WO2024035774A1 - Biocharbon employé dans la fabrication d'acier - Google Patents

Biocharbon employé dans la fabrication d'acier Download PDF

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Publication number
WO2024035774A1
WO2024035774A1 PCT/US2023/029831 US2023029831W WO2024035774A1 WO 2024035774 A1 WO2024035774 A1 WO 2024035774A1 US 2023029831 W US2023029831 W US 2023029831W WO 2024035774 A1 WO2024035774 A1 WO 2024035774A1
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WO
WIPO (PCT)
Prior art keywords
agglomerates
agglomerate
approximately
dry weight
weight basis
Prior art date
Application number
PCT/US2023/029831
Other languages
English (en)
Inventor
Brett SPIGARELLI
Matthew MLINAR
Matthew Young
Original Assignee
Regents Of The University Of Minnesota
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Regents Of The University Of Minnesota filed Critical Regents Of The University Of Minnesota
Publication of WO2024035774A1 publication Critical patent/WO2024035774A1/fr

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Classifications

    • 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
    • C21C5/52—Manufacture of steel in electric furnaces
    • C21C5/527—Charging of the electric furnace
    • 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
    • C21C5/52—Manufacture of steel in electric furnaces
    • C21C5/54—Processes yielding slags of special composition
    • 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
    • C22B15/00—Obtaining copper
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B14/00—Crucible or pot furnaces
    • F27B14/06—Crucible or pot furnaces heated electrically, e.g. induction crucible furnaces with or without any other source of heat
    • 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
    • C21C5/52—Manufacture of steel in electric furnaces
    • C21C5/527—Charging of the electric furnace
    • C21C2005/5276—Charging of the electric furnace with liquid or solid rest, e.g. pool, "sumpf"
    • 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
    • C22B25/00—Obtaining tin
    • C22B25/06—Obtaining tin from scrap, especially tin scrap

