WO2018216513A1 - 酸化鉱石の製錬方法 - Google Patents
酸化鉱石の製錬方法 Download PDFInfo
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- WO2018216513A1 WO2018216513A1 PCT/JP2018/018395 JP2018018395W WO2018216513A1 WO 2018216513 A1 WO2018216513 A1 WO 2018216513A1 JP 2018018395 W JP2018018395 W JP 2018018395W WO 2018216513 A1 WO2018216513 A1 WO 2018216513A1
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- reducing agent
- reduction
- mixture
- oxide ore
- metal
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B5/00—General methods of reducing to metals
- C22B5/02—Dry methods smelting of sulfides or formation of mattes
- C22B5/10—Dry methods smelting of sulfides or formation of mattes by solid carbonaceous reducing agents
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B1/00—Preliminary treatment of ores or scrap
- C22B1/14—Agglomerating; Briquetting; Binding; Granulating
- C22B1/24—Binding; Briquetting ; Granulating
- C22B1/248—Binding; Briquetting ; Granulating of metal scrap or alloys
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- 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
- C22B23/023—Obtaining nickel or cobalt by dry processes with formation of ferro-nickel or ferro-cobalt
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/04—Making ferrous alloys by melting
- C22C33/06—Making ferrous alloys by melting using master alloys
Definitions
- the present invention relates to a method for smelting oxide ore, for example, smelting by reducing and heating pellets produced from an oxide ore such as nickel oxide ore and a reducing agent at a high temperature in a reduction furnace. And a smelting method for obtaining a reduced product such as ferronickel.
- limonite or saprolite which is a kind of oxide ore
- dry smelting method to produce nickel matte using smelting furnace, iron and nickel using rotary kiln or moving hearth furnace Known are a dry smelting method for producing ferronickel, an alloy of the above, a hydrometallurgical method for producing mixed sulfide using an autoclave, and the like.
- the raw material nickel oxide ore is crushed to an appropriate size in order to proceed with the reaction.
- a process of forming a lump is performed as a pretreatment.
- nickel oxide ore when nickel oxide ore is agglomerated, that is, when powdered or finely divided ore is agglomerated, the nickel oxide ore is mixed with other components such as binders and coke reducing agents. The mixture is further adjusted for moisture, etc., and then charged into a lump manufacturing machine, for example, a lump (pellet, briquette, etc. having a side or diameter of about 10 to 30 mm. Hereinafter, simply referred to as “pellet”. ).
- an agglomerate containing a metal oxide and a carbonaceous reducing agent is supplied to a hearth of a moving bed type reduction melting furnace and heated to reduce and melt the metal oxide.
- the bed density A method is disclosed in which an agglomerate having an average diameter of 19.5 mm or more and 32 mm or less is supplied onto a hearth so that the bed density is 0.5 or more and 0.8 or less and heated.
- the productivity of granular metallic iron can be enhanced by controlling the bed density and the average diameter of the agglomerates together.
- Patent Document 1 is a technique for controlling a reaction occurring outside the agglomerate, and is a control of the reaction occurring inside the agglomerate, which is the most important factor in the reduction reaction. Is not focused on. On the other hand, by controlling the reaction that takes place inside the agglomerate, it has been demanded to obtain higher quality metals (metals, alloys) by increasing the reaction efficiency and promoting the reduction reaction more uniformly. .
- the process using the so-called total melting method in which all the raw materials are melted and reduced has a big problem in terms of operation cost.
- the temperature in order to completely melt the raw nickel oxide ore, it is necessary to raise the temperature to 1500 ° C. or higher.
- such a high temperature condition requires a large energy cost and is used at such a high temperature. Repairing furnaces are expensive because they are easily damaged.
- the nickel oxide ore of the raw material contains only about 1% of nickel, it is not necessary to recover anything other than iron corresponding to the nickel, but even a large amount of components that are unnecessary to recover are included. Will melt everything, making it extremely inefficient.
- the present invention has been proposed in view of such circumstances, and in a smelting method for producing metal by reducing a mixture containing an oxide ore such as nickel oxide ore and a carbonaceous reducing agent, productivity is improved.
- Another object of the present invention is to provide a method capable of manufacturing a high-quality metal at a low manufacturing cost with high efficiency.
- the carbonaceous reducing agent is constituted by particles (reducing agent particles), and the number of reducing agent particles having a maximum particle length of 25 ⁇ m or less is 2% or more and 25% or less with respect to the total number of reducing agent particles,
- a reduction product is obtained by reducing the metal oxide with this carbonaceous reducing agent using an average maximum particle length of 30 ⁇ m or more and 80 ⁇ m or less with respect to the reducing agent particles having a maximum particle length exceeding 25 ⁇ m.
- the present invention provides the following.
- the first invention of the present invention is a smelting process in which an oxidized ore and a carbonaceous reducing agent are mixed, and the resulting mixture is heated and subjected to a reduction treatment to obtain reduced metal and slag.
- the second invention of the present invention is a method for smelting ore oxide according to the first invention, wherein the reduction temperature in the reduction treatment is 1200 ° C. or higher and 1450 ° C. or lower.
- the third invention of the present invention is a method for refining oxide ore according to the first or second invention, wherein the oxide ore is nickel oxide ore.
- a fourth invention of the present invention is the method of smelting ore oxide according to any one of the first to third inventions, wherein the metal is ferronickel.
- a high-quality metal is produced with high productivity and efficiency and at a low production cost. Can be provided.
- the method for smelting oxide ore according to the present invention comprises using an oxide ore as a raw material, mixing the oxide ore and a carbonaceous reducing agent into a mixture, and subjecting the resulting mixture to a reduction treatment at a high temperature to obtain a reduced product. It is the method of manufacturing the metal which is. For example, nickel oxide ore containing nickel oxide, iron oxide, etc. is used as a raw material, and the nickel oxide ore is mixed with a carbonaceous reducing agent, and nickel contained in the mixture is preferentially reduced at high temperatures. In addition, there is a method for producing ferronickel, which is an alloy of iron and nickel, by partially reducing iron.
