WO2018094886A1 - 一种煤基竖炉直接还原工艺 - Google Patents

一种煤基竖炉直接还原工艺 Download PDF

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WO2018094886A1
WO2018094886A1 PCT/CN2017/074678 CN2017074678W WO2018094886A1 WO 2018094886 A1 WO2018094886 A1 WO 2018094886A1 CN 2017074678 W CN2017074678 W CN 2017074678W WO 2018094886 A1 WO2018094886 A1 WO 2018094886A1
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coal
reduction
shaft furnace
mixture
based shaft
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PCT/CN2017/074678
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English (en)
French (fr)
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李建涛
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武汉科思瑞迪科技有限公司
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/02—Making spongy iron or liquid steel, by direct processes in shaft furnaces
    • 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

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  • the invention relates to the technical field of metal fire smelting, in particular to a coal-based shaft furnace direct reduction process, which is mainly used for producing sponge metal with high metallization rate.
  • the direct reduction technology for the production of sponge iron at home and abroad has two major categories of gas base and coal base.
  • the gas base mainly includes MIDREX (Medrex method), HYL (Hilfa), etc.;
  • MIDREX Medrex method
  • HYL HyL
  • rotary kiln method rotary hearth furnace method
  • tunnel kiln tunnel kiln and so on.
  • the above technologies all have their own shortcomings.
  • the gas-based reduction technology requires high-quality reducing gas, reducing gas preparation and reforming processes and equipments are very complicated, the reduction process is difficult to control, high requirements on raw materials, large investment, high operating costs, etc.
  • coal-based direct reduction technologies have shortcomings such as high raw material requirements, large energy consumption, small output, difficult to control reduction process, low operating rate, difficult to large-scale equipment, and large-scale production. It is based on the above various reasons. The promotion of direct reduction worldwide is limited and the total output is small.
  • the current coal-based direct reduction mainly includes rotary hearth furnace, rotary kiln, tunnel kiln, etc.
  • the specific disadvantages of these direct reduction technologies are as follows:
  • the rotary kiln has shortcomings such as high requirements for raw fuel, easy ring formation in the kiln, difficulty in controlling the temperature in the reduction zone, difficulty in operation, high energy consumption, unstable product quality, and incapable of achieving large-scale production with an annual output of over 200,000 tons;
  • the process mixes iron oxide powder containing iron oxide with a binder to form a ball, and the outer layer of the iron ball is adhered to
  • the layer of carbon powder is oxidized into a double-layer oxidized pellet by high-temperature flue gas, which is not only indispensable, but also complicated in process.
  • the refractory material of the process reduction chamber is made of SiC material, which has poor oxidation resistance, low thermal conductivity and limited life, resulting in high energy consumption and high cost.
  • the invention aims to provide a coal-based shaft furnace direct reduction furnace process, which has the advantages of simple and reliable process flow, large-scale production, strong adaptability of raw fuel, sufficient energy utilization, low cost and good product quality. Significant advantages in product application and low investment.
  • the technical scheme adopted by the present invention uses a coal-based shaft furnace as shown in FIG. 2, and the illustrated coal-based shaft furnace is composed of a modular combination of a reduction chamber and a combustion chamber, and a plurality of reduction chambers 1 are arranged in a large combustion.
  • the mixture in the reduction chamber is isolated from the combustion chamber by a partition wall.
  • the reduction chamber 1 is divided into a preheating section 4, a reduction section 5 and a cooling section 7 from top to bottom.
  • Each of the reduction chamber 1 and the combustion chamber 2 is provided with a heat transfer partition wall 6, and a partition between the reduction chamber and the combustion chamber.
  • the wall is made of a cermet product, and the partition wall has a thermal conductivity higher than 22 W/mk.
  • the heat required for the reduction chamber 1 is generated by the combustion of the gas in the combustor 3 in the combustion chamber 2, and the temperatures in the reduction chambers 1 are substantially the same. After the mixture is added from the top and then passed through the preheating section 4, the reduction section 5 and the cooling section 7, It is discharged at a reasonable flow rate under the control of the discharge device 8.
