WO2024023565A1 - Procédé de fabrication de fonte brute dans un four de fusion électrique et four de fusion électrique associé - Google Patents
Procédé de fabrication de fonte brute dans un four de fusion électrique et four de fusion électrique associé Download PDFInfo
- Publication number
- WO2024023565A1 WO2024023565A1 PCT/IB2022/057043 IB2022057043W WO2024023565A1 WO 2024023565 A1 WO2024023565 A1 WO 2024023565A1 IB 2022057043 W IB2022057043 W IB 2022057043W WO 2024023565 A1 WO2024023565 A1 WO 2024023565A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- pig iron
- smelting furnace
- containing material
- vessel
- carbon containing
- Prior art date
Links
- 229910000805 Pig iron Inorganic materials 0.000 title claims abstract description 58
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000003723 Smelting Methods 0.000 title claims abstract description 32
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 20
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 39
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 39
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 28
- 239000010959 steel Substances 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims abstract description 22
- 239000002893 slag Substances 0.000 claims abstract description 14
- 238000002844 melting Methods 0.000 claims abstract description 5
- 230000008018 melting Effects 0.000 claims abstract description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 24
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 12
- 239000002245 particle Substances 0.000 claims description 12
- 239000010703 silicon Substances 0.000 claims description 12
- 229910052710 silicon Inorganic materials 0.000 claims description 12
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 10
- 229910052742 iron Inorganic materials 0.000 claims description 10
- 239000001301 oxygen Substances 0.000 claims description 10
- 229910052760 oxygen Inorganic materials 0.000 claims description 10
- 239000007789 gas Substances 0.000 claims description 8
- 239000007788 liquid Substances 0.000 claims description 8
- 239000005997 Calcium carbide Substances 0.000 claims description 7
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 7
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 7
- CLZWAWBPWVRRGI-UHFFFAOYSA-N tert-butyl 2-[2-[2-[2-[bis[2-[(2-methylpropan-2-yl)oxy]-2-oxoethyl]amino]-5-bromophenoxy]ethoxy]-4-methyl-n-[2-[(2-methylpropan-2-yl)oxy]-2-oxoethyl]anilino]acetate Chemical compound CC1=CC=C(N(CC(=O)OC(C)(C)C)CC(=O)OC(C)(C)C)C(OCCOC=2C(=CC=C(Br)C=2)N(CC(=O)OC(C)(C)C)CC(=O)OC(C)(C)C)=C1 CLZWAWBPWVRRGI-UHFFFAOYSA-N 0.000 claims description 7
- 239000002028 Biomass Substances 0.000 claims description 6
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 239000003153 chemical reaction reagent Substances 0.000 claims description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 4
- 239000000571 coke Substances 0.000 claims description 4
- 239000001257 hydrogen Substances 0.000 claims description 4
- 229910052739 hydrogen Inorganic materials 0.000 claims description 4
- 238000007664 blowing Methods 0.000 claims description 3
- RHZUVFJBSILHOK-UHFFFAOYSA-N anthracen-1-ylmethanolate Chemical compound C1=CC=C2C=C3C(C[O-])=CC=CC3=CC2=C1 RHZUVFJBSILHOK-UHFFFAOYSA-N 0.000 claims description 2
- 239000003830 anthracite Substances 0.000 claims description 2
- 239000012159 carrier gas Substances 0.000 claims description 2
- 238000002485 combustion reaction Methods 0.000 claims description 2
- 239000002131 composite material Substances 0.000 claims description 2
- 239000000047 product Substances 0.000 description 22
- 229910052751 metal Inorganic materials 0.000 description 9
- 239000002184 metal Substances 0.000 description 9
- 241000196324 Embryophyta Species 0.000 description 8
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 7
- 238000002347 injection Methods 0.000 description 7
- 239000007924 injection Substances 0.000 description 7
- 238000007792 addition Methods 0.000 description 6
- 230000005611 electricity Effects 0.000 description 6
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 6
- 238000006243 chemical reaction Methods 0.000 description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 5
- 238000009628 steelmaking Methods 0.000 description 5
- 239000002699 waste material Substances 0.000 description 5
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 4
- 239000005864 Sulphur Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 239000002023 wood Substances 0.000 description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 3
- 235000013980 iron oxide Nutrition 0.000 description 3
- 239000003345 natural gas Substances 0.000 description 3
- 230000007935 neutral effect Effects 0.000 description 3
- 229910052717 sulfur Inorganic materials 0.000 description 3
- 239000011593 sulfur Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 2
- 241001465754 Metazoa Species 0.000 description 2
- 235000011941 Tilia x europaea Nutrition 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 229940043430 calcium compound Drugs 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000006477 desulfuration reaction Methods 0.000 description 2
- 230000023556 desulfurization Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 235000013305 food Nutrition 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 239000004571 lime Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 238000007670 refining Methods 0.000 description 2
- 229910000029 sodium carbonate Inorganic materials 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 239000004484 Briquette Substances 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 241000195493 Cryptophyta Species 0.000 description 1