- the method for smelting oxidized ore comprises mixing an oxidized ore and a carbonaceous reducing agent, heating the resulting mixture as a raw material, subjecting it to a reduction treatment,
- the carbonaceous reducing agent is composed of particles (hereinafter also referred to as “reducing agent particles”), and the reducing agent particles having a maximum particle length exceeding 25 ⁇ m, which is obtained by the following formula (1).
- the ratio of the number of reducing agent particles having a maximum particle length of 25 ⁇ m or less contained in the carbonaceous reducing agent is determined by the ratio of the reducing agent particles contained in the carbonaceous reducing agent. It is characterized by being 2% or more and 25% or less with respect to the total number.
- Average maximum particle length the sum of the maximum particle lengths of 300 reducing agent particles / 300 (1)
- the contact area between the oxidized ore and the carbonaceous reducing agent can be increased, and the reduction reaction of the oxidized ore can be facilitated.
- the dispersibility of the carbonaceous reducing agent in the mixture is increased, aggregation and uneven distribution of the carbonaceous reducing agent are suppressed, so that the reduction reaction can be promoted uniformly.
- high-quality metal can be manufactured with high productivity and efficiency and at a low manufacturing cost.
- the present embodiment a method for smelting nickel oxide ore will be described as an example.
- the nickel oxide ore that is a smelting raw material contains at least nickel oxide (NiO) and iron oxide (Fe 2 O 3 ), and the nickel oxide ore is reduced using the nickel oxide ore as a smelting raw material.
- an iron-nickel alloy ferrronickel
- the present invention is not limited to nickel oxide ore as an oxide ore, and the smelting method is not limited to a method for producing ferronickel from nickel oxide ore containing nickel oxide or the like.
- Nickel oxide ore smelting method In the smelting method of nickel oxide ore according to the present embodiment, the nickel oxide ore is mixed with a carbonaceous reducing agent to form a mixture, and the mixture is subjected to a reduction treatment, whereby ferronickel that is a metal as a reduced product. And slag.
- ferronickel is produced by preferentially reducing nickel (nickel oxide) in the mixture and partially reducing iron (iron oxide).
- the ferronickel which is a metal can be collect
- FIG. 1 is a process diagram showing an example of the flow of a nickel oxide ore smelting method.
- this smelting method includes a mixing treatment step S1 in which nickel oxide ore and a carbonaceous reducing agent are mixed, and reduction charging in which the obtained mixture is agglomerated or filled into a predetermined container and molded.
- Pretreatment step S2 reduction treatment step S3 in which the mixture that has been agglomerated or filled in the container is heated at a predetermined temperature (reduction temperature), and a mixture (mixture) containing the metal and slag generated in the reduction treatment step S3
- a separation step S4 for separating and recovering the metal from the product.
- the mixing treatment step S1 is a step of obtaining a mixture by mixing raw material powders containing nickel oxide ore. Specifically, in the mixing treatment step S1, a carbonaceous reducing agent is added to and mixed with nickel oxide ore which is a raw material ore, and optional additives such as iron ore, flux components, binders, etc. A powder having a particle size of about 0.1 mm to 0.8 mm is added and mixed to obtain a mixture.
- the mixing process can be performed using a mixer or the like.
- Nickel oxide ore Although it does not specifically limit as a nickel oxide ore which is a raw material ore, Limonite ore, a saprolite ore, etc. can be used.
- the nickel oxide ore contains at least nickel oxide (NiO) and iron oxide (Fe 2 O 3 ).
- Carbonaceous reducing agent Although it does not specifically limit as a carbonaceous reducing agent, Coal powder, coke powder, etc. are mentioned.
- the carbonaceous reducing agent those composed of particles (reducing agent particles) and having an average maximum particle length of not less than 30 ⁇ m and not more than 80 ⁇ m of reducing agent particles having a maximum particle length exceeding 25 ⁇ m are used.
- the ratio of the number of reducing agent particles having a maximum particle length of 25 ⁇ m or less contained in the carbonaceous reducing agent is 2% or more and 25% or less with respect to the total number of reducing agent particles contained in the carbonaceous reducing agent. Is used. That is, this carbonaceous reducing agent contains reducing agent particles having a maximum particle length of 25 ⁇ m or less and reducing agent particles having a maximum particle length exceeding 25 ⁇ m.
- the “maximum particle length” of the reducing agent particle is the longest side or diameter of the reducing agent particle. Specifically, for example, when the reducing agent particles are elliptical, the maximum particle length is a long diameter, and when the reducing agent particles are rectangular parallelepiped, the maximum particle length is a diagonal line.
- FIG. 2 is a schematic diagram showing the maximum particle length of the amorphous particles, and the maximum particle length T can be measured using a metal microscope.
- the “average maximum particle length” of the reducing agent particles is an average value of the maximum particle length T in the number average of 300 randomly selected reducing agent particles, and is obtained by the following formula (1).
- Average maximum particle length the sum of the maximum particle lengths of 300 reducing agent particles / 300 (1)
- the contact area between the nickel oxide ore and the carbonaceous reducing agent increases, and the reduction reaction of the nickel oxide ore. Can be made easier.
- a reduction reaction can be advanced uniformly.
- the average maximum particle length of the reducing agent particles contained in the carbonaceous reducing agent is 30 ⁇ m or more. If the average maximum particle length is too small, the proportion of fine reducing agent particles increases too much, and the carbonaceous reducing agent aggregates or is unevenly distributed. Therefore, it becomes difficult to obtain a uniform mixture, which makes it difficult for the reduction reaction to proceed uniformly.
- the average maximum particle length of the reducing agent particles having a maximum particle length exceeding 25 ⁇ m is 80 ⁇ m or less, and more preferably 60 ⁇ m or less. If this average maximum particle length is too large, the proportion of coarse reducing agent particles becomes too high, and the dispersibility of the carbonaceous reducing agent in the mixture deteriorates. Therefore, it becomes difficult to obtain a uniform mixture, and the reduction reaction does not proceed uniformly.
- the ratio of the number of reducing agent particles contained in the carbonaceous reducing agent is 2% with respect to the total number of reducing agent particles of the carbonaceous reducing agent. Above, it is more preferable that it is 3% or more. If the ratio of the reducing agent particles having a maximum particle length of 25 ⁇ m or less is too small, the fine reducing agent particles are too small, and it is difficult to uniformly mix the carbonaceous reducing agent and the nickel oxide ore in the mixture. This makes it difficult for the reduction reaction to proceed uniformly.