  • a direct reduction process for a coal-based shaft furnace for producing sponge iron specifically comprising the following steps:
  • the iron concentrate and the binder are mixed, pressed and dried, and then mixed with a reducing agent and a desulfurizing agent to form a mixture;
  • the mixture is transported into the reduction chamber of the coal-based shaft furnace through the transportation and distribution device of the coal-based shaft furnace, and the mixture is run downward in the reduction chamber, and is preheated for 6 to 10 hours through the preheating section, and preheated.
  • the temperature of the section is 300-800 ° C, and then reduced by the reduction section for 10 to 16 h, and the reduction temperature is controlled at 900-1250 ° C;
  • the mixture is cooled by the cooling section to a heat discharge temperature of 500-850 ° C or a cold discharge temperature of 50-150 ° C, and then discharged out of the furnace through a discharge device of the coal-based shaft furnace;
  • the raw material is a lump ore, there is no need to mix and press the two links.
  • the mass ratio of the iron fine powder to the reducing agent in the first step is 1:0.35 to 0.50.
  • the reducing agent is one or more of powdered anthracite, bituminous coal, lignite, coke, blue carbon or charcoal.
  • the transportation and distributing device of the coal-based shaft furnace in the second step is equipped with a belt combination.
  • the heat required for the preheating and reduction in the reduction chamber in the second step is derived from the heat generated by the combustion of the combustion chamber fuel outside the partition wall of the reduction chamber, and the heat is transferred to the mixture in the reduction chamber through the partition wall.
  • the combustion chamber After the high-temperature flue gas generated by the combustion of the combustion chamber exits the combustion chamber, the combustion chamber is combusted with a combustion-supporting gas and/or a dry mixture by a heat exchanger.
  • the sponge iron produced by the direct reduction process of the coal-based shaft furnace is mainly used as a raw material of an electric furnace or a cold material of a converter or as a raw material for manufacturing products of high-purity iron, carbonyl iron powder and molten iron, and can also be used as a composite of vanadium-titanium magnetite. Used to achieve efficient separation of vanadium and iron or titanium from iron.
  • the process can add a certain proportion of pulverized coal at the time of pelleting as needed to form an inner carbon pellet to improve the reduction efficiency and shorten the reduction time, thereby increasing the yield;
  • the separation of sponge iron and other powders after the reduction of the process is not a vacuum vacuum suction system with high energy consumption and difficulty in adapting to large-scale production.
  • the process uses a combination of screening and magnetic separation to realize the mixture.
  • the effective separation of sponge iron from other powders not only has good separation effect, but also satisfies the needs of large-scale production;
  • the process can achieve high output of large-scale production of more than 1 million tons, because the reduction chamber and the combustion chamber can be modularized according to the production demand, and the coal-based shaft furnace is advanced and reasonable. And perfect technology has created conditions for large-scale production;
  • the reduction chamber and the combustion chamber of the process are independent of each other, and the respective reducing atmosphere and the oxidizing atmosphere do not interfere with each other, and the temperature field can be uniform, and the process can effectively control and adjust the reduction temperature and the reduction time according to the difference of the raw materials, thereby obtaining high Metallization rate product;
  • the partition wall between the reduction chamber and the combustion chamber of the process is made of cermet product, and its thermal conductivity is above 22 W/mk. It has high thermal conductivity, low porosity, high temperature resistance and wear resistance, and is more efficient than other materials. High and long service life;
  • the briquetting material and the reducing agent of the process are in a loose state of being dispersed and uniformly distributed in the reducing chamber, which can completely eliminate the expansion effect of the briquetting material in the reducing process, and is advantageous for the life of the reducing chamber;
  • the temperature of the sponge iron discharged by the process can reach 500-850 ° C, so that it can be directly hot-packed into the electric furnace, which greatly reduces the energy consumption; the temperature of the sponge iron discharged by the process can also reach 50-150 ° C, after pressing After the block, the need for long-term storage and long-distance transportation is met.
  • the process can control the temperature of the reduction chamber by adjusting the temperature of the combustion chamber. Therefore, the reduction technology can realize direct reduction of a plurality of different metal materials, and the range of metal materials that can be processed is wide, and is particularly suitable for comprehensive recovery of vanadium-titanium magnetite. use.
  • FIG. 1 is a flow chart of a direct reduction process of a coal-based shaft furnace for producing sponge iron according to the present invention
  • FIG. 2 is a schematic view of a coal-based direct reduction shaft furnace used in the present invention.