- 229910005347 FeSi Inorganic materials 0.000 description 1
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 1
- 244000068988 Glycine max Species 0.000 description 1
- 235000010469 Glycine max Nutrition 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 241001520808 Panicum virgatum Species 0.000 description 1
- 240000000111 Saccharum officinarum Species 0.000 description 1
- 235000007201 Saccharum officinarum Nutrition 0.000 description 1
- 229910004534 SiMn Inorganic materials 0.000 description 1
- 229910000720 Silicomanganese Inorganic materials 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000000035 biogenic effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 150000001674 calcium compounds Chemical class 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 238000004939 coking Methods 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 238000005868 electrolysis reaction Methods 0.000 description 1
- 210000003608 fece Anatomy 0.000 description 1
- -1 firewood Substances 0.000 description 1
- 239000010794 food waste Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 1
- 238000009847 ladle furnace Methods 0.000 description 1
- 239000010871 livestock manure Substances 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 150000002681 magnesium compounds Chemical class 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- QMQXDJATSGGYDR-UHFFFAOYSA-N methylidyneiron Chemical compound [C].[Fe] QMQXDJATSGGYDR-UHFFFAOYSA-N 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 239000010813 municipal solid waste Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 238000011946 reduction process Methods 0.000 description 1
- 238000010079 rubber tapping Methods 0.000 description 1
- 239000003923 scrap metal Substances 0.000 description 1
- 239000010865 sewage Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000012265 solid product Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002916 wood waste Substances 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
- 239000010925 yard waste Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B11/00—Making pig-iron other than in blast furnaces
- C21B11/10—Making pig-iron other than in blast furnaces in electric furnaces
-
- 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
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/14—Multi-stage processes processes carried out in different vessels or furnaces
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
- C21C5/28—Manufacture of steel in the converter
- C21C5/42—Constructional features of converters
- C21C5/46—Details or accessories
- C21C5/4606—Lances or injectors
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
- C21C5/28—Manufacture of steel in the converter
- C21C5/42—Constructional features of converters
- C21C5/46—Details or accessories
- C21C5/4606—Lances or injectors
- C21C5/4613—Refractory coated lances; Immersion lances
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
- C21C5/28—Manufacture of steel in the converter
- C21C5/42—Constructional features of converters
- C21C5/46—Details or accessories
- C21C5/4653—Tapholes; Opening or plugging thereof
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/0025—Adding carbon material
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/0037—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00 by injecting powdered material
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/0068—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00 by introducing material into a current of streaming metal
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/064—Dephosphorising; Desulfurising
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/064—Dephosphorising; Desulfurising
- C21C7/0645—Agents used for dephosphorising or desulfurising
-
- 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
- F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Tank furnaces
- F27B3/10—Details, accessories, or equipment peculiar to hearth-type furnaces
- F27B3/18—Arrangements of devices for charging
-
- 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
- F27D3/00—Charging; Discharging; Manipulation of charge
- F27D3/18—Charging particulate material using a fluid carrier
-
- 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
- F27D3/00—Charging; Discharging; Manipulation of charge
- F27D3/18—Charging particulate material using a fluid carrier
- F27D2003/185—Conveying particles in a conduct using a fluid
Definitions
- the invention is related to a method of manufacturing pig iron, also called hot metal and to a method of producing steel out of such pig iron.
- BF-BOF route consists in producing hot metal in a blast furnace, by use of a reducing agent, mainly coke, to reduce iron oxides and then transform hot metal into steel into a converter process or Basic Oxygen furnace (BOF).
- a reducing agent mainly coke
- BOF Basic Oxygen furnace
- 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 undergoes further processing in electric furnaces to produce steel.
- Another option consists in using smelting furnaces powered by electric energy to melt the DRI products to produce pig iron.
- This option has the advantage that pig iron is produced, as in the Blast Furnace, which allows oxides removal in molten slag and thus classical liquid steel treatment tools such a Basic Oxygen Furnace and refining ladles may be used.
- the pig iron obtained by this route has a carbon content which is relatively low compared to classical pig iron. This paradoxically reduces the environmental interest of this route because the higher the carbon rate, the more it will be possible to add recycled scrap metal in the BOF.