Definitions

  • BIOCHAR IN STEELMAKING This disclosure relates to agglomerates composed of biochar and iron and/or steel waste materials that are applicable to electric arc furnace (EAF) steelmaking processes as a substitute for coal feedstocks.
  • Electric Arc furnace EAF is an important process for steel production. EAF is used to recycle and melt steel scrap to produce steel. An EAF process currently requires a high amount of fossil coal. Biomass derived char referred to as biochar has been used in an EAF as an alternative substitute for fossil coal. However, there are different physical properties between the biochar currently used and coal that lead to significant differences in process behavior in EAF- steel production.
  • the biochar whether in pellet or briquette size tends to float atop the slag being produced in the EAF process and not within the slag of the EAF process. Situated above the slag, the benefits of the biochar are not being realized, including insulating the molten metal bath, protecting the refractory and electrodes, and preventing impurities from entering the molten metal.
  • This disclosure describes a method of steel production in an electric arc furnace containing a slag portion above a molten metal portion by supplying an agglomerate or agglomerates comprising iron or steel waste or both in particulate form within a biochar matrix held together by a binder wherein the bulk density of the agglomerate or agglomerates is sufficient for the agglomerate or agglomerates to be within the slag portion.
  • This disclosure also describes a method wherein the bulk density of the agglomerates is at least about 20 lbs./ft3.
  • This disclosure also describes a method wherein the agglomerate or agglomerates have a carbon content of approximately 25-90% by wt. [0006] This disclosure also describes a method wherein a volatile matter content of the agglomerate or agglomerates is approximately 3-40% wt. [0007] This disclosure also describes a method wherein a moisture content of the agglomerate or agglomerates is less than approximately 10% wt. [0008] This disclosure also describes a method wherein an ash content of the biochar is less than approximately 10% wt. [0009] This disclosure also describes a method wherein an ash content of the agglomerate or agglomerates is less than approximately 90% wt.
  • This disclosure also describes a method wherein the carbon content of the ash of the agglomerate is 1-70% wt. [0011] This disclosure also describes a method wherein the iron oxide content of the ash of the agglomerate is 1-80% wt. [0012] This disclosure also describes a method wherein the agglomerate is between approximately 3/32 inches (2.38 millimeters) and three inches (76.2 millimeters) in thickness.
  • this disclosure describes agglomerates for use in an electric arc furnace, wherein an agglomerate comprises iron or steel or both in particulate form within a biochar matrix held together by a binder wherein the bulk density of the agglomerates is at least about 20 lbs./ft3 (320 kg/m3).
  • This disclosure also describes the agglomerates being between approximately 3/32 inches and three inches in thickness.
  • This disclosure also describes the agglomerates having a f i x e d carbon content of approximately 10-90% by wt.
  • This disclosure also describes the agglomerates having a volatile matter content of approximately 3-40% wt.
  • this disclosure also describes the agglomerates having a moisture content of less than approximately 10% wt.
  • the disclosure describes a method of producing an agglomerate or agglomerates for use in an electric arc furnace, by comminuting iron or steel, or iron or steel byproducts or iron or steel waste or any combination thereof and biochar to a selected particle size; [0019] Mixing the comminuted the iron or steel, or iron or steel byproducts, or iron or steel waste, or any combination thereof and the biochar in selected proportions to from a mixture such that the resulting agglomerate comprises a bulk density of at least 20lbs./ft3 and an ash content of less than approximately 90 % by wt.
  • This disclosure also describes a method of producing an agglomerate wherein the agglomerate comprises the carbon content of the ash comprises approximately 25-90% by wt. [0021] This disclosure also describes a method of producing an agglomerate wherein the iron oxide content of the ash comprises approximately comprises 1-80% wt. [0022] This disclosure also describes a method of producing an agglomerate wherein the densification of the mixture results in the agglomerate being formed as a pellet or briquette.
  • This disclosure describes an agglomerate containing iron/steel waste and biochar for use in an electric arc furnace (EAF) that is of sufficient density to enter and be part of the slag portion in an EAF.
  • the aim of the agglomerate of this disclosure is to substitute for coal feedstocks and specifically to be used as a substitute for injection carbon within the slag portion or to complement injection carbon within the slag portion.
  • This disclosure describes an agglomerate containing iron or steel waste or both and biochar for use in an electric arc furnace (EAF) that is of sufficient density and energy content to be compliant with existing electric arc furnace charge carbon conveyance and furnace infrastructure.
  • the aim of the agglomerate of this disclosure is also to substitute for coal feedstocks and specifically to be used as a substitute for charged carbon or to complement charged carbon in the furnace.
  • An EAF typically reuses existing steel, avoiding the need for raw materials and their processing.
  • the furnace is charged with steel scrap.
  • the EAF can also include some direct reduced iron (DRI) or pig iron for chemical balance.
  • DRI direct reduced iron
  • the EAF operates on the basis of an electrical charge between two electrodes providing the heat for the process.
  • the power is supplied through the electrodes placed in the furnace, which produce an arc of electricity through the scrap steel (around 35 million watts), which raises the temperature to about 1600 ⁇ C, melting the scrap.
  • any impurities may be removed through the use of fluxes and drained off as slag through a taphole.
  • the phrase “electric arc furnace charge conveyance” refers to the process of transporting the raw materials, often in solid form, to an electric arc furnace (EAF) for steelmaking or other metallurgical processes. This phrase is well known in the art. However, a brief explanation is being given herein.
  • EAF electric arc furnace
  • various materials such as scrap metal, iron ore, and the bio char of this disclosure are included. This charge of materials is loaded into a charging system, which can be a mechanical or automated system designed to efficiently introduce the materials into the EAF.
  • the furnace shell is typically a large, cylindrical, and usually water-cooled vessel that contains the entire EAF setup. It is made of heavy steel plates and refractory lining to withstand the intense heat generated during the steelmaking.
  • Electrode Regulator An electrode regulator is a mechanism that controls the positioning of the electrodes within the furnace. It adjusts the electrode length and maintains the proper arc length during operation. This is essential for controlling the furnace's power input and temperature.
