WO2024164076A1 - Système et procédé d'alimentation d'un four électrique - Google Patents
Système et procédé d'alimentation d'un four électrique Download PDFInfo
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- WO2024164076A1 WO2024164076A1 PCT/CA2024/050154 CA2024050154W WO2024164076A1 WO 2024164076 A1 WO2024164076 A1 WO 2024164076A1 CA 2024050154 W CA2024050154 W CA 2024050154W WO 2024164076 A1 WO2024164076 A1 WO 2024164076A1
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- WIPO (PCT)
- Prior art keywords
- feed
- furnace
- mixture
- electric furnace
- components
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 42
- 238000002156 mixing Methods 0.000 claims abstract description 59
- 239000000203 mixture Substances 0.000 claims abstract description 51
- 230000004907 flux Effects 0.000 claims abstract description 31
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 30
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 29
- 238000011144 upstream manufacturing Methods 0.000 claims description 19
- 238000003723 Smelting Methods 0.000 claims description 11
- 238000006243 chemical reaction Methods 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 10
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 10
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 9
- 239000001301 oxygen Substances 0.000 claims description 9
- 229910052760 oxygen Inorganic materials 0.000 claims description 9
- 238000001035 drying Methods 0.000 claims description 5
- 239000011261 inert gas Substances 0.000 claims description 5
- 239000003345 natural gas Substances 0.000 claims description 5
- 238000009851 ferrous metallurgy Methods 0.000 claims description 4
- 239000007789 gas Substances 0.000 claims description 4
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000010926 purge Methods 0.000 claims 3
- 239000008240 homogeneous mixture Substances 0.000 abstract description 17
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 10
- 229910052742 iron Inorganic materials 0.000 description 10
- 229910052799 carbon Inorganic materials 0.000 description 9
- 230000008569 process Effects 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000002893 slag Substances 0.000 description 6
- 230000009467 reduction Effects 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 3
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 238000013019 agitation Methods 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 230000037361 pathway Effects 0.000 description 3
- 239000003923 scrap metal Substances 0.000 description 3
- 238000000926 separation method Methods 0.000 description 3
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 235000011941 Tilia x europaea Nutrition 0.000 description 2
- RHZUVFJBSILHOK-UHFFFAOYSA-N anthracen-1-ylmethanolate Chemical compound C1=CC=C2C=C3C(C[O-])=CC=CC3=CC2=C1 RHZUVFJBSILHOK-UHFFFAOYSA-N 0.000 description 2
- 239000003830 anthracite Substances 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 238000009844 basic oxygen steelmaking Methods 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 238000010891 electric arc Methods 0.000 description 2
- 231100001261 hazardous Toxicity 0.000 description 2
- 239000004571 lime Substances 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000008188 pellet Substances 0.000 description 2
- 238000009827 uniform distribution Methods 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- 229910000805 Pig iron Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- -1 and in some cases Substances 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 229910001570 bauxite Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910021538 borax Inorganic materials 0.000 description 1
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 1
- YLUIKWVQCKSMCF-UHFFFAOYSA-N calcium;magnesium;oxygen(2-) Chemical compound [O-2].[O-2].[Mg+2].[Ca+2] YLUIKWVQCKSMCF-UHFFFAOYSA-N 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 239000004035 construction material Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910001873 dinitrogen Inorganic materials 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000010436 fluorite Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 230000010399 physical interaction Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 210000003625 skull Anatomy 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000009628 steelmaking Methods 0.000 description 1
- 230000000153 supplemental effect Effects 0.000 description 1
- 239000003039 volatile agent Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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
- C21B13/0086—Conditioning, transformation of reduced iron ores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
- B01F23/70—Pre-treatment of the materials to be mixed
-
- 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
- C21B13/12—Making spongy iron or liquid steel, by direct processes 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
- C21B13/14—Multi-stage processes processes carried out in different vessels or furnaces
- C21B13/143—Injection of partially reduced ore into a molten bath
-
- 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
-
- 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
Definitions
- the present invention relates to ferrous metallurgical technology and specifically to ferrous electric furnaces and feeding ferrous electric furnaces.