- the aim of the present invention is therefore to remedy the drawbacks of the pig iron and steelmaking manufacturing routes by providing a new route efficiently minimizing the environmental impact of such manufacturing.
- Such method may also comprise the optional characteristics of claims 2 to 10 considered separately or in any possible technical combinations.
- the invention also deals with a method for manufacturing steel according to claim 11.
- Such method may also comprise the optional characteristics of claims 12 to 13 considered separately or in any possible technical combinations.
- the invention also deals with an electrical smelting furnace according to claim 14.
- Figure 1 illustrates a pig iron and steelmaking process according to the smelting I BOF route
- Figure 2 illustrates a smelting furnace
- FIG. 3 illustrates an embodiment of the method according to the invention
- Figure 1 illustrates a steel production route according to the DRI route, from the reduction of iron to the casting of the steel into semi-products such as slabs, billets, blooms, or strips.
- Iron ore 10 is first reduced in a direct reduction plant 11.
- This direct reduction plant 11 may be designed to implement any kind of direct reduction technology such as MIDREX® technology or Energiron®.
- the direct reduction process may for example be a traditional natural-gas or a biogas-based process
- the DRI product used in the method according to the invention is manufactured using a reducing gas based on biogas coming from combustion of biomass.
- Biomass is renewable organic material that comes from plants and animals.
- Biomass sources include notably wood and wood processing wastes such as 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 such as corn, soybeans, sugar cane, switchgrass, woody plants, and algae, and crop and food processing residues, but also biogenic materials in municipal solid waste such as paper, cotton, and wool products, and food, yard, and wood wastes, animal manure and human sewage.
- biomass may also encompass plastics residues, such as recycled waste plastics like Solid Refuse Fuels or SRF.
- the carbon content of the DRI product can be set to a maximum of 3 % in weight and usually to a range of 2 to 3% in weight.
- the DRI product used in the method according to the invention is manufactured through a so called H2-DRI process where the reducing gas comprises more than 50 % and preferably more than 60, 70, 80 or 90 % in volume of hydrogen or is even entirely made of hydrogen.
- the H2- DRI product will contain a far lower level of carbon than the natural gas or biogas DRI, so typically below 1 % in weight or even lower.
- the hydrogen used in the DRI reducing gas comes from the electrolysis of water, which is preferably powered in part or all by CO2 neutral electricity.
- CO2 neutral electricity 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.
- 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.
- the use of electricity coming from nuclear sources can be used as it is not emitting CO2 to be produced.
- the resulting Direct Reduced Iron (DRI) Product 12 is then charged into a smelting furnace 13 where the reduction of iron oxide is completed, and the product is melted to produce pig iron.
- the DRI product can be transferred to the smelting furnace in various forms.
- the directly reduced iron product (DRI product) is fed to the smelting furnace in a hot form as HDRI product (so-called Hot DRI), or in a cold form as CDRI product (so-called Cold DRI), or in hot briquette form as HBI product (so-called Hot Briquetted Iron) and/or in particulate form, preferably with an average particle diameter of at most 10.0 mm, more preferably with an average particle diameter of at most 5.0 mm.
- It is preferably charged directly at the exit of the direct reduction plant 11 as a hot product with a temperature from 500°C to 700°C. This allows reducing the amount of energy needed to melt it.
- hot charging is not possible, for example if the direct reduction plant 11 and the smelting furnace 13 are not on same location, or if the smelting furnace 13 is stopped for maintenance and thus DRI product must be stored, then the DRI product may be charged cold, or a preheating step may be performed.
- the smelting furnace 13 uses electric energy provided by several electrodes to melt the DRI product 12 and produce pig iron. In a preferred embodiment, part or all of the electricity needed comes from CO2 neutral electricity. Further detailed description of the smelting furnace will be given later, based on figure 2.
- the pig iron may then optionally be transferred to a desulphurization station 15 to perform a desulphurization step.
- This desulphurization step is needed for production of steel grades requiring a low Sulphur content, which is, for example set at a maximum of 0.03 weight percent of sulphur.
- Desulfurization in oxidizing conditions is not effective and is thus preferentially performed either on pig iron before oxygen refining, or in steel ladle after steel deoxidizing. For very low sulfur contents, for example below 0.004 weight percent of sulfur, deoxidizing and desulphurization are combined for overall higher performance. Low sulfur grades thus benefit from performing pig iron desulfurization before the conversion step.
- Desulphurization of the pig iron can be done by adding reagents, notably based on calcium or magnesium compounds, such as sodium carbonate, lime, calcium carbide, and/or magnesium into the pig iron. It may be done for example by injection of those reagents in the pig iron previously transferred in a ladle. This ladle may be a simple one as illustrated one figure 1 but could also be a torpedo ladle.