- the ratio of particles having a maximum particle length of 25 ⁇ m or less to the total number of reducing agent particles of the carbonaceous reducing agent is 25% or less, and more preferably 20% or less. If the proportion of reducing agent particles having a maximum particle length of 25 ⁇ m or less is too large, the proportion of fine reducing agent particles increases too much, causing the carbonaceous reducing agent to aggregate or be unevenly distributed. Therefore, it becomes difficult to obtain a uniform mixture, which makes it difficult for the reduction reaction to proceed uniformly.
- the carbonaceous reducing agent added to the raw material ore is composed of particles (reducing agent particles), and the average maximum particle length of the reducing agent particles having a maximum particle length exceeding 25 ⁇ m is 30 ⁇ m or more and 80 ⁇ m or less,
- the ratio of the number of reducing agent particles having a maximum particle length of 25 ⁇ m or less contained in the carbonaceous reducing agent is 2% or more and 25% or less with respect to the total number of reducing agent particles of the carbonaceous reducing agent.
- the carbonaceous reducing agent and the nickel oxide ore are uniformly mixed therein, and the contact area between the nickel oxide ore and the carbonaceous reducing agent can be increased. Thereby, in the reduction treatment step S3 to be described later, uniform reduction can be realized more efficiently, and as a result, the reaction time can be shortened and the manufacturing cost can be reduced. The quality of nickel can be further increased.
- the amount of the carbonaceous reducing agent in the mixture is the chemical equivalent necessary for nickel metal reduction of the total amount of nickel oxide constituting the nickel oxide ore.
- total value of both the chemical equivalents necessary for reducing iron oxide (ferric oxide) to metallic iron (for convenience, also referred to as “total value of chemical equivalents”) is 100% by mass, Can be adjusted so as to have a carbon content ratio of 5 mass% to 60 mass%, more preferably 10 mass% to 40 mass%.
- the mixing amount of the carbonaceous reducing agent to a ratio of 5% by mass or more with respect to 100% by mass of the total value of chemical equivalents, the reduction of nickel can be efficiently progressed and productivity is improved.
- the ratio of 60% by mass or less to 100% by mass of the total value of chemical equivalents it is possible to suppress the reduction amount of iron, prevent the deterioration of nickel quality, and produce high-quality ferronickel. it can.
- the amount of the carbonaceous reducing agent is set to a ratio of 5% by mass or more and 60% by mass or less of the carbon component with respect to the total value of 100% by chemical equivalent, so that the metal component is added to the surface of the mixture
- the shell (metal shell) produced by the above can be uniformly produced to improve productivity, and high quality ferronickel with high nickel quality can be obtained, which is preferable.
- iron ore in addition to nickel oxide ore and carbonaceous reducing agent, iron ore can be added as an optional component to adjust the iron-nickel ratio in the mixture.
- the iron ore is not particularly limited.
- iron ore having an iron grade of about 50% or more, hematite obtained by wet smelting of nickel oxide ore, or the like can be used.
- Binder examples include bentonite, polysaccharides, resins, water glass, and dehydrated cake.
- Examples of the flux component include calcium oxide, calcium hydroxide, calcium carbonate, silicon dioxide and the like.
- Table 1 below shows an example of the composition (% by weight) of some raw material powders to be mixed in the mixing treatment step S1.
- the composition of the raw material powder is not limited to this.
- a mixture is obtained by uniformly mixing the raw material powder containing the nickel oxide ore as described above.
- the raw material powder may be kneaded.
- mixing of raw material powder may be performed simultaneously with mixing, and may be performed after mixing.
- shear force is applied to the mixture, and the agglomeration of the raw material powders including the carbon reducing agent is dissolved and mixed more uniformly, thereby increasing the contact area between the raw material powders and reducing the voids contained in the mixture.
- the adhesion of each particle is improved. Therefore, the reaction time of the reduction reaction can be shortened, and quality variation can be reduced. Therefore, highly productive processing can be performed, and high quality ferronickel can be manufactured.
- the mixture may be extruded using an extruder.
- an extruder by extruding with an extruder, a much higher kneading effect is obtained, so that the contact area between the raw material powders increases and the voids contained in the mixture decrease. Therefore, high quality ferronickel can be manufactured more efficiently.
- the reduction pre-treatment process S2 is a process in which the mixture containing the nickel oxide ore and the carbonaceous reducing agent obtained in the mixing process S1 is formed and dried as necessary. That is, in this pre-reduction charging treatment step S2, the mixture obtained by mixing the raw material powders can be easily put into a furnace used in the reduction treatment step S3 described later, and the reduction reaction can be efficiently performed. Mold.
- the mixture When molding the obtained mixture, the mixture may be agglomerated (granulated) to form a massive shaped body (pellet, briquette, etc.), and the mixture is filled into a container or the like.
- a filling container may be used.
- a predetermined amount of water necessary for agglomeration is added to the mixture containing nickel oxide ore and a carbonaceous reducing agent, for example, a lump production apparatus (rolling granulation) Or a compression molding machine, an extrusion molding machine or the like, or a pelletizer), and is formed into a massive molded body such as pellets or briquettes (hereinafter sometimes simply referred to as “pellets”).
- a carbonaceous reducing agent for example, a lump production apparatus (rolling granulation) Or a compression molding machine, an extrusion molding machine or the like, or a pelletizer
- the shape for molding the mixture that is, the shape of the pellet is not particularly limited, and may be a cube, a rectangular parallelepiped, a cylinder, or a sphere. Among these, it is particularly preferable to form a spherical pellet.
- the reduction reaction can be facilitated relatively uniformly, and the mixture can be easily molded to reduce the cost of molding.
- the shape of the pellet is simplified, it is possible to reduce the molding defects.
- the size of the pellet obtained by the agglomeration is not particularly limited.
- the drying process in the pretreatment process S2 and the drying process in the reduction process S3 drying process S31
- the reduction treatment reduction step S33
- the thickness can be about 10 mm to 30 mm.
- the reduction process step S3 and the like will be described later in detail.