- Electric furnaces such as for example electric smelting furnaces (ESF) and electric arc furnaces (EAF) are used for processing and refining metals, for example to produce steel.
- ESF electric smelting furnaces
- EAF electric arc furnaces
- these electric furnaces operate by charging scrap metal into the furnace, then boring the electrodes, such as graphite electrodes, into the scrap metal heap, and engaging the electrodes to form electric arcs to melt the scrap.
- the electric furnace may be operated by resistive heating as current passes through a molten slag layer between electrodes.
- Oxygen and I or other process gases may also be blown into the furnace, to promote combustion, which can help with the overall melting process.
- these operations comprise loading scrap into openings in the top of the furnace.
- the openings lead to chutes which provide passage of materials into the interior of the furnace.
- the openings may have clamshell doors for a base to control the charging of materials into the chutes and ultimately into the interior of the furnace.
- iron- bearing metallics such as DRI, HBI, and/or pig iron, may be used in place of or in addition to scrap metal.
- Standard furnace setups tend to be more complex and include additional smaller openings for receiving and controlling the charging of reductants into the furnace.
- Reductants may include for example, anthracite or coke. These smaller openings may be connected to the furnace via chutes and other pathways so that reductants can be slowly fed into the furnace simultaneously with the scrap or DRI or in other configurations, separately fed to the center of the furnace.
- the furnace set-up can further comprise additional openings for holding fluxes.
- Fluxes may include for example, limestone, silica, fluorite, borax and lime.
- the flux-specific openings are typically connected by their own chutes or pathways to the center of the furnace. As more openings are added to introduce extra or different reductants or fluxes, more chutes or pathways are added to the furnace set up.
- FIG. 1 shows a block diagram representation of an electric furnace feeding system in accordance with an embodiment of the present disclosure.
- the present invention provides a method for feeding or charging an electric furnace with materials in the field of ferrous metallurgy.
- the electric furnace may be for example an electric arc furnace (EAF), and may be used for steelmaking, ironmaking, melting, slag cleaning, and any other ferrous electric smelting furnace (ESF) applications.
- the method comprises combining feed components including one or more of direct reduced iron (DRI), with reductants and/or fluxes together, and optionally scrap, before the feed components are charged into the furnace.
- the feed components may be initially separated and then combined upstream of the furnace and upstream of any feed chute to the furnace.
- the feed may be a premixed feed.
- the feed components may comprise any of DRI (in any form or any combination), including briquettes, fines, pellets, mini-briquettes, micro-pellets, Hot DRI (HDRI), cold DRI (CDRI), reductants, fluxes, scrap, other revert and supplemental materials including mill scale, furnace and ladle slags and skulls, ore fines, lump ore, off gas dust and/or sludge.
- the furnace feed components may comprise any combination of the foregoing or any combination of the foregoing and any other feed component as may be necessary or desired for a particular furnace application.
- a first feed component may comprise DRI while a separate second feed component may comprise reductants and fluxes, for example, unreacted reductant and fluxes.
- Maintaining a separation of a first feed component of DRI may be beneficial as it reduces the amount of excess materials in a reduction of iron step while also allowing the iron to be reduced using less carbon intensive processes.
- iron may be reduced by less carbon intensive processes such as by using natural gas or H2.
- reduced iron may be produced off-site with the less carbon intensive processes which may not be available at all electric smelting facilities.
- the separation of feed components namely separation of DRI from other components, may also help avoid oxidation during reduction of the iron and may increase the efficiency of the process overall.
- the combination of feed components may be achieved by adding the components to a feed component mixing area such as a bin, basket, or other vessel to produce a homogeneous mixture.
- a homogeneous mixture may be a mixture that has a completely or substantially uniform distribution thermally and/or compositionally.
- a mixture that has a uniform compositional distribution through about 80% or more of the mixture may be a compositionally homogeneous mixture.