- the desulphurized pig iron 16 has preferentially a content of Sulphur lower than 0.004 weight percent.
- the desulphurized pig iron 16 can then transferred into a converter 17.
- the converter basically turns the molten metal into liquid steel by blowing oxygen through molten metal to decarburize it. It is commonly named Basic Oxygen Furnace (BOF). Ferrous scraps 18, coming from recycling of steel, may also be charged into the converter 17 to take benefit of the heat released by the exothermic reactions resulting from the oxygen injection into the pig iron.
- BOF Basic Oxygen Furnace
- Liquid steel 19 thus formed can then be transferred, whenever needed, to one or more secondary metallurgy tools 20A, 20B such as Ladle furnaces, RH (Ruhrstahl-Heareus) vacuum vessel, Vacuum Tank degasser, alloying and stirring stations, etc.... to be treated to reach the required steel composition according to the steel grades to be produced.
- Liquid steel with the required composition 21 can then be transferred to a casting plant 22 where it can be turned into solid products, such as slabs, billets, blooms or strips.
- the smelting furnace 13 is composed of a vessel 20 able to contain hot metal.
- the vessel 20 may have a circular or a rectangular shape, for example.
- This vessel 20 may be closed by a roof provided with some apertures to receive electrodes 22 to be inserted into the vessel 20 and with other apertures to allow charging of the raw materials into the vessel 20.
- the electrodes 22 provide the required electric energy to melt the charged raw materials and form pig iron. They are preferably Soderberg-type electrodes.
- a pig iron 14 layer which is the densest and is thus located at the bottom of the vessel 20 and a slag layer 23 located above the pig iron 14.
- the slag layer 23 can be partially covered by piles of raw materials 24 waiting to be melted.
- the vessel 20 is also provided with apertures named tap holes 25 located in its lower part and allowing to discharge the pig iron 14 while keeping most of the slag into the vessel 20. They may be located in the lateral walls of the vessel or in its bottom wall.
- the smelting furnace 13 may be a SAF (Submerged-Arc Furnace) wherein the electrodes are immersed into the slag layer 23 or an OSBF (open-slag bath furnace) wherein the electrodes 22 are located above the slag layer 23. It is preferentially an OSBF as illustrated in the figures.
- SAF Submerged-Arc Furnace
- OSBF open-slag bath furnace
- the carbon content of the pig iron 14 produced through the DRI route will generally be lower than 3 % in weight.
- the pig iron should preferentially have a carbon content as close as possible to 4.5% in weight, which is the level of saturation.
- the pig iron carbon content is in the range of 4.0 to 4.5% in weight.
- a carbon containing material is added in the smelting furnace 13, directly in the pig iron layer 14. This addition can be done though an injection device.
- the carburization process can reach a very high yield, above 80%.
- the slag layer 23 has a high height, that can be above 50 cm and the density of carbon sources is usually lower than the slag density itself. This triggers physical limitations for carbon to go through the slag into the pig iron layer 14.
- the direct injection of carbon ensures an optimal energy efficiency of the smelting process as carburization requires a high amount of energy that can be optimally provided by electric heating in the smelting furnace rather than by an additional heating station.
- the injection device is a tuyere 26 inserted in the bottom of the vessel 20.
- Such bottom tuyere opens in the pig iron layer 14 to allow direct addition.
- this bottom tuyere 26 avoids injecting the carbon-containing material from the top of the smelting furnace 13 where the available space may be scarce due to the presence of electrodes and charging devices for the DRI product.
- the carbon is injected together with a carrier-gas to avoid clogging the injection device.
- This gas is preferably inert and may be made of nitrogen, argon, helium or carbon monoxide or any mixtures of such gases.
- the carbon containing material may come from different sources. It may be chosen, for example, among coke, anthracite, silicon carbide, calcium carbide, or a mixture of any of those sources, but can also advantageously come from renewable sources like biomass for part or all the carbon load.
- biochar can be used.
- Adding calcium carbide is particularly advantageous as the calcium atoms can provide a desulphurizing effect.
- Adding silicon carbide is also particularly advantageous as it allows increasing the silicon content of the pig iron.
- the carbon containing material to be injected through the injection device preferably has a particle size below 3mm.
- said material has a particle size less than or equal to 75pm, remaining particles having a particle size less than or equal to 2 mm.
- the carbon containing material may also be made of composite briquettes of an iron source mixed with one or several of the previously mentioned carbon sources.