- the mixture containing the nickel oxide ore and the carbonaceous reducing agent is filled into a predetermined container or the like while kneading with an extruder or the like, can do.
- the obtained mixture-filled container may be used as it is for the subsequent reduction treatment step S3.
- the mixture contained in the container or the like is pressed and hardened for use in the reduction treatment step S3. preferable.
- the mixture contained in a container or the like is pressed and molded, and the formed mixture is subjected to the subsequent reduction treatment step S3, thereby reducing voids generated between the mixtures and increasing the density.
- the density becomes uniform, the reduction reaction can be facilitated more uniformly. Therefore, ferronickel with less variation in quality can be produced.
- the shape of the mixture-filled container is not particularly limited, but is preferably a shape such as a rectangular parallelepiped, a cube, or a cylinder.
- the size is not particularly limited, for example, in the case of a rectangular parallelepiped or a cube, it is generally preferable that the inner dimensions of the vertical, horizontal, and height are each 500 mm or less.
- the mixture containing the nickel oxide ore and the carbonaceous reducing agent may be subjected to a drying treatment at least before or after forming the mixture.
- a mixture containing nickel oxide ore and a carbonaceous reducing agent may contain a lot of moisture, and when such a mixture is rapidly heated to the reduction temperature, the moisture is vaporized and expanded. May destroy the mixture.
- the mixture is often in a state of being sticky due to moisture.
- the solid content of the lump is about 70% by mass and the water content is about 30% by mass, so that the mixture collapses in the subsequent reduction treatment step S3. Can be prevented, thereby making it difficult to remove from the reduction furnace.
- the sticky state of the surface can be eliminated by subjecting the mixture to a drying treatment, handling up to charging into the reduction furnace can be facilitated.
- the drying treatment for the mixture is not particularly limited, but for example, hot air of 200 ° C. to 400 ° C. is blown against the mixture to dry.
- the drying process may be performed only once or may be performed a plurality of times including a drying process (drying process S31) in the reduction process S3 described later.
- drying process S31 drying process in the reduction process S3 described later.
- energy efficiency can be improved more by performing drying process S31 in reduction process process S3 so that it may mention later.
- Table 2 below shows an example of the composition (parts by weight) in the solid content of the pellets after the drying treatment.
- the composition of the pellet is not limited to this.
- FIG. 3 is a process diagram showing the process executed in the reduction process S3.
- the reduction treatment step S3 includes a drying step S31 for drying the mixture, a preheating step S32 for preheating the dried mixture, a reduction step S33 for heating and reducing the mixture, and the obtained reduction. And cooling step S35 for cooling the object.
- the reduction heat treatment in the reduction treatment step S3 is performed using a reduction furnace or the like.
- the reduction furnace used for the reduction heat treatment is not particularly limited, but a moving hearth furnace is preferably used.
- a moving hearth furnace By using a moving hearth furnace as the reducing furnace, after placing the mixture on the hearth outside the furnace, it can be charged into the moving hearth furnace, making the reducing furnace more efficient. It can be operated.
- the reduction reaction proceeds continuously, and the reaction can be completed with one facility, and the processing temperature can be controlled rather than using a separate furnace for each process. Can be performed accurately.
- heat loss is reduced and the atmosphere in the furnace can be controlled accurately, so that the reaction can proceed more effectively. Therefore, an iron-nickel alloy with high nickel quality can be obtained more effectively.
- the moving hearth furnace is not particularly limited, and a rotary hearth furnace, a roller hearth kiln, or the like can be used.
- a rotary hearth furnace for example, as shown in FIG. 4, a rotary hearth furnace (rotary hearth furnace) 20 having a circular shape and divided into a plurality of processing chambers 23 to 26 is provided.
- a reduction furnace 2 can be mentioned.
- the rotary hearth furnace 20 includes a hearth that rotates and moves on a plane, and the furnace floor on which the mixture is placed rotates and moves in a predetermined direction, whereby each process is performed in each region. At this time, the processing temperature in each region can be adjusted by controlling the time (movement time, rotation time) at the time of passing through each region. Smelted.
- all of the processing chambers 23 to 26 may be used as reduction chambers, and the reduction treatment may be performed in the processing chambers 23 to 26 on the mixture 10 sequentially supplied from the drying chamber 21.
- the processing chamber 23 is a preheating chamber
- the processing chamber 24 is a reduction chamber
- the processing chamber 25 is a temperature holding chamber
- the processing chamber 26 is a cooling chamber. Then, preheating is performed, reduction processing is performed in the processing chamber 24, temperature is maintained in the processing chamber 25, cooling is performed in the processing chamber 26, and further cooling processing is performed in the external cooling chamber 27.
- the processing chambers 23 to 26 are partitioned by a movable partition wall in order to strictly control the reaction temperature and suppress energy loss.
- a configuration is preferable.
- the arrow on the rotary hearth furnace 20 in FIG. 4 shows the moving direction of a processed material (mixture) while showing the rotation direction of a hearth.
- the temperature in the reduction furnace can be maintained at a high temperature. There is no need to raise or lower the energy cost, and the energy cost can be reduced. Therefore, ferronickel with high productivity and good quality can be produced continuously and stably.
- a carbonaceous reducing agent (hereinafter also referred to as “furnace carbonaceous reducing agent”) is preliminarily spread on the hearth of the reducing furnace, and the hearth carbon that has been spread.
- the mixture may be placed on the quality reducing agent.
- the container filled with the mixture is placed on the hearth carbonaceous reducing agent, it can be covered with the carbonaceous reducing agent.
- the reduction heat treatment is performed in a state where the mixture is charged into the reduction furnace in which the carbonaceous reducing agent is spread on the hearth or is surrounded by the carbonaceous reducing agent so as to further cover the charged mixture.
- the smelting reaction can proceed more rapidly while suppressing the collapse of the mixture.
- the reaction with the hearth can be suppressed even if the reduction reaction proceeds in the processing chambers 23 to 26 and nickel metal or slag is generated. Soaking and sticking can be reduced.
- drying process S31 a drying process is performed with respect to the mixture obtained by mixing raw material powder.
- the main purpose of this drying step S31 is to blow off water and crystal water in the mixture.
