Classifications

• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21B—MANUFACTURE OF IRON OR STEEL
  • C21B13/00—Making spongy iron or liquid steel, by direct processes
  • C21B13/0073—Selection or treatment of the reducing gases
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C1/00—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon
  • C07C1/02—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon from oxides of a carbon
  • C07C1/12—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon from oxides of a carbon from carbon dioxide with hydrogen
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21B—MANUFACTURE OF IRON OR STEEL
  • C21B13/00—Making spongy iron or liquid steel, by direct processes
  • C21B13/0066—Preliminary conditioning of the solid carbonaceous reductant
• • 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
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21B—MANUFACTURE OF IRON OR STEEL
  • C21B13/00—Making spongy iron or liquid steel, by direct processes
  • C21B13/0086—Conditioning, transformation of reduced iron ores
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
  • C25B1/00—Electrolytic production of inorganic compounds or non-metals
  • C25B1/01—Products
  • C25B1/02—Hydrogen or oxygen
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21B—MANUFACTURE OF IRON OR STEEL
  • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
  • C21B2100/20—Increasing the gas reduction potential of recycled exhaust gases
  • C21B2100/26—Increasing the gas reduction potential of recycled exhaust gases by adding additional fuel in recirculation pipes
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21B—MANUFACTURE OF IRON OR STEEL
  • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
  • C21B2100/20—Increasing the gas reduction potential of recycled exhaust gases
  • C21B2100/28—Increasing the gas reduction potential of recycled exhaust gases by separation
  • C21B2100/282—Increasing the gas reduction potential of recycled exhaust gases by separation of carbon dioxide
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
  • C25B1/00—Electrolytic production of inorganic compounds or non-metals
  • C25B1/01—Products
  • C25B1/02—Hydrogen or oxygen
  • C25B1/04—Hydrogen or oxygen by electrolysis of water
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
  • C25B15/00—Operating or servicing cells
  • C25B15/08—Supplying or removing reactants or electrolytes; Regeneration of electrolytes
  • C25B15/081—Supplying products to non-electrochemical reactors that are combined with the electrochemical cell, e.g. Sabatier reactor
• • 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
  • Y02P10/10—Reduction of greenhouse gas [GHG] emissions
  • Y02P10/134—Reduction of greenhouse gas [GHG] emissions by avoiding CO2, e.g. using hydrogen