  • Refractory Lining Inside the furnace shell, there is a refractory lining made of heat- resistant materials.
  • Hearth The bottom part of the EAF is the hearth. It is also made of refractory materials and serves as the base for the charge materials to rest on during melting.
  • Cooling Systems To prevent overheating of the furnace components, EAFs have water- cooling systems. The furnace shell, roof, electrodes, and other critical parts have water-cooling channels to dissipate excess heat.
  • Charging System The charging system is responsible for introducing the raw materials, ( the charge,) into the EAF. It typically includes a conveyor system or mechanical charging arms to load the scrap metal and biochar.
  • Off-Gas System During the steelmaking process, gases and fumes are produced. An off- gas system is needed to capture and treat these emissions before releasing them into the atmosphere. This system helps to minimize environmental impacts and capture any usable by- products.
  • Tapping System Once the steel is fully melted and the desired chemical composition is achieved, the liquid metal is tapped out of the EAF through a tap hole located in the furnace shell. The tapping system consists of a tapping spout, ladle, and other equipment required to transport the molten metal to further processing units.
  • the agglomerate of this disclosure is a mixture comprising biochar, iron and steel waste, binder, and water.
  • the agglomerate may be rod shaped, disk shaped, plate shaped, briquette shaped, or spherical.
  • an agglomerate is meant a particle ranging in form from a pellet to a briquette. From a size standpoint, the agglomerate may be from approximately 3/32 inches up to about three inches in thickness.
  • Biochar is a charcoal-like substance that is made by burning biomass through pyrolysis. There are several well-known ways of producing biochar such as thermal pyrolysis, torrefaction, or hydrothermal conversion.
  • Nonlimiting biomass sources may include agricultural residues, waste from other industrial processes (food, paper, wood), manure, sewage sludge, landfill wastes or virgin biomass, biomass that is not the byproduct or result of an industrial or agricultural process such as algae.
  • Iron or steel or iron or steel byproducts or iron or steelwaste or any combination thereof and biochar are incorporated into the pellet/briquette.
  • Nonlimiting sources for iron and steel waste include blast furnace dust, DRI (direct reduced iron) dust, DRI fines, oxide fines, iron and steel slags, EAF dust, filter fines, and sludges.
  • the iron and steel waste may consist of cementite (iron carbide), metallic iron, silica, DRI, lime, magnesia, alumina, and iron oxides.
  • the agglomerate is introduced in the E.A.F. as the main components of the steelmaking process.
  • the agglomerate is introduced into molten steel in the E.A.F. as an additional component of the steel making process.
  • the biochar introduces additional energy for use in the steelmaking process.
  • the agglomerate of this disclosure comprises biochar, iron and steel waste, binder, and water that has a fixed carbon by difference content of approximately 25-90%, a bulk density greater than approximately 20 lbs./ft3 (320 kg/m3), volatile matter content of approximately 3-40%, moisture content less than approximately 10%, and an agglomerate ash content less than approximately 10%.
  • moisture content is determined according to ISO 18134- 1:2022 (Solid biofuels — Determination of moisture content).
  • ash content is determined according to ISO 18122:2022(en) (Solid biofuels-Determination of Ash Content); ashing temperature of 1022°F (550°C).
  • volatile matter is determined according to ISO 18123:2023(en) Solid biofuels — Determination of volatile matter.
  • fixed carbon by difference is calculated according to ISO ISO 17246:2010 (en) Coal — Proximate Analysis.
  • the bulk density of the agglomerate is sufficient to ensure that the agglomerate is within the slag of the EAF and not above the slag. Volatile matter results from the organic components of the agglomerate. Enough moisture is added to facilitate agglomeration. Ash is minimized since ash requires energy to melt and since ash is typically an oxide it ends up being an energy sink. However, some amount of ash is not harmful though.
  • Material Sizing [0046] Materials undergo comminution until a suitable selected particle size is reached for the densification process and agglomerate application. Materials are pre-sized using the appropriate size reduction device such as: grinders, pulverizers, high shear paddle mixers, crushers, shredders, hammer mills, jet mills, pin mills, cage mills, and ball mills. [0047] Material Mixing: [0048] The sized materials are mixed with the appropriate mixing device such as a: pin mixer, ribbon mixer, paddle mixer, plow mixer, rotary drum mixer, planetary mixer, or twin shaft mixer.
  • the appropriate mixing device such as a: pin mixer, ribbon mixer, paddle mixer, plow mixer, rotary drum mixer, planetary mixer, or twin shaft mixer.
  • the material is either cut to size at the die outlet or immediately transported to a disc pelletizer set at a rotation speed that equates to a disc edge velocity in the range of approximately 100-1200 feet/min (31-366 meters/min); due to centrifugal forces, the edge speed determines the amount of energy/compaction imparted on the agglomerates.
  • Residence time of agglomerates in the disc pelletizer can range from approximately 5 seconds to 2 minutes; residence time is dependent on material plasticity, strength, etc.
  • Ring Die Pelleting [0053] Material may be compressed through a rotating die and roller system. The appropriate compression ratio (pellet barrel length/pellet barrel diameter) is selected based on the material properties and pellet application.
  • Die compression ratio selection is dependent on the desired density and strength of the product, material particle size, material fibrosity/brittleness, material compressibility, material lubrication character, frictional heat and melt-flow properties of materials, and desired throughput rate.
  • Rotary Briquetting [0055] Material may be compacted by a feed screw that forces material into the die space of two vertical or horizontal rollers. Material plasticity, material particle size, material fibrosity/brittleness, material compressibility, briquetter torque, briquetter roll pressure, briquetter die geometry, and briquette roll temperature all influence the final briquette properties.
  • Ram Piston Briquetting [0057] A piston forces material down a barrel with a clamped end that controls material pressure.
  • the density can then be computed from the mass and volume (after at least 24 hours of curing). 2) Bulk density and volume of solid refractories by wax immersion method a. See ASTM C914-09(reapproved 1999) for a full procedure 3) Bulk density a. The density would be measured by recording the mass of agglomerates in a known volume. The mass would then be divided by the volume to obtain a bulk density. [0066] Proximate and Ultimate Analysis: [0067] Proximate and ultimate analysis was conducted by Twin Ports Testing on the final products to determine the chemical properties of the agglomerates.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