- the mixture obtained in the mixing treatment step S1 contains a large amount of moisture and the like, and when it is rapidly heated to a high temperature such as the reduction temperature during the reduction treatment, the moisture is vaporized and expanded all at once. The resulting mixture is cracked and, in some cases, ruptured into pieces, making it difficult to perform uniform reduction treatment. Therefore, by performing a drying process on the mixture to remove moisture before performing the reduction process, it is possible to reduce such destruction of the mixture and thereby promote a uniform reduction process.
- drying process in drying process S31 is performed in the form connected to a reduction furnace.
- an area (drying area) for performing a drying process in the reduction furnace it is conceivable to provide an area (drying area) for performing a drying process in the reduction furnace, but in this case, since the drying process in the drying area becomes rate-limiting, the efficiency of the process in the reduction step S33 and There is a possibility that the efficiency of the process in the temperature holding step S34 is lowered.
- the drying process in the drying step S31 is performed in a drying chamber provided outside the furnace for performing the reduction reaction and directly or indirectly connected to the furnace.
- a drying chamber can be designed completely separate from the steps such as preheating, reduction, and cooling described later, The pre-heat treatment, the reduction treatment, and the cooling treatment can be easily performed.
- the drying chamber 21 is designed to have a longer overall length, or inside the drying chamber 21. What is necessary is just to design so that the conveyance speed of this mixture 10 may become slow.
- the drying temperature of the drying chamber 21 is not particularly limited, but is preferably set to 500 ° C. or lower from the viewpoint of preventing the reduction reaction from starting, and the entire mixture 10 is uniformly dried at a temperature of 500 ° C. or lower. More preferably.
- preheating process S32 the mixture after water
- the main purpose of the preheating step S32 is to allow the temperature to rise smoothly to the reduction temperature during reduction.
- the mixture When the mixture is charged from the outside to the inside of the furnace where the reduction reaction is performed, the mixture may be rapidly heated to the reduction temperature, and the mixture may be cracked or powdered due to thermal stress. In addition, since the temperature of the mixture does not rise uniformly, the reduction reaction may vary, and the quality of the metal produced may vary. Therefore, after performing drying process S31 with respect to a mixture, it is preferable to preheat even to predetermined temperature, and thereby, destruction of a mixture and the dispersion
- the preheating process in the preheating step S32 may be performed in a preheating chamber provided in the rotary hearth furnace, provided outside the rotary hearth furnace, and continuously from the drying chamber to the rotary hearth furnace through the preheating chamber. You may carry out in the preheating chamber provided.
- the inside of the rotary hearth furnace 20 is formed by setting a processing chamber 23 provided continuously from the drying chamber 21 in the rotary hearth furnace 20 as a preheating chamber. Therefore, the energy required for reheating the rotary hearth furnace 20 supplied with the mixture 10 in the reduction step S33 can be greatly reduced.
- preheating temperature in preheating process S32 It is preferable that it is 600 degreeC or more, and it is more preferable that it is 700 degreeC or more.
- the upper limit of the preheating temperature in the preheating step S32 may be 1280 ° C. In particular, by performing the treatment at a high preheating temperature, it is possible to significantly reduce the energy required for reheating to the reduction temperature in the reduction step S33.
- Reduction step S33 the mixture preheated in the preheating step S32 is subjected to reduction treatment at a predetermined reduction temperature.
- the main purpose of the reduction step S33 is to reduce the mixture preheated in the preheating step S32.
- nickel oxide which is a metal oxide contained in nickel oxide ore, is reduced as completely as possible, while it is derived from iron ore mixed as raw material powder together with nickel oxide ore. It is preferable that iron oxide is partially reduced so that the desired nickel-grade ferronickel is obtained.
- reduction temperature in reduction process S33 It does not specifically limit as reduction temperature in reduction process S33, It is preferable to set it as the range of 1200 to 1450 degreeC.
- the reduction temperature in the reduction step S33 is preferably 1200 ° C, more preferably 1300 ° C.
- the reduction temperature in the reduction step S33 is preferably 1450 ° C., more preferably 1400 ° C.
- the time for performing the reduction heat treatment in the reduction step S33 is set according to the temperature of the reduction furnace, but is preferably 10 minutes or more, and more preferably 15 minutes or more.
- the upper limit of the time for performing the reduction heat treatment in the reduction step S33 may be 50 minutes or less or 40 minutes or less from the viewpoint of suppressing an increase in manufacturing cost.
- the reduction heat treatment in the reduction step S33 for example, in a short time of about 1 minute, first, nickel oxide and iron oxide are reduced and metalized in the vicinity of the surface of the mixture where the reduction reaction easily proceeds, and an iron-nickel alloy (ferronickel) ) To form a shell (hereinafter also referred to as “shell”).
- an iron-nickel alloy ferrronickel
- the slag component in the mixture gradually melts to form liquid phase slag.
- a metal made of an alloy such as ferronickel or a metal (hereinafter simply referred to as “metal”) and a slag made of an oxide (hereinafter simply referred to as “slag”) are separated.
- metal made of an alloy such as ferronickel or a metal
- slag a slag made of an oxide
- the slag formed by the reduction heat treatment is melted into a liquid phase, but the metal and slag that have already been separated and produced do not mix with each other. As a separate phase with slag solid phase, it becomes a mixed material.
- the volume of the mixture is shrunk to a volume of about 50% to 60% as compared with the mixture to be charged.
- the reduction process in the reduction step S33 is performed using a reduction furnace or the like.
- a reduction furnace or the like.
- the metal component in the reduced product is small in the state obtained by the reduction treatment, for example, when a bulk metal of about 200 ⁇ m or less is obtained, the metal and slag are separated in the subsequent separation step S4. Becomes difficult.
- the reduced product is kept at a high temperature, so that the metal having a specific gravity larger than that of the slag in the reduced product can be settled and aggregated to coarsen the metal.
- the holding temperature of the reduced product in the temperature holding step S34 can be appropriately set according to the reduction temperature in the reduction step S33, and is preferably in the range of 1300 ° C or higher and 1500 ° C or lower.
- the metal component in the reduced product can be efficiently precipitated to obtain a coarse metal.
- the holding temperature is less than 1300 ° C.