  • the present invention provides a direct reduction process for a coal-based shaft furnace for producing sponge iron, the main production steps of which include:
  • the combustion chamber is located around or on both sides of the reduction chamber. Several burners are arranged in the combustion chamber. The combustion of the fuel and the combustion-supporting gas will generate high-temperature flue gas of 1100-1400 °C. The heat of the high-temperature flue gas is uniformly heated through the partition wall. a mixture in the wall; the fuel is at least one of coal gas, blast furnace gas, converter gas, coke oven gas, natural gas, petroleum liquefied gas or shale gas;
  • the temperature of the flue gas discharged from the combustion chamber is relatively high, about 900-1200 ° C.
  • the high-temperature flue gas after discharge is heat-recovered through the heat exchanger, preheating the combustion-supporting gas entering the combustion chamber, and the combustion-supporting gas can be preheated to 500-700. °C, the temperature of the flue gas after heat exchange is reduced to 400-600 ° C, and can also be used for drying raw materials, etc., the flue gas of 100-150 ° C after drying is discharged through the chimney;
  • the reducing materials generated in the interior of the reduction chamber such as CO, H2, etc., are returned to the combustion chamber as a supplementary fuel in the head space of the reduction chamber;
  • the mixture finally passes through the cooling section and can reach 500-850 ° C according to the required temperature or 50-150 ° C, continuously discharged outside the furnace through the discharge device, after hot or cold screening, can be directly hot-filled or cold-packed into the electric furnace, or first hot-pressed or cold-pressed into pieces, and then charged into the electric furnace or converter Or other devices for further processing;
  • the process can also treat the reduction of metal raw materials other than iron concentrate, such as the reduction of vanadium ore or nickel ore;
  • the process can not only process the raw materials after the briquetting, but also directly process the natural lump ore raw materials;
  • the reduction furnace in the process consists of a reduction chamber and a combustion chamber, and the number of reduction chambers is modularly combined according to the production requirements, and the size and quantity of the combustion chamber are adjusted according to the number of reduction chambers;
  • the metallization rate of sponge iron is as high as 93% or more;
  • the product of this process has a wide range of applications, which can be used as raw materials for electric furnaces and converters, as well as raw materials for manufacturing high-purity iron, carbonyl iron powder and molten iron, and can also be used as a comprehensive utilization of vanadium-titanium magnetite. Effective separation of vanadium from iron or titanium with iron.
  • the direct reduction process of the coal-based shaft furnace for producing sponge iron of the present invention comprises the following steps:
  • the preheating section and the reducing section of the reduction chamber are rectangular, the width is 300-800 mm, the length is 1000-1800 mm, and the height is 10000-18000 mm;
  • the temperature of the flue gas coming out of the combustion chamber is about 1000 °C, and the high-temperature flue gas after the discharge is heat-recovered through the heat exchanger, and the combustion air entering the combustion chamber is preheated to 600 ° C, and then the bulk material is passed through the heat exchanger. Drying, the temperature of the exhausted flue gas is reduced to 100-150 ° C, and finally through the chimney outside;
  • the process has a high operating rate, and the daily direct reduced iron production is about 300 tons or more, and the annual output can reach more than 1 million tons. It is the coal-based direct reduction process with the largest capacity at present.