Definitions

• the invention is related to a method for manufacturing Direct Reduced Iron (DRI) and to a DRI manufacturing equipment
• DRI Direct Reduced Iron
• Steel can be currently produced through two main manufacturing routes.
• most commonly used production route consists in producing pig iron in a blast furnace, by use of a reducing agent, mainly coke, to reduce iron oxides.
• a reducing agent mainly coke
• coke a reducing agent
• this method approx. 450 to 600 kg of coke, is consumed per metric ton of pig iron; this method, both in the production of coke from coal in a coking plant and in the production of the pig iron, releases significant quantities of C02.
• the second main route involves so-called “direct reduction methods”.
• direct reduction methods are methods according to the brands MIDREX, FINMET, ENERGIRON/HYL, COREX, FINEX etc., in which sponge iron is produced in the form of HDRI (Hot Direct Reduced Iron), CDRI (cold direct reduced iron), or HBI (hot briquetted iron) from the direct reduction of iron oxide carriers.
• Sponge iron in the form of HDRI, CDRI, and HBI usually undergo further processing in electric arc furnaces.
• each direct reduction shaft with cold DRI discharge There are three zones in each direct reduction shaft with cold DRI discharge: Reduction zone at top, transition zone at the middle, cooling zone at the cone shape bottom. In hot discharge DRI, this bottom part is used mainly for product homogenization before discharge.
• the reducing gas generally comprises hydrogen and carbon monoxide (syngas) and is obtained by the catalytic reforming of natural gas.
• syngas carbon monoxide
• MIDREX so-called MIDREX method
• first methane is transformed into a reformer according to the following reaction to produce the syngas or reduction gas:
• Injection of natural gas in the transition zone is using sensible heat of the metallized product in the transition zone to promote hydrocarbon cracking and carbon deposition. Due to relatively low concentration of oxidants, transition zone natural gas is more likely to crack to H2 and Carbon than reforming to H2 and CO. Natural gas cracking provides carbon for DRI carburization and, at the same time adds reductant (H2) to the gas that increases the gas reducing potential.
• H2 reductant
• Content of carbon in the DRI product is a key parameter at it plays an important role into the subsequent steps, such as slag foaming at the electric Arc furnace, but it also helps to improve the transportability of the DRI product.
• Solutions are already known to increase the carbon content of the product, they mainly consist in injecting hydrocarbons into the shaft, usually CH4, or coke oven gas. But those gases will contribute to increase the carbon footprint of the DRI process which is not in line with the switch to pure H2 reduction.
• the method of the invention may also comprise the following optional characteristics considered separately or according to all possible technical combinations:
• the biochar is produced by the pyrolysis of biomass
• the solid compound is briquette and/or pellet
• the reducing gas comprises more than 50% in volume of hydrogen
• the reducing gas comprises more than 99% in volume of hydrogen
• the hydrogen of the reducing gas is at least partly produced by electrolysis
• a top reduction gas is captured at the exit of the direct reduction furnace and subjected to at least one separation step to be split between a C02-rich gas and an H2-rich gas, said H2-richgas being at least partly used as reduction gas,
• the C02-rich gas is subjected to a methanation step.
• Figure 1 illustrates a layout of a direct reduction plant allowing to perform a method according to the invention
• Figure 1 illustrates a layout of a direct reduction plant allowing to perform a method according to the invention.
• the direct reduction furnace (or shaft) 1 is charged at its top with a compound 10 made of a mixture of oxidized iron and biochar.
• Said compound may have any suitable shape allowing the loading into the furnace, it is preferentially charged in form of briquettes and/or pellets.
• the compound 10 comprises from 0.01 to 10% by weight of biochar.
• Biochar it is meant a charcoal that is produced by pyrolysis of biomass in the absence of oxygen.
• Biomass is renewable organic material that comes from plants and animals.
• Biomass sources for energy include wood and wood processing wastes — firewood, wood pellets, and wood chips, lumber and furniture mill sawdust and waste, and black liquor from pulp and paper mills, agricultural crops and waste materials — corn, soybeans, sugar cane, switchgrass, woody plants, and algae, and crop and food processing residues, biogenic materials in municipal solid waste — paper, cotton, and wool products, and food, yard, and wood wastes and animal manure and human sewage.
• the compound 10 will provide both the iron oxides to be reduced and the necessary carbon-source to carburize the metallized product.
• carbon content of the Direct Reduced Iron is set from 0.5 to 3 wt.%, preferably from 1 to 2 wt.% which allows getting a Direct Reduced Iron that can be easily handled and that keeps a good combustion potential for its future use.
• Said compound 10 is reduced into the furnace 1 by a reducing gas 11 injected into the furnace and flowing counter-current from the compound 10.
• Reduced iron 12 exits the bottom of the furnace 1 for further processing, such as briquetting, before being used in subsequent steelmaking steps.
• Reducing gas, after having reduced iron, exits at the top of the furnace as a top reduction gas 20 (TRG).
• a cooling gas 13 can be captured out of the cooling zone of the furnace, subjected to a cleaning step into a cleaning device 30, such as a scrubber, compressed in a compressor 31 and then sent back to the cooling zone of the shaft 1.
• a cleaning device 30 such as a scrubber
• the reducing gas 11 comprises at least 50%v of hydrogen, and more preferentially more than 99%v of H2.
• An H2 stream 40 may be supplied to produce said reducing gas 11 by a dedicated H2 production plant 9, such as an electrolysis plant. It may be a water or steam electrolysis plant. It is preferably operated using CO2 neutral electricity which includes notably electricity from renewable source which is defined as energy that is collected from renewable resources, which are naturally replenished on a human timescale, including sources like sunlight, wind, rain, tides, waves, and geothermal heat. In some embodiments, the use of electricity coming from nuclear sources can be used as it is not emitting CO2 to be produced.
• H2 stream 40 may be mixed with part of the top reduction gas 20 to form the reducing gas 11.
• the top reduction gas 20 usually comprises from 15 to 25%v of CO, from 12 to 20%v of C02, from 35 to 55%v of
• H2 from 15 to 25%v of H20, from 1 to 4% of N2. It has a temperature from 250 to 500°C.
• the composition of said top reduction gas will be rather composed of 40 to 80%v of H2, 20-50%v of H20 and some possible gas impurities coming from seal system of the shaft or present in the hydrogen stream 40.
• the top gas 20 will have an intermediate composition between the two previously described cases.
• the top reduction gas 20 after a dust and mist removal step in a cleaning device 5, such as a scrubber and a demister, is sent to a separation unit 6 where it is divided into two streams 22,23.
• the first stream 22 is a C02-rich gas which can be captured and used in different chemical processes. In a preferred embodiment, this C02-rich gas 22 is subjected to a methanation step.
• the second stream 23 is a H2-rich gas which is sent to a preparation device 7 where it will be mixed with other gas, optionally reformed and heated to produce the reducing gas 11. In a preferred embodiment, the preparation device 7 is a heater.
• the method according to the invention allows to obtain a DRI product having enough carbon content without impairing the C02 footprint of the process.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Manufacturing & Machinery (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Electrochemistry (AREA)
• Life Sciences & Earth Sciences (AREA)
• Environmental & Geological Engineering (AREA)
• General Life Sciences & Earth Sciences (AREA)
• Geochemistry & Mineralogy (AREA)
• Geology (AREA)
• General Chemical & Material Sciences (AREA)
• Oil, Petroleum & Natural Gas (AREA)
• Inorganic Chemistry (AREA)
• Manufacture Of Iron (AREA)
• Manufacture And Refinement Of Metals (AREA)
• Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)

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• 2021
  • 2021-05-18 MX MX2023013535A patent/MX2023013535A/es unknown
  • 2021-05-18 EP EP21727941.3A patent/EP4341449A1/en active Pending
  • 2021-05-18 JP JP2023571579A patent/JP7795560B2/ja active Active
  • 2021-05-18 CA CA3219995A patent/CA3219995A1/en active Pending
  • 2021-05-18 BR BR112023023873A patent/BR112023023873A2/pt unknown
  • 2021-05-18 WO PCT/IB2021/054259 patent/WO2022243726A1/en not_active Ceased
  • 2021-05-18 US US18/559,909 patent/US20240254576A1/en active Pending
  • 2021-05-18 CN CN202180098331.1A patent/CN117337337A/zh active Pending
  • 2021-05-18 AU AU2021446056A patent/AU2021446056B2/en active Active
  • 2021-05-18 UA UAA202306007A patent/UA129931C2/uk unknown
• 2023
  • 2023-11-07 ZA ZA2023/10357A patent/ZA202310357B/en unknown

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