- a large part of the reduced product becomes a solid phase, so that it takes time to obtain a coarse metal even if the metal component does not settle or settles.
- the holding temperature exceeds 1500 ° C., the reduction product may not be recovered due to the reaction between the obtained reduction product and the hearth or hearth carbonaceous reducing agent, and the furnace may be damaged. I might let you.
- the temperature holding time in the temperature holding step S34 is set according to the temperature of the reducing furnace, but is preferably 10 minutes or more, and more preferably 15 minutes or more.
- the upper limit of the time for holding the temperature in the temperature holding step S34 may be 50 minutes or less or 40 minutes or less from the viewpoint of suppressing an increase in manufacturing cost.
- the treatment in the temperature holding step S34 is preferably performed continuously in the furnace in which the reduction reaction is performed, following the reduction step S33.
- the temperature holding step S34 is performed in the processing chamber 25 of the reduction furnace 2 in FIG. 4, it is preferable to reduce the mixture in the processing chamber 24 and then move the mixture to the processing chamber 25 by rotating the hearth.
- Cooling step S35 is cooled down to a temperature at which the reduced product after maintaining the temperature in the temperature maintaining step S34 can be separated and recovered in the subsequent separation step S4 after passing through the reduction step S33. It is a process to do.
- the cooling of the reduced product in the cooling step S35 can be performed in at least one of a processing chamber inside the furnace where the reduction reaction is performed and a processing chamber connected to the outside of the furnace.
- a processing chamber inside the furnace where the reduction reaction is performed For example, in the reduction furnace 2 of FIG. 4, the temperature drop inside the rotary hearth furnace 20 is reduced by using the processing chamber 26 of the rotary hearth furnace 20 as a cooling chamber and providing the external cooling chamber 27 outside the furnace. Therefore, the energy loss in the reduction furnace 2 can be reduced. In particular, since it becomes difficult for heat to be transferred from the rotary hearth furnace 20 to the external cooling chamber 27, the reduced product can be cooled more smoothly.
- the temperature at which the reduced product after the reducing step S33 is transferred to the cooling chamber may be any temperature at which the reduced product can be handled substantially as a solid.
- the recovery temperature is preferably as high as possible. At this time, by raising the temperature at the time of recovery as much as possible, the temperature drop of the hearth of the rotary hearth furnace 20 until it is transferred to the cooling chamber is reduced. Therefore, energy loss due to cooling to the rotary hearth and the atmosphere in the furnace and preheating can be reduced, and energy required for reheating can be further saved.
- the recovery temperature in the cooling step S35 is preferably 600 ° C. or higher.
- the energy required for reheating is significantly reduced, so that an efficient smelting process can be performed at a lower cost.
- the temperature difference in the hearth of the rotary hearth furnace 20 is reduced, the thermal stress applied to the hearth and the furnace wall is also reduced, so that the life of the rotary hearth furnace 20 can be greatly extended. Problems during operation of the rotary hearth furnace 20 can be greatly reduced.
- the mixture after the reduction treatment step S3 is a mixture of metal and slag.
- the reaction in the reduction treatment step S3 progresses ideally, the mixture after the reduction treatment step S3 is a mixture of metal and slag.
- the reaction in the reduction treatment step S3 progresses ideally, the mixture after the reduction treatment step S3 is a mixture of metal and slag.
- the reaction in the reduction treatment step S3 progresses ideally, the mixture after the reduction treatment step S3 is a mixture of metal and slag.
- Separation process In the separation step S4, metal (ferronickel metal) is separated and recovered from the reduced product generated in the reduction treatment step S3. Specifically, the metal phase is separated and recovered from a mixture (reduced product) containing a metal phase (metal solid phase) and a slag phase (slag solid phase) obtained by reducing and heating the mixture. To do.
- metal ferrronickel metal
- the obtained metal phase and slag phase can be easily separated because of poor wettability.
- the above-mentioned large mixture can be dropped with a predetermined drop or screened. At this time, by applying an impact such as applying a predetermined vibration, the metal phase and the slag phase can be easily separated from the mixture.
- the metal phase can be recovered and made into a ferronickel product.
- the carbonaceous reducing agent is composed of particles (reducing agent particles), and the ratio of the reducing agent particles having a maximum length of 25 ⁇ m or less with respect to the total number of reducing agent particles and the reduction having a maximum length exceeding 25 ⁇ m.
- the average maximum particle length value for the agent particles is the one shown in Table 4.
- the content of the carbonaceous reducing agent is 100% by mass, which is necessary for reducing nickel oxide and iron oxide (Fe 2 O 3 ) contained in the nickel oxide ore that is the raw material ore without excess or deficiency. Occasionally, the content was 31% by mass.
- the average maximum particle length described in Table 4 is an average value of the maximum particle length of 300 reducing agent particles randomly selected from those having a maximum length exceeding 25 ⁇ m using a metal microscope. Asked.
- the mixture was obtained by kneading the raw materials using a twin-screw kneader.
- Pretreatment process The mixture obtained by the mixing process is agglomerated by forming into a spherical pellet of ⁇ 18 ⁇ 1.2 mm using a pan-type granulator, and then the solid content is about 70% by weight and the water content is 30%.
- a drying treatment was performed by blowing hot air of 200 ° C. to 250 ° C. so that the ratio would be about%.
- Table 3 shows the solid content composition (excluding carbon) of the mixture (pellet) after the drying treatment.
- the drying chamber 21 was continuously provided in the rotary hearth furnace 20.
- the pellets were transferred to the processing chamber 23, which is a preheating chamber, and the temperature in the preheating chamber was maintained in the range of 700 ° C. or higher and 1280 ° C. or lower, and the pellet was pre-heat-treated.
- the preheat-treated pellets were transferred to the treatment chamber 24 in the rotary hearth furnace 20 and subjected to reduction treatment at the temperatures and times shown in Table 4.
- the reduced product of the pellets obtained through the reduction treatment is transferred in the order of the treatment chamber 25 which is a temperature holding chamber maintained at the same temperature as the reduction temperature shown in Table 4, and the treatment chamber 26 which is a cooling chamber, and then Then, it was transferred to the external cooling chamber 27 connected to the rotary hearth furnace 20, and quickly cooled to room temperature while flowing nitrogen and taken out into the atmosphere.