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  • Chemical & Material Sciences (AREA)
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  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
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Abstract

一种生产海绵铁的煤基竖炉直接还原工艺，包括以下步骤：铁精粉和粘结剂经过混匀、压块和烘干后与还原剂和脱硫剂混合，通过炉顶布料装置将混合料装入煤基竖炉的还原室（1）中，混合料在煤基竖炉的还原室（1）中经过预热段（4）、还原段（5）和冷却段（7）后，通过排料装置（8）排出炉外，然后通过热筛或冷筛后，可以直接装入熔炼装置，或者压块后再装入熔炼装置；筛下物经过磁选后全部回收利用。

Description

一种煤基竖炉直接还原工艺 技术领域
本发明涉及金属火法冶炼的技术领域，具体涉及一种煤基竖炉直接还原工艺，主要用于生产高金属化率的的海绵铁。
背景技术
目前国内外生产海绵铁的直接还原技术，根据还原剂种类，有气基和煤基两大类，气基主要有MIDREX(米德雷克斯法)、HYL(希尔法)等；煤基主要有回转窑法、转底炉法、隧道窑等。以上技术均存在各自的不足，气基还原技术需要优质的还原气、还原气的制备和重整工艺和装置非常复杂、还原过程难以控制、对原料要求高、投资大、运行费用高等缺点；现有的煤基直接还原技术均存在原料要求高、能耗大、产量小、还原过程难以控制、作业率低、设备难以大型化、不能实现大规模生产等缺点，正是基于以上种种原因，目前世界范围内直接还原的推广受到限制，总产量不大。
目前的煤基直接还原主要有转底炉、回转窑、隧道窑等，这些直接还原技术各自的具体缺点如下：
(1)转底炉存在炉床一直在作圆周运动，炉床不断地处于升温、降温的循环过程，带来床体耐材易损坏、降低其寿命、床体结构件易变形、还原性气氛难以控制、产品金属化率低、能耗高、产量受到技术限制、很难实现年产量40万吨以上的规模化生产等缺点；
(2)回转窑存在原燃料要求高、窑内易结圈、还原区温度难以控制、操作困难、能耗高、产品质量不稳定、不能实现年产量20万吨以上的规模化生产等缺点；
(3)隧道窑的机械化装斜罐不稳定、人工装卸罐劳动强度很大、环保差、反应罐处于反复升温降温过程导致罐体寿命低、能耗高、不能实现年产量20万吨以上的规模化生产等缺点。
近几年新出现了一种煤基竖炉工艺技术，专利号为CN200610018495.6，这是一种小规模的煤基直接还原竖炉，该技术存在以下问题：
(1)该工艺将含铁氧化物的铁矿粉与粘接剂混合造球，铁球外层粘上一 层碳粉再经高温烟气氧化成双层氧化球团，不仅必要性差，而且工艺复杂。
(2)该工艺还原后海绵铁和其它粉料的分离采用真空负压吸送系统，能耗高，难以适应大规模生产的需要。
(3)该工艺还原室的耐材采用SiC材质，抗氧化能力很差，而且导热系数不高，寿命有限，造成能耗高、成本大。
(4)炉顶布料系统不合理，产量受到严重制约，不能实现20万吨以上的规模化生产。
(5)该工艺只考虑了热出料方案，没有冷处理方案，产品的适应性差。
发明内容
本发明的发明目的在于，提供了一种煤基竖炉直接还原炉工艺，该工艺具有工艺流程简单可靠、能够实现规模化生产、原燃料适应性强、能源利用充分、成本低、产品质量好、产品应用广、投资低等显著优点。
本发明所采用的技术方案使用了如图2所示的煤基竖炉，所示煤基竖炉由还原室和燃烧室模块化组合而成，多个还原室1布置在一个很大的燃烧室2中，所述还原室中的混合料通过隔墙与燃烧室隔离。还原室1从上到下分为预热段4、还原段5和冷却段7，每个还原室1和燃烧室2之间设有传热隔墙6，还原室和燃烧室之间的隔墙采用金属陶瓷产品，所述隔墙的导热系数高于22W/m.k。通过燃烧室2中的燃烧器3燃烧煤气产生还原室1所需要的热量，各还原室1内温度基本一致，混合料从顶部加入后经过预热段4、还原段5和冷却段7后，在排料装置8的控制下按照合理流量排出。