- iron source can be chosen among sludges from electric furnaces, converters or smelters, slags from electric furnaces or from converters, DRI fines or any waste rich in iron from pig iron or steel production route.
- silicon containing material may be injected together with the carbon containing material in the pig iron layer 14.
- Silicon has a strong deoxidizing power at high temperature and notably around 1600°C which is the temperature of the liquid steel in the converter. It reacts with oxygen and contributes then to the formation of the slag. The reaction is exothermic and therefore provides additional energy for scrap melting in the converter. It can also improve the performance of the desulphurization operation, if any.
- Such silicon can be added under different forms. It may be metal Silicon Si, silicon carbide SiC, silicomanganese SiMn, calcium silicate SiCa or a ferro silicon alloy FeSi such as FeSi75 or FeSi65.
- the use of DRI products in the smelting furnace 13 will lead to a natural amount of silicon usually below 0.2 or even below 0.1 % in weight.
- the final silicon content of the pig iron is preferentially set at a value of 0.1 to 0.4% in weight, preferably of 0.2 to 0.4 % in weight. Further additions of silicon in the desulphurization station 15 and/or the converter 17 may be performed if required.
- desulphurization reagents can also be injected together with the carbon containing material, with or without silicon addition.
- Such reagents can notably be based on calcium compounds, such as sodium carbonate, lime, and/or calcium carbide.
- the final sulphur content of the pig iron is preferentially set at a maximum value of 0.03 weight percent and preferably at a maximum value of 0.004 weight percent.
- Performing desulphurization in the smelting furnace can allow suppressing the need for a desulphurizing treatment between the smelting furnace 13 and the converter 17 or at least reducing such treatment.
- adding calcium carbide is particularly advantageous as the calcium addition can provide a desulphurizing effect on top of adding carbon.
- Adding silicon carbide is also particularly advantageous as it allows increasing the silicon content of the pig iron on top of acting carbon. Adding a mix of calcium carbide and silicon carbide is even more advantageous as it provides carbon and silicon addition, while ensuring desulphurization.
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Abstract
L'invention concerne un procédé de fabrication de fonte brute dans un four de fusion électrique (13) comprenant une cuve (20), ledit procédé comprenant les étapes successives suivantes : - le chargement du produit DRI dans ladite cuve (20), − la fusion dudit produit DRI pour former une couche de fonte brute (14) surmontée d'une couche de laitier (23) et - l'injection d'un matériau contenant du carbone directement dans ladite couche de fonte brute (14). L'invention concerne également la fabrication d'acier à partir de ladite fonte brute et le four de fusion électrique (13) associé.
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PCT/IB2022/057043 WO2024023565A1 (fr) | 2022-07-29 | 2022-07-29 | Procédé de fabrication de fonte brute dans un four de fusion électrique et four de fusion électrique associé |
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PCT/IB2022/057043 WO2024023565A1 (fr) | 2022-07-29 | 2022-07-29 | Procédé de fabrication de fonte brute dans un four de fusion électrique et four de fusion électrique associé |
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PCT/IB2022/057043 WO2024023565A1 (fr) | 2022-07-29 | 2022-07-29 | Procédé de fabrication de fonte brute dans un four de fusion électrique et four de fusion électrique associé |
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WO (1) | WO2024023565A1 (fr) |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1144696A1 (fr) * | 1998-10-30 | 2001-10-17 | Midrex Technologies, Inc. | Procede de production de fer liquide dans des fours duplex |
US6524362B1 (en) * | 1997-10-07 | 2003-02-25 | Metallgesellschaft Ag | Method of melting fine grained direct reduced iron in an electric arc furnace |
-
2022
- 2022-07-29 WO PCT/IB2022/057043 patent/WO2024023565A1/fr unknown
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6524362B1 (en) * | 1997-10-07 | 2003-02-25 | Metallgesellschaft Ag | Method of melting fine grained direct reduced iron in an electric arc furnace |
EP1144696A1 (fr) * | 1998-10-30 | 2001-10-17 | Midrex Technologies, Inc. | Procede de production de fer liquide dans des fours duplex |
Non-Patent Citations (1)
Title |
---|
AKIO ITO ET AL: "Roland Berger: Direct Reduced Iron is best for CO2 Reduction", METALLURGICAL PLANT AND TECHNOLOGY INTERNATIONAL, 1 June 2020 (2020-06-01), Dusseldorf, pages 22, XP055922587, Retrieved from the Internet <URL:https://www.rolandberger.com/publications/publication_pdf/rroland_berger_future_of_steelmaking.pdf> [retrieved on 20220518] * |
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