- the reductant was collected from the rotary hearth furnace 20 when the reductant was transferred to the external cooling chamber 27, and was collected by placing the reductant along a guide installed in the external cooling chamber 27.
- the nickel metalization rate and the nickel content in the metal were calculated by analyzing with an ICP emission spectroscopic analyzer (SHIMAZU S-8100 type).
- Nickel metal conversion rate Amount of Ni metalized in pellets / (total amount of Ni in pellets) ⁇ 100 (%)
- Nickel content in metal Amount of metallized Ni in pellet ⁇ (total amount of metallized Ni and Fe in pellet) x 100 (%)
- Table 4 below shows the nickel metal conversion rate and the nickel content in the metal obtained from the samples of Examples 1 to 12 and Comparative Examples 1 to 4.
- the number of reducing agent particles composed of particles (reducing agent particles) as the carbonaceous reducing agent and having a maximum particle length of 25 ⁇ m or less is the total number of reducing agent particles of the carbonaceous reducing agent.
- the nickel metallization rate is 98.3 by using those having an average maximum particle length of 30 ⁇ m or more and 80 ⁇ m or less for a reducing agent particle having a maximum particle length of 25% or more and 25% or less. It was found that high quality ferronickel having a high content of at least% and nickel content in the metal of at least 18.2% could be produced (Examples 1 to 12).
- the nickel metallization rate is as high as 98.5% or higher, resulting in higher quality. It has been found that ferronickel can be produced.
- the reason why the high-quality ferronickel can be produced is that the addition of a fine carbonaceous reducing agent suppresses aggregation and uneven distribution in the mixture, so that the nickel oxide ore and the carbonaceous reducing agent are suppressed. It is conceivable that the contact area with the mixture and the uniformity of the mixture have been increased, thereby enabling uniform and efficient refining treatment.
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Abstract
Description
平均最大粒子長=還元剤粒子300個の最大粒子長の総和/300 ・・・(1)
本発明に係る酸化鉱石の製錬方法は、酸化鉱石を原料として、その酸化鉱石と炭素質還元剤とを混合して混合物とし、得られた混合物を高温下で還元処理に付して還元物であるメタルを製造する方法である。例えば、酸化鉱石として、酸化ニッケルや酸化鉄等を含有するニッケル酸化鉱石を原料とし、そのニッケル酸化鉱石を炭素質還元剤と混合して、高温下において、混合物に含まれるニッケルを優先的に還元し、また鉄を部分的に還元することで鉄とニッケルの合金であるフェロニッケルを製造する方法が挙げられる。
平均最大粒子長=還元剤粒子300個の最大粒子長の総和/300 ・・・(1)
本実施の形態に係るニッケル酸化鉱石の製錬方法は、ニッケル酸化鉱石を炭素質還元剤と混合して混合物とし、その混合物に対して還元処理を施すことによって、還元物としてメタルであるフェロニッケルとスラグとを生成させる方法である。この製錬方法では、混合物中のニッケル(酸化ニッケル)を優先的に還元させ、また、鉄(酸化鉄)を部分的に還元することで、フェロニッケルを生成させる。なお、メタルであるフェロニッケルは、還元処理を経て得られたメタルとスラグとを含む混合物から、そのメタルを分離することで回収することができる。
混合処理工程S1は、ニッケル酸化鉱石を含む原料粉末を混合して混合物を得る工程である。具体的には、混合処理工程S1では、原料鉱石であるニッケル酸化鉱石に、炭素質還元剤を添加して混合し、また任意成分の添加剤として、鉄鉱石、フラックス成分、バインダー等の、例えば粒径が0.1mm~0.8mm程度の粉末を添加して混合し、混合物を得る。なお、混合処理は、混合機等を用いて行うことができる。
原料鉱石であるニッケル酸化鉱石としては、特に限定されないが、リモナイト鉱、サプロライト鉱等を用いることができる。なお、ニッケル酸化鉱石は、酸化ニッケル(NiO)と、酸化鉄(Fe2O3)とを少なくとも含有する。
炭素質還元剤としては、特に限定されないが、石炭粉、コークス粉等が挙げられる。
平均最大粒子長=還元剤粒子300個の最大粒子長の総和/300 ・・・(1)
ニッケル酸化鉱石と炭素質還元剤のほか、混合物における鉄-ニッケル比を調整するために任意成分として鉄鉱石を添加することができる。ここで、鉄鉱石としては、特に限定されないが、例えば、鉄品位が50%程度以上のものや、ニッケル酸化鉱石の湿式製錬により得られるヘマタイト等を用いることができる。
また、バインダーとしては、例えば、ベントナイト、多糖類、樹脂、水ガラス、脱水ケーキ等を挙げることができる。また、フラックス成分としては、例えば、酸化カルシウム、水酸化カルシウム、炭酸カルシウム、二酸化珪素等を挙げることができる。