本发明所采用的技术方案如下：
一种生产海绵铁的煤基竖炉直接还原工艺，具体包括以下步骤：
(1)铁精粉和粘结剂经过混匀、压块和烘干后与还原剂和脱硫剂混合后形成混合料；
(2)将混合料通过煤基竖炉的运输和布料装置装入煤基竖炉的还原室中，混合料在还原室中向下运行，先经过预热段预热6～10h，预热段的温度在300-800℃，再经过还原段还原10～16h，还原温度控制在900-1250℃；
(3)还原完成后，混合料经过冷却段冷却至热出料温度500-850℃或冷出料温度50-150℃后，通过煤基竖炉的排料装置排出炉外；
(4)上述冷却至500-850℃的混合料经过热筛或上述冷却至50-150℃的混 合料经过冷筛后，装入熔炼装置，或者压块后再装入熔炼装置；
(5)热筛的筛下物先进行冷却，然后经过磁选，冷筛的筛下物直接进行磁选，磁选后的含铁颗粒和残煤全部回收利用。
步骤一中，如果原料是块矿，就不需要混匀和压块两个环节。
优选地，步骤一中铁精粉与还原剂的质量比为1：0.35～0.50。
优选地，步骤一中还原剂为粉状的无烟煤、烟煤、褐煤、焦炭、兰炭或木炭的一种或多种。
优选地，步骤二中所述煤基竖炉的运输和布料装置采用皮带组合式装备。
步骤二中所述还原室内的预热和还原所需的热量，来源于还原室隔墙外燃烧室燃料燃烧产生的热量，热量通过隔墙传给还原室中的混合料。
所述燃烧室燃烧产生的高温烟气排出燃烧室后，通过换热器来预热燃烧室燃烧用助燃气体和/或烘干混合料。
所述煤基竖炉直接还原工艺生产的海绵铁主要用作电炉的原料或转炉的冷料或作为制造高纯铁、羰基铁粉及铁水等产品的原料，还可以用作钒钛磁铁矿的综合利用以实现钒与铁或钛与铁的有效分离。
实施本发明的煤基竖炉直接还原工艺，具有以下有益效果：
1)该工艺将铁矿粉与粘接剂混合造球后，铁球表面不需要再粘上一层碳粉，更不需要再经高温烟气氧化成双层氧化球团，这样简化了工艺流程，提高了造球效率，降低了生产成本；
2)该工艺根据需要可以在造球时添加一定比例的煤粉，形成内配碳球团，以提高还原效率，缩短还原时间，从而提高产量；
3)该工艺采用皮带组合式布料设备，具有优化和完善的炉顶布料工艺，运输和布料能力大，每年的运输和布料能力达到200万吨以上，确保了海绵铁的规模化生产；
4)该工艺还原后的海绵铁和其它粉料的分离不是采用能耗高及难以适应大规模生产的真空负压吸送系统，该工艺采用了筛分和磁选组合工艺来实现混合料中的海绵铁与其它粉料的有效分离，不仅分离效果好，而且很好地满足了大规模生产的需要；
5)该工艺可以实现100万吨以上规模化生产的高产量，原因在于：还原室和燃烧室可以根据产量需要进行模块化组合，另外煤基竖炉前后先进、合理 和完善的工艺为规模化生产创造了条件；
6)该工艺还原过程中采用缓慢向下的连续运动，能够很好地避免还原室中物料的粘接，不至于造成排料困难和中断生产，还原完毕，海绵铁在冷却段能够冷却到需要的温度；
7)该工艺还原室和燃烧室各自独立，各自的还原气氛和氧化气氛互不干涉，能够实现温度场均匀，同时该工艺根据原料的差异能够有效控制和调整还原温度和还原时间，从而得到高金属化率的产品；
8)该工艺还原室和燃烧室之间的隔墙采用金属陶瓷产品，其导热系数达到22W/m.k以上，具有高导热、低气孔、耐高温、耐磨损等性能，比其它材料还原效率更高、使用寿命更长；
9)该工艺的压块料和还原剂在还原室中处于分散、均匀分布的疏松状态，能够充分消除还原过程中压块料的膨胀作用，对还原室的寿命有利；
10)该工艺燃烧室最终排出的高温烟气采用高温热交换器进行热量回收，用来预热燃烧室用的助燃空气和压块料，降低了能耗，提高了能源利用效率；
11)该工艺还原室预热段排出的还原性气体返回至燃烧室再利用，可节约能源、降低能源消耗；