- a mixture that has no significant hot or cold spots may be considered a thermally homogeneous mixture.
- a homogeneous mixture has a temperature that is the same or close to the same throughout at least 80% or more of the mixture.
- a thermally uniform distribution may be characterized by a steady temperature profile throughout the mixture, for example a mixture having a temperature gradient but no significant hot or cold spots.
- a homogeneous mixture may for example be observed when any section of the mixture has substantially the same features (such as amounts of components by weight or volume, temperature of components, and/or equal distribution of one component within another component) as any other section of the mixture.
- the ratio of DRI to flux to reductant in a first portion of the homogeneous mixture may be similar or the same as a ratio of DRI to flux to reductant in a second portion of the homogeneous mixture.
- Supplying a homogeneous feed to the furnace may therefore comprise supplying a generally consistent ratio of feed components to the electric furnace over time.
- a generally consistent ratio may be for example a ratio of components that averages to about the same ratio for each component over time.
- the feed components may be passively or actively combined together.
- the feed components may passively combine together during addition into the vessel or actively be combined together by way of additional agitator integrated with or added to the vessel, or through the use of dedicated mixing vessels (e.g., mixing drum).
- additional agitator integrated with or added to the vessel
- dedicated mixing vessels e.g., mixing drum
- the components naturally combine and mix as they are added into the vessel. Smaller portions of each of the components may be added together over a period of time to achieve this natural intermixing of components and homogeneity.
- a stirrer or other agitation apparatus may be used to aid in mixing or combining the components.
- the components may naturally combine on addition into the vessel but may then settle or separate into layers, strata or distinct groupings.
- an additional agitation means may be used to actively re-mix the components until the mixture or combination of components is homogeneous.
- the agitation means may include one or more of, a stirrer, the addition of further components to disrupt the contents of the vessel and cause mixing, or shaking, rotation, or vibrations of the vessel to disturb the contents and cause the components to combine.
- the unit used for combining the feed components upstream of the furnace and upstream of any furnace feed chute may be any suitable vessel capable of holding the feed components.
- the feed collection and/or mixing unit may have a refractory lining to withstand hot temperatures and may be a bin, container, basket, or other vessel-type holding unit.
- the unit may be positioned anywhere upstream of the furnace.
- the unit used to collect and/or combine the feed components may be for example the same as or a replacement to existing feed bins positioned above a furnace.
- the unit may include or be integrated with several other components including a mixing bin, a transfer vessel, bin or other device, and/or a feed bin to provide a broader system.
- the components may be combined in a mixing bin, moved to a transfer bin that can then provide the homogeneous mixture to the feed bin for charging the furnace.
- the feed components may be mixed directly in the feed bin and charged to the furnace.
- the mixing bin and the transfer bin may be one and the same bin.
- a belt or screw conveyor may also be used for transferring the components from a first bin to a second bin, and in the case of the screw conveyor, may provide for further mixing of the components.
- Hot DRI mixed with additional feed components may start to react in the feed component mixing area, for example in a combination vessel. Some reactions in the vessel are acceptable, but some may cause hazardous environments or degradation of feed components and are undesirable.
- the feed components may be pre-treated or conditioned before and/or after addition to the combination vessel. For example, wet, or high moisture feed may react in the hot mixture to create hydrogen and/or additional oxygen causing a hazardous environment which is undesired. Wet feed components may therefore be pre-dried before being added to the combination vessel. Predrying may be done by a heat dryer or other methods suitable for removing water components. For example, drying wet feed may comprise lowering the moisture content to no more than 2 wt%.
- oxygen in the combination vessel may react with carbon from the feed components and lead to production of carbon monoxide. Oxygen may also lead to degradation of DRI and iron oxide in the vessel.
- the vessel may therefore be purged with an inert gas to drive out oxygen before or while adding in the feed components.
- Inert gas may be for example, nitrogen gas, or argon gas, and in some cases, carbon dioxide may be used.
- some reactions in the combination vessel or feed component mixing area may be desired.
