many of which are considered waste materials from the standpoint that prior to the present invention it was either not believed that any useful product(s) could be obtained from these materials or there was no efficient process for recovering products from these materials.
  • the overall concept of the present invention is to use a waste material as a feed stream and produce therefrom at least one and preferably two or more useful products. These products can be recovered from the channel induction furnace as a released vapor that is subsequently collected and/or a slag product and/or a molten product that is obtained from the molten bath in the channel induction furnace.
  • FIG. 6 is a schematic illustration of how feed materials react in the channel induction furnace.
  • a mass of feed material identified by reference numeral 24 represents a briquette, or pelletized or accumulated volume or mass of loose feed material that contains volatile metal oxides and non- volatile metal oxides.
  • the mass of feed material 24 floats on or in slag layer 21 so that a significant portion of the surface area of the mass of feed material 22 is exposed to the slag in the slag layer 21.
  • the volatile metal oxides in the feed material are represented by zinc oxide (ZnO), it being understood that other volatile metals could be included such as cadmium, lead, and other metals that will enter the vapor phase at the operating conditions of the channel induction furnace.
  • ZnO zinc oxide
  • the non- volatile metal oxides are represented by iron oxide (Fe 2 O 3 ), it being understood that the feed materials could contain other non-volatile metal oxides which can be reduced into elemental metals which are in the liquid phase at the operating conditions of the channel induction furnace. It is further noted that the feed materials typically contain other components which produce the slag and can include for example non-metallic components and compounds such as calcium silicates, silica, alumina, calcia, magnesium, etc. For simplicity, these material components that form the slag are not shown in Fig. 6.
  • the molten bath 22 contains carbon as a reductant.
  • the carbon in the molten bath 22 reacts both with the volatile metal oxides in the feed materials and reacts with the non-volatile metal oxides in the feed materials, hi the exemplary case of zinc oxide, the zinc oxide reacts with carbon from the molten bath 22 as follows: ZnO + C ⁇ Zn + CO
  • the elemental zinc (Zn) produced by the carbon reduction of zinc oxide forms in the vapor phase and passes through or leaves the slag layer 21 and enters the headspace 20 of the channel induction furnace for collection and processing as discussed herein.
  • the carbon monoxide forms as a gas and passes through or leaves the slag layer 21 and enters the headspace 20 of the channel induction furnace.
  • iron oxide Fe 2 Os
  • the iron oxide reacts with carbon from the molten bath 22 as follow:
  • the elemental iron (Fe) produced by the carbon reduction of iron oxide forms in the liquid phase and passes through or leaves the slag layer 21 and enters the molten bath 22 beneath the slag layer 21.
  • the carbon monoxide forms as a gas and passes through or leaves the slag layer 21 and enters the headspace 20 of the channel induction furnace.
  • the reaction zone for each mass of feed material is located substantially in the slag layer.
  • the discrete masses or volumes of the feed materials break up and/or dissolve so that by the time they flow from the inlet 8 of the channel induction furnace to the slag discharge 16 with the moving slag layer they are completely reacted and converted into elemental volatile metals that leave through the headspace 20 via vapor phase and/or elemental non- volatile metals that enter the molten bath in the liquid phase and/or non-metallic components that become part of the slag layer.
  • the reaction or residence time of the discrete masses or volumes of the feed materials through the channel induction furnace 1 can accordingly be controlled by removal of the slag through the slag discharge.
  • the chemistry and fluidity of the slag layer can be controlled as desired by adding appropriate agents to the slag and carbon, which is depleted from the molten bath as the reactions proceed, can be replenished by adding reductants together with the feed materials or otherwise into the molten bath independently of the feed materials.
  • feed materials which provide a source of iron which is recovered from the molten bath as a iron product, e.g. pig iron, as listed in Table 1
  • other feed materials can provide a source of iron alloy and either a source of slag or a source of a volatile metal such as zinc.
  • feed materials include EAF dust from stainless steel processes, stainless steel sludges, and spent catalysts.
  • feed materials provide a source of iron, a source of slag and a source of volatile metals such as zinc.
  • feed materials include EAF dust from carbon steel processes, BOF dust and AOD dust.
  • feed materials can provide both a source of iron and a reductant.
  • feed materials include blast furnace dust, iron and/or steel borings, iron and/or steel stampings, kish fines, and iron carbonate.
  • feed materials provide a source of iron and a minor source of slag. These feed materials include mill scale and waste iron oxides.
  • feed materials provide a conditioner for the slag and a reductant.
  • feed materials include silica carbide, silica wastes and silicon wastes.
  • Waste paints and cola/soft drink syrups are examples of feed materials that function as binders for briquettes or pellets with waste paints exemplifying feed materials that also provide a source of volatile metals such as zinc.
  • the feed materials exemplified in Table 1 can be used separately or in combination.
  • the Feed materials can be subjected to a briquetting or pelletizing process or fed in as a loose material.
  • the feed materials can also be pre-heated if desired. Due to the extreme operating temperature of the induction furnace, the feed materials can contain moisture and/or organic components, including oily components. Such moisture and organic components will quickly vaporize as the feed materials enter the induction furnace. Further, any organics exiting the induction furnace will be oxidized with carbon monoxide and volatile materials (e.g. zinc).
  • the feed materials can include waste materials that are considered as hazardous wastes, including those which are classified as hazardous wastes under RCRA. hi such cases these waste materials will not be subject to RCRA regulations due to the fact that they are being used as feedstocks according to the present invention to produce commercial products.
  • the process of the present invention can be preformed at the site where waste materials are produced by installing and operating a channel induction furnace as described herein.
  • waste products can be transported from a site where the waste materials are produced to a separate facility that operates a channel induction furnace as described herein.