12)该工艺排出的海绵铁的温度可以达到500-850℃，这样可以直接热装进入电炉，大大降低了能源的消耗；该工艺排出的海绵铁的温度也可以达到50-150℃，经过压块后满足长时间储存和长距离运输的需要。
13)该工艺可通过调节燃烧室温度来控制还原室温度，因此，该还原技术可实现多种不同金属原料的直接还原，可处理的金属原料范围广泛，特别适合钒钛磁铁矿的综合回收利用。
附图说明
图1为本发明生产海绵铁的煤基竖炉直接还原工艺的流程图；
图2为本发明所使用的煤基直接还原竖炉的示意图。
具体实施方式
为了使本发明技术方案更容易理解，现结合附图采用具体实施例的方式，对本发明的技术方案进行清晰、完整的描述。应当注意，在此所述的实施例仅为本发明的部分实施例，而非本发明的全部实现方式，所述实施例只有示例性， 其作用只在于为审查员及公众提供理解本发明内容更为直观明了的方式，而不是对本发明所述技术方案的限制。在不脱离本发明构思的前提下，所有本领域普通技术人员没有做出创造性劳动就能想到的其它实施方式，及其它对本发明技术方案的简单替换和各种变化，都属于本发明的保护范围。
实施例1
如图1所示，本发明提供了一种生产海绵铁的煤基竖炉直接还原工艺，其主要生产步骤包括：
1)铁精粉和粘结剂经过充分混匀后压块，压块的粒度大小为15-45mm，然后进行烘干，烘干后与还原剂和脱硫剂混合；铁精粉和粘结剂混匀过程中，根据需要可以加入少量的煤粉，以提高还原效率；如果原料是块矿，就不需要混匀和压块两个环节，直接进行烘干及后面的工序；
2)混合料由煤基竖炉的布料装置从还原室顶部进料，还原室被混合料全部填充，物料呈分散、均匀分布状态，料面高出还原炉本体一定高度，还原剂为无烟煤、烟煤、褐煤、焦炭、兰炭或木炭等的至少一种；
3)混合料在还原室中靠重力向下运行，经过预热段、还原段后完成还原过程，还原室内温度为1100℃，还原室中进行预热和还原所需的热量，来源于还原室隔墙外燃烧室燃烧产生的热量，热量通过隔墙传给还原室中的混合料；
4)燃烧室位于还原室四周或两侧，燃烧室内设置若干个烧嘴，燃料和助燃气体燃烧会产生1100～1400℃的高温烟气，高温烟气的热量整体均匀通过隔墙加热还原室隔墙内的混合料；燃料为煤制煤气、高炉煤气、转炉煤气、焦炉煤气、天然气、石油液化气或页岩气等的至少一种；
5)混合料在还原室内进行充分的还原反应，根据原料条件和工艺需要，还原室内的温度和还原反应的时间均能实现可调、可控；
6)燃烧室排出的烟气温度较高，约900～1200℃，排出后的高温烟气通过换热器进行热量回收，预热进入燃烧室的助燃气体，助燃气体可预热至500～700℃，换热后的烟气温度降低至400～600℃，还可用于烘干原料等，烘干后的100～150℃的烟气通过烟囱外排；
7)各个还原室内部还原物料在反应过程中，产生的还原性气体，如CO、H2等，在还原室顶部空间返回至燃烧室作为补充燃料；
8)混合料最后经过冷却段，根据需要的温度可以达到500-850℃或 50-150℃，通过排料装置连续排出炉外，经过热筛或冷筛后，可以直接热装或冷装装入电炉，或者先进行热压或冷压成块，再装入电炉或转炉或其它装置做进一步处理；
9)热筛的筛下物先进行冷却，然后经过磁选，冷筛的筛下物直接进行磁选，磁选后含铁颗粒和残煤全部回收利用。
本发明工艺具有以下优点：
1)该工艺还可以处理除铁精粉以外的金属原料的还原，如钒钛矿或镍矿的还原；
2)该工艺既可以处理压块后的原料，还可以直接处理天然块矿原料；
3)该工艺的能源利用充分，能源浪费很少，并且资源都得到循环利用；
4)该工艺中的还原炉由还原室和燃烧室组成，还原室的数量根据产量要求进行模块化的组合，燃烧室的大小和数量根据还原室的多少进行调整；
5)海绵铁的金属化率高达93％以上；
6)该工艺的产品应用范围广，既可以用作电炉和转炉的原料，也可以作为制造高纯铁、羰基铁粉及铁水等产品的原料，还可以用作钒钛磁铁矿的综合利用以实现钒与铁或钛与铁的有效分离。
实施例2
本发明的生产海绵铁的煤基竖炉直接还原工艺包括以下步骤：