- Reactions between reductant and DRI for example may promote an increased retention of carbon which may in turn help control the metal chemistry in downstream processes, such as, for example in downstream ESF, EAF and BOF systems.
- hot metal carburization due to the reactions between carbon and DRI may also be increased which may more efficiently achieve the carbon concentration in the hot metal as required by downstream basic oxygen steelmaking furnaces, for example.
- the feed components may be added simultaneously to a single feed mixing location, for example, one mixing vessel or, may be added to more than one feed mixing location, such as two or more mixing areas or vessels.
- DRI, fluxes, and reductants of various kinds may be simultaneously channeled or fed into a single or multiple mixing vessels.
- the fluxes may be pre-mixed, or the reductants may be premixed, separately before being mixed together with DRI in one or more mixing vessels.
- the fluxes may be pre-mixed, the reductants may then be added to the fluxes and mixed with the fluxes before the mixture of reductants and fluxes is mixed together with the DRI.
- feed components may be mixed separately or with other feed components before combining in the final mix.
- the pre-mixing may occur directly in the final mixing vessel.
- the pre-mixing may occur in one or more vessels upstream of the final mixing vessel.
- the feed components may be mixed in any combination, sequence or any number of stages such as to result in a homogeneous mixture of the feed components in the final mix before the mixture is charged to the furnace.
- the feed components may be added simultaneously or in other words all at once.
- the feed components may be added partially in parallel or in other words some feed components may be pre-mixed together and then added together to a mixing location with other feed components, such as pre-mixing fluxes and reductants together and then mixing the mixture of fluxes and reductants with DRI.
- the feed components may be added in series to a mixing location or in other words added one at a time to the mixing location. Any one or more of the aforementioned examples may be combined.
- the homogeneous feed mixture Once the homogeneous feed mixture has been prepared, it may be charged to the electric furnace, for example to one or more sections of the electric furnace or, for example to two or more sections of the electric furnace. Charging the homogeneous feed mixture may be done using a continuous or a batch process.
- Charging the homogeneous feed mixture may be done using an existing furnace feed system.
- the homogeneous mixture may be distributed into existing feed bins that are distributed above the furnace before being charged to the furnace.
- Existing feed bins may be for example existing bins for receiving DRI mixtures.
- the homogeneous mixture may form a feed bank (also referred to as a charge bank), where the feed enters the furnace and forms a pile or mountain of feed.
- the feed banks may be distributed around the periphery of the furnace.
- the feed banks may be discrete piles or connected piles, for example the feed banks may be distributed such as to provide discrete “mountains” or a continuous “mountain range” of feed.
- the feed bank of homogeneous mixture may allow for feed components in the feed bank to both react and interact physically, chemically and thermally with each other prior to melting in the furnace, and more uniformly than if the feed components were separately charged into the furnace.
- the homogeneous mixture may further provide for physical interactions and chemical reactions between feed components in the mixing vessel before being charged into the furnace.
- the homogeneous feed mixture may be charged into an open bath with no charge bank or into a furnace with a shield arc or submerged arc that comprises a charge bank that covers the whole furnace cross-sectional surface area.
- additional small amounts of one or more of the feed components may be added to the furnace by separate feed chute. For example, small amounts of trim feed may be added directly to an open bath area of the furnace.
- a homogeneous mixture may allow for more consistent contact, interactions and reactions between the feed components and the hot metal in the furnace.
- the homogeneous feed mixture may be provided across multiple feed banks or charge points across a large portion of the slag layer surface area of an electric furnace.
- FIG. 1 shows an electric furnace feeding system 100 in accordance with an embodiment of the present disclosure.
- the electric furnace feeding system 100 comprises a feed collection and/or mixing unit 102 upstream of an electric furnace 104.
- the feed collection and/or mixing unit 102 may be directly upstream of the furnace such that it is directly adjacent to the furnace so as to reside at the opening, or adjacent to and upstream of a feed chute or furnace feeding system 106.
- the feed collection unit 102 may have one or more inputs 108a, 108b.