還元投入前処理工程S2は、混合処理工程S1で得られた、ニッケル酸化鉱石と炭素質還元剤とを含有する混合物を成形させ、必要に応じて乾燥させる工程である。すなわち、この還元投入前処理工程S2では、原料粉末を混合して得られた混合物を、後述する還元処理工程S3にて使用する炉に投入し易くし、また効率的に還元反応が起こるように成形する。
得られた混合物を成形する場合、その混合物を塊状化(造粒)して塊状の成形体(ペレット、ブリケット等)にしてもよく、混合物を容器等に充填して混合物充填容器にしてもよい。
このうち、混合物を塊状化する場合、ニッケル酸化鉱石と炭素質還元剤とを含有する混合物に対して、塊状化に必要な所定量の水分を添加し、例えば塊状物製造装置(転動造粒機、圧縮成形機、押出成形機等、あるいはペレタイザーともいう)を用いて、ペレット、ブリケット等の塊状の成形体(以下、単に「ペレット」という場合がある。)に成形する。
他方で、混合物を容器等に充填して成形する場合、ニッケル酸化鉱石と炭素質還元剤とを含有する混合物を押出機等で混練しながら所定の容器等に充填することで、混合物充填容器とすることができる。得られた混合物充填容器は、そのまま次工程の還元処理工程S3に供してもよいが、容器等に収容されている混合物をプレス等によって押し固めたものを、還元処理工程S3に供することがより好ましい。特に、容器等に収容されている混合物を押し固めて成形し、成形された混合物を次工程の還元処理工程S3に付すことで、混合物の間に生じる空隙を低減させて密度を高めることができ、また、密度が均一化することで還元反応をより均一に進め易くすることができる。したがって、品質のばらつきのより小さいフェロニッケルを作製することができる。
ニッケル酸化鉱石と炭素質還元剤とを含有する混合物には、混合物を成形する前後の少なくともいずれかにおいて、乾燥処理を行ってもよい。ここで、ニッケル酸化鉱石と炭素質還元剤を含有する混合物には水分が多く含まれていることがあり、このような混合物を急激に還元温度まで昇温すると、水分が一気に気化し、膨張して混合物が破壊することがある。また、混合物は、水分によってべたべたした状態となっていることも多い。
還元処理工程S3では、還元投入前処理工程S2を経て成形された混合物を還元炉に装入して、所定の還元温度に還元加熱する。このように、混合物に対して加熱処理することで、製錬反応(還元反応)が進行して、メタルとスラグとの混在物が生成する。
乾燥工程S31では、原料粉末を混合して得られた混合物に対して乾燥処理を施す。この乾燥工程S31は、混合物中の水分や結晶水を飛ばすことを主な目的とする。
予熱工程S32では、乾燥工程S31での乾燥処理によって水分を除去した後の混合物を予熱(予備加熱)する。この予熱工程S32は、還元時に温度がスムーズに還元温度まで上がるようにすることを主な目的とする。
還元工程S33では、予熱工程S32にて予熱した混合物に対し、所定の還元温度で還元処理を施す。この還元工程S33は、予熱工程S32で予熱した混合物を還元することを主な目的とする。
還元工程S33を経て得られた還元物に対して、回転炉床炉内で所定の温度条件で保持する温度保持工程S34を行ってもよい。具体的に、この温度保持工程S34は、還元工程S33における還元温度を同等の温度に還元物を保持することによって、その還元物中におけるメタル成分をさらに沈降させて纏め、メタルを粗大化させる。これにより、メタルを回収し易くすることができる。
冷却工程S35は、還元工程S33を経て、あるいは必要に応じて温度保持工程S34にて温度を保持した後の還元物を、続く分離工程S4にて分離回収できる温度にまで冷却する工程である。
分離工程S4では、還元処理工程S3にて生成した還元物から、メタル(フェロニッケルメタル)を分離して回収する。具体的には、混合物を還元加熱処理することによって得られた、メタル相(メタル固相)とスラグ相(スラグ固相)とを含む混在物(還元物)から、メタル相を分離して回収する。
実施例1~12、比較例1~4の各試料について、原料鉱石としてのニッケル酸化鉱石と、鉄鉱石と、フラックス成分である珪砂及び石灰石、バインダー、及び炭素質還元剤(石炭粉)を、適量の水を添加しながら混合機を用いて混合した。
混合処理によって得られる混合物に対して、パン型造粒機を用いてφ18±1.2mmの球形状のペレットに成形することで塊状化した後、固形分が70重量%程度、水分が30重量%程度となるように、200℃~250℃の熱風を吹き付けて乾燥処理を施した。下記表3に、乾燥処理後の混合物(ペレット)の固形分組成(炭素を除く)を示す。
前処理を行った後のペレットを、実質的に酸素を含まない窒素雰囲気にした、回転炉床炉を有する還元炉に各々装入した。還元炉としては、図4に示すように、炉床が回転移動する領域を4分割するように4つの処理室23~26を備えた回転炉床炉20を有するものを用いた。この還元炉2では、乾燥室21が回転炉床炉20の処理室23に接続されており、また、外部冷却室27が回転炉床炉20の処理室26に接続されている。
ニッケルメタル化率=
ペレット中のメタル化したNi量÷(ペレット中の全てのNi量)×100(%)
メタル中のニッケル含有率=
ペレット中のメタル化したNi量÷(ペレット中のメタル化したNiとFeの合計量)×100(%)
10 混合物
2 還元炉
20 回転炉床炉
21 乾燥室
23~26 処理室
27 外部冷却室
Claims (4)
- 酸化鉱石と炭素質還元剤とを混合し、得られた混合物を加熱して還元処理に付し、還元物であるメタルとスラグとを得る製錬方法であって、
前記炭素質還元剤として粒子(還元剤粒子)から構成されるものを用い、
前記炭素質還元剤に含まれる最大粒子長が25μm以下の還元剤粒子の数の割合が、該炭素質還元剤に含まれる還元剤粒子の総数に対して2%以上25%以下であり、
下記式(1)により求められる、最大粒子長が25μmを超える還元剤粒子の平均最大粒子長が30μm以上80μm以下である
酸化鉱石の製錬方法。
平均最大粒子長=還元剤粒子300個の最大粒子長の総和/300 ・・・(1) - 前記還元処理における還元温度を、1200℃以上1450℃以下とする
請求項1に記載の酸化鉱石の製錬方法。 - 前記酸化鉱石は、ニッケル酸化鉱石である
請求項1又は2に記載の酸化鉱石の製錬方法。 - 前記メタルは、フェロニッケルである
請求項1乃至3のいずれかに記載の酸化鉱石の製錬方法。
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US10626480B2 (en) | 2020-04-21 |
EP3636783A1 (en) | 2020-04-15 |
CA3058888C (en) | 2020-02-11 |
JP2018197381A (ja) | 2018-12-13 |
AU2018271516B2 (en) | 2020-02-06 |
PH12019502432A1 (en) | 2020-07-20 |
CN110637101B (zh) | 2021-07-20 |
CA3058888A1 (en) | 2018-11-29 |
PH12019502432B1 (en) | 2020-07-20 |
CN110637101A (zh) | 2019-12-31 |
EP3636783A4 (en) | 2020-12-02 |
EP3636783B1 (en) | 2024-03-27 |
US20200056262A1 (en) | 2020-02-20 |
JP6439828B2 (ja) | 2018-12-19 |
AU2018271516A1 (en) | 2019-10-31 |
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