Abstract

L'invention concerne un procédé d'utilisation d'un four à induction en canal pour traiter un matériau d'alimentation et obtenir à partir de celui-ci un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie. Le procédé comprend l'utilisation de différents matériaux d'alimentation qui contribuent à former le produit métallique fondu et/ou le produit métallique en phase vapeur et/ou le produit de scorie et/ou qui jouent le rôle de liant pour transformer en briquettes ou en pastilles le matériau d'alimentation.
PCT/US2009/049561 2009-07-02 2009-07-02 Utilisation d'un four à induction en canal pour traiter un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie à partir de différents matériaux d'alimentation WO2011002465A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2009/049561 WO2011002465A1 (fr) 2009-07-02 2009-07-02 Utilisation d'un four à induction en canal pour traiter un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie à partir de différents matériaux d'alimentation

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2009/049561 WO2011002465A1 (fr) 2009-07-02 2009-07-02 Utilisation d'un four à induction en canal pour traiter un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie à partir de différents matériaux d'alimentation

Publications (1)

Publication Number Publication Date
WO2011002465A1 true WO2011002465A1 (fr) 2011-01-06

Family

ID=43411327

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2009/049561 WO2011002465A1 (fr) 2009-07-02 2009-07-02 Utilisation d'un four à induction en canal pour traiter un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie à partir de différents matériaux d'alimentation

Country Status (1)

Country Link
WO (1) WO2011002465A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112267021A (zh) * 2020-09-07 2021-01-26 钢研晟华科技股份有限公司 一种含锌尘泥与熔融钢渣协同处理的系统及方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR19980052524A (ko) * 1996-12-24 1998-09-25 김종진 전기로 분진 처리방법
KR19980076710A (ko) * 1997-04-12 1998-11-16 황용길 Ld전로제강 더스트와 eaf제강 더스트 및 ld전로제강 슬래그로부터 선철과 아연을 회수하는 방법
KR20080011157A (ko) * 2005-04-01 2008-01-31 제임스 이. 브라티나 에너지 절약, 휘발성 금속 제거 및 슬래그 제어를 위한산화철 회수로의 조작
KR100902401B1 (ko) * 2007-09-04 2009-06-11 (주)풍전비철 제강 분진을 함유한 아연 제련용 분말 및 그 제조방법

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR19980052524A (ko) * 1996-12-24 1998-09-25 김종진 전기로 분진 처리방법
KR19980076710A (ko) * 1997-04-12 1998-11-16 황용길 Ld전로제강 더스트와 eaf제강 더스트 및 ld전로제강 슬래그로부터 선철과 아연을 회수하는 방법
KR20080011157A (ko) * 2005-04-01 2008-01-31 제임스 이. 브라티나 에너지 절약, 휘발성 금속 제거 및 슬래그 제어를 위한산화철 회수로의 조작
KR100902401B1 (ko) * 2007-09-04 2009-06-11 (주)풍전비철 제강 분진을 함유한 아연 제련용 분말 및 그 제조방법

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112267021A (zh) * 2020-09-07 2021-01-26 钢研晟华科技股份有限公司 一种含锌尘泥与熔融钢渣协同处理的系统及方法

Similar Documents

Publication Publication Date Title
AU2006232236B2 (en) Operation of iron oxide recovery furnace for energy savings, volatile metal removal and slag control
CA2636155C (fr) Utilisation d'un four a induction pour la fabrication de fer a partir de minerai
US5188658A (en) Method for recovering zinc from zinc-containing waste materials
US7740681B2 (en) Reductant addition in a channel induction furnace
KR101619169B1 (ko) 고농도의 아연을 갖는 철광석들로부터 유가 철의 추출 및 아연의 분리 방법
CN104105802A (zh) 贱金属回收
US7776126B2 (en) Processing parameters for operation of a channel induction furnace
US7785389B2 (en) Feed material composition and handling in a channel induction furnace
KiranKumar et al. A review on processing of electric arc furnace dust (EAFD) by pyro-metallurgical processes
US7727302B2 (en) Slag control in a channel induction furnace
WO1996034987A1 (fr) Procede de recuperation de metaux a partir de matieres contenant de l'oxyde de fer
US7776127B2 (en) Use of a channel induction furnace to process at least one of a molten metal product, a vapor phase metal product and a slag product from a variety of feed materials
WO2011002465A1 (fr) Utilisation d'un four à induction en canal pour traiter un produit métallique fondu, un produit métallique en phase vapeur et/ou un produit de scorie à partir de différents matériaux d'alimentation
WO2011002466A1 (fr) Ajout d’un réducteur dans un four à induction à canal
WO2011002468A1 (fr) Paramètres de traitement pour l'exploitation d'un four à induction à canal
WO2011002467A1 (fr) Maîtrise des scories dans un four à induction à canal
Kaya Galvanizing Residue and Electrical Arc Furnace (EAF) Dust
Passant et al. UK fine particulate emissions from industrial processes
RU2182184C1 (ru) Способы переработки железосодержащих материалов
AU2004201657A1 (en) Dual use of an induction furnace to produce hot metal or pig iron while processing iron and volatile metal containing materials
SK32011U1 (sk) Spôsob výroby a úpravy kovonosnej vstupnej vsádzky a zariadenie na vykonávanie tohto spôsobu

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 09846949

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 09846949

Country of ref document: EP

Kind code of ref document: A1