- the input(s) may be openings or inlets.
- the inputs 108a, 108b may be connected to upstream sources of furnace feed.
- the inputs 108a, 108b may be connected to upstream mixing vessels for pre-mixing feed components, separately or in smaller groupings, before a final mix.
- the inputs 108a, 108b may be connected to optional upstream feed conditioning units 110a, 110b, for example such as drying units.
- feed condition units 110a, 110b help prevent the re-oxidation of the DIR / hydrogen generation.
- the feed components 112a, 112b may comprise any one or more, or any one or more combinations of, hot or cold DRI, scrap, fluxes such as calcined lime, calcined dolomitic lime, and calcined bauxite, reductants such as anthracite and reverts.
- the inputs may be directly or indirectly connected for example to an upstream direct reduction plant for producing hot DRI.
- the feed collection and/or mixing unit 102 is adapted to combine all the feed components that enter the unit through the inputs, and expel a homogeneous feed mixture via an output or outputs 114a, 114b.
- the feed collection and/or mixing unit 102 may be a bin, container or other vessel or equipment that allows for mixing of feed components to produce a homogeneous mixture of feed.
- the feed collection and/or mixing unit 102 may be connected to transfer equipment 116 such as a container, vessel, or conveyor to move feed from the collection and/or mixing unit 102 to the electric furnace 104 or to another vessel before ultimately charging the feed into the electric furnace 104.
- the transfer equipment 116 may be a rotary kiln, for example.
- the transfer equipment 116 may help with avoiding issues with volatiles and I or hydrogen build-up.
- the transfer equipment 116 may help mix flux and reductants.
- the feed collection and/or mixing vessel 102 may be moveable between an area upstream of the furnace 104 and an area adapted for charging the furnace 104 with the contents of the unit 102.
- the unit 102 may be stationary.
- the unit 102 may be stationary and already positioned in place above the furnace 104 to allow for direct charging into the furnace 104.
- the unit 102 may be stationary and connected to the transfer equipment 116 that is movable from a receiving position, where the transfer vessel 116 receives a feed mixture from the mixing vessel 102, to an unloading position, where the transfer vessel 116 expels the feed mixture to another vessel or directly into the furnace 104.
- the transfer equipment 116 In the receiving position the transfer equipment 116 may be connected or proximate to, for example below but detached from, the mixing vessel 102 and in the unloading position the transfer equipment 116 may be connected or proximate to, for example above but detached from, the furnace 104.
- the system may comprise a screw conveyor that both mixes the feed and transfers the feed from an input at a first location to an output at a second location.
- the screw conveyor may be the feed collection and mixing unit 102 and/or the transfer equipment 116.
- the collection unit 102 may be connected to transfer equipment 116 comprising a conveyor for transferring feed from the collection unit 102 to the furnace 104.
- the feed collection unit 102 may include other mechanical mixers such as a stirrer or agitator.
- a stirrer may be used to mix contents in a vessel, or an agitator may be used to shake the vessel or otherwise disturb the contents of the vessel.
- the output or outputs 114a, 114b of the feed collection unit may be any outlet(s) for releasing the contents of the feed collection unit.
- the output may be a clamshell door at the bottom of a vessel.
- the output may be a feed chute directed at a feed bin formerly used for holding DRI mixture above the furnace, or the output may be connected directly to the furnace, by feed chute or other fluid connection or furnace feed system 106.
- the material of the container is adapted to withstand the temperatures and chemistries of the feed components.
- the feed collection unit 102 may be adapted to accept the hot DRI, for example the unit 102 may comprise a refractory lining to prevent the material eroding the unit walls.
- the unit 102 may be adapted to accept the cold DRI and more ambient temperature feed and therefore may comprise other construction material that would be known by a skilled person which would not deteriorate under the temperature or chemistry of the feed.
- the feed collection unit 102 may need to be pre-treated to reduce or eliminate oxygen in the system.
- the feed collection unit 102 may be purged with an inert gas such as nitrogen, argon or even with carbon dioxide.