1)将含铁品位64％的铁精粉及粘结剂充分混匀后压块，压块后的粒度大小约25mm，经过烘干机烘干处理后运至槽下料仓；
2)将以上得到的烘干块料和无烟煤还原剂和石灰石脱硫剂混合，要求混合尽量均匀，块料和还原剂的比例约为1:0.4，混合料由炉顶布料器从还原炉顶部装入还原室，混合料将还原室全部装满，并高出还原炉顶面一定高度；
3)还原室的预热段和还原段为长方形，其宽度为300～800mm，长度为1000～1800mm，高度10000～18000mm；
4)通过管道向燃烧器供应的煤气和预热后达到600℃的助燃空气在燃烧室内燃烧，燃烧产生1350℃的高温烟气，混合料在还原室内进行还原反应；还原室内的温度控制在1100℃，还原反应时间控制在15-20h；
5)燃烧室出来的烟气温度约1000℃，排出后的高温烟气通过热交换器进行热量回收，将进入燃烧室助燃空气预热至600℃，再经过换热器将块状原料 烘干，排出的烟气温度降低至100～150℃，最后通过烟囱外排；
6)各还原室混合料反应完毕后，1050～1100℃的海绵铁及剩余碳粉经过冷却段后温度达到750℃后从排料装置排出，得到金属化率达95％的海绵铁，直接由链板输送机热态装入电炉。
该工艺作业率高，每天直接还原铁产量为约300吨以上，年产量可达100万吨以上，是目前最大产能的煤基直接还原工艺。
上面结合附图对本发明的实施例进行了描述，但本发明并不局限于上述的具体实施方式，上述的具体实施方式仅仅是示意性的，而不是限制性的，本领域的普通技术人员在本发明的启示下，在不脱离本发明宗旨和权利要求所保护的范围情况下，还可做出很多形式，这些均属于本发明的保护之内。

Claims (6)

  1. 一种生产海绵铁的煤基竖炉直接还原工艺，其特征在于具体包括以下步骤：
    (1)铁精粉和粘结剂经过混匀、压块和烘干后与还原剂和脱硫剂混合后形成混合料；
    (2)将混合料通过煤基竖炉的运输和布料装置装入煤基竖炉的还原室中，混合料在还原室中向下运行，先经过预热段预热6～10h，预热段的温度在300-800℃，再经过还原段还原10～16h，还原温度控制在900-1250℃；
    (3)还原完成后，混合料经过冷却段冷却至热出料温度500-850℃或冷出料温度50-150℃后，通过煤基竖炉的排料装置排出炉外；
    (4)上述冷却至500-850℃的混合料经过热筛或上述冷却至50-150℃的混合料经过冷筛后，装入熔炼装置，或者压块后再装入熔炼装置；
    (5)热筛的筛下物先进行冷却，然后经过磁选，冷筛的筛下物直接进行磁选，磁选后的含铁颗粒和残煤全部回收利用。
  2. 根据权利要求1所述生产海绵铁的煤基竖炉直接还原工艺，其特征在于，所述步骤一中铁精粉与还原剂的质量比为1：0.35～0.50。
  3. 根据权利要求1或2所述生产海绵铁的煤基竖炉直接还原工艺，其特征在于，所述步骤一中还原剂为粉状的无烟煤、烟煤、褐煤、焦炭、兰炭或木炭的一种或多种。
  4. 根据权利要求1所述生产海绵铁的煤基竖炉直接还原工艺，其特征在于，步骤二中所述煤基竖炉的运输和布料装置采用皮带组合式装备。
  5. 根据权利要求1所述生产海绵铁的煤基竖炉直接还原工艺，其特征在于，步骤二中所述还原室内的预热和还原所需的热量，来源于还原室隔墙外燃烧室燃料燃烧产生的热量，热量通过隔墙传给还原室中的混合料。
  6. 根据权利要求5所述生产海绵铁的煤基竖炉直接还原工艺，其特征在于，所述燃烧室燃烧产生的高温烟气排出燃烧室后，通过换热器来预热燃烧室燃烧用助燃气体和/或烘干混合料。
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CN115537487B (zh) * 2022-09-20 2024-02-27 张计辉 一种钒钛磁铁矿冶炼方法及冶炼系统

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