L'invention concerne des agglomérats destinés à être utilisés dans un four à arc électrique, les agglomérats comprenant du fer et/ou de l'acier sous forme particulaire et du biocharbon maintenus ensemble par un liant, la densité apparente des agglomérats étant suffisante pour que les agglomérats soient présents dans les scories d'un four à arc électrique.
PCT/US2023/029831 2022-08-10 2023-08-09 Biocharbon employé dans la fabrication d'acier WO2024035774A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263396812P 2022-08-10 2022-08-10
US63/396,812 2022-08-10

Publications (1)

Publication Number Publication Date
WO2024035774A1 true WO2024035774A1 (fr) 2024-02-15

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050092130A1 (en) * 2002-03-19 2005-05-05 Golberger William M. Process and apparatus for the direct reduction of iron oxides in an electrothermal fluidized bed and resultant product
US20080196619A1 (en) * 2005-06-17 2008-08-21 Ferrinov Inc. Anti-Corrosion Pigments Coming Form Dust Of An Electric Arc Furnace And Containing Sacrificial Calcum
US20160333430A1 (en) * 2013-12-30 2016-11-17 Genrikh Alekseevich Dorofeev Method for making steel in an electric arc furnace and electric arc furnace
US20220228082A1 (en) * 2021-01-21 2022-07-21 Carbon Technology Holdings, LLC Reactivity-moderated biocarbon pellets

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050092130A1 (en) * 2002-03-19 2005-05-05 Golberger William M. Process and apparatus for the direct reduction of iron oxides in an electrothermal fluidized bed and resultant product
US20080196619A1 (en) * 2005-06-17 2008-08-21 Ferrinov Inc. Anti-Corrosion Pigments Coming Form Dust Of An Electric Arc Furnace And Containing Sacrificial Calcum
US20160333430A1 (en) * 2013-12-30 2016-11-17 Genrikh Alekseevich Dorofeev Method for making steel in an electric arc furnace and electric arc furnace
US20220228082A1 (en) * 2021-01-21 2022-07-21 Carbon Technology Holdings, LLC Reactivity-moderated biocarbon pellets

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