- the feed components may need to be pretreated to reduce or eliminate moisture on the feed components and prior to or after providing into the feed collection and/or mixing unit 102.
- the output of the feed collection unit 102 may be connected to one or more, for example two or more, locations in the furnace 104.
- the one or more locations in the furnace 104 may be distributed about the cross- sectional area of the electric furnace 104 such as to form distributed feed banks throughout the furnace 104.
- an apparatus for producing hot iron may comprise a rectangular or circular furnace cross-sectional area.
- the apparatus may further comprise multiple electrodes that may be inserted into the furnace cross-sectional area.
- a slag layer may be present and substantially covering the furnace cross- sectional area.
- a bath of molten metal may be disposed beneath the layer of slag.
- the apparatus further comprises a homogeneous feed bank or banks as described herein.
- the homogeneous feed bank or banks may comprise a combination of two or more reductants, fluxes, scrap, reverts and DRI.
- Feeding the homogeneous feed into the furnace in accordance with embodiments as described herein may help to minimize the variations in conditions and reactions that occur throughout the furnace.
- the homogeneous feed may help allow for a consistent composition, both chemically and thermally to be introduced across the cross- sectional area of the furnace so that similar reactions and rates of reactions may be observed throughout the furnace.
- a method of feeding an electric furnace for ferrous metallurgy comprises providing a direct reduced iron (DRI) as a first feed component; providing unreacted reductants and fluxes as a second feed component; combining together upstream of an electric smelting furnace the DRI first feed component and the unreacted reductants and fluxes second feed component to produce a mixture comprising the first feed component and the second feed component; and supplying the mixture to an opening in the electric furnace, wherein the first feed component is separate from the second feed component prior to combining.
- the direct reduced iron (DRI) is prepared ahead of any furnace process, and that DRI is kept separate from the reductants/fluxes for as long as possible prior to being provided into the electric furnace.
- Production of the DRI ahead of any furnace smelting (instead of reducing ore in a furnace at the same time as that ore is mixed with other feed components) can be efficient because it may reduce the amount of unparticipating materials in the reduction of iron step. Furthermore, production of DRI ahead of any furnace smelting may enable the creation of the DRI from iron reduced using less carbon intensive processes, such as using natural gas or H2. Furthermore, production of DRI ahead of any furnace smelting may allow for the iron to be reduced off-site from the location of the smelting furnace (and potentially stored off-site too) by enabling the production of more stable reduced iron. Producing reduced iron off-site can allow for the iron to be reduced using less carbon intensive processes which may not be available at all smelting furnace site. Lastly, production of DRI ahead of any furnace smelting may help avoid oxidizing during reduction of the iron.
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Abstract
L'invention concerne un procédé et un système d'alimentation d'un mélange d'alimentation dans un four électrique. Le procédé comprend la production d'un mélange d'alimentation homogène et le chargement du four avec le mélange d'alimentation homogène. Le mélange d'alimentation homogène, qui est un ou les deux parmi l'homogénéité de composition et thermique, comprend DRI, et un ou plusieurs flux, déchets, réducteurs et ferrailles récupérées, utilisés pour charger des fours électriques. Le système comprend une unité de mélange pour combiner des composants d'alimentation en un mélange homogène. L'unité de mélange peut être un transporteur à vis. L'unité de mélange est reliée au four pour charger le four avec le mélange d'alimentation homogène.
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US202363444153P | 2023-02-08 | 2023-02-08 | |
US63/444,153 | 2023-02-08 |
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WO2024164076A1 true WO2024164076A1 (fr) | 2024-08-15 |
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4412858A (en) * | 1982-07-12 | 1983-11-01 | Hylsa, S.A. | Method of converting iron ore into molten iron |
CA2340191A1 (fr) * | 1997-08-22 | 1999-03-04 | William Lyon Sherwood | Fabrication directe du fer et de l'acier |
US5946339A (en) * | 1997-07-22 | 1999-08-31 | Itz A Gaz, Inc. | Steelmaking process using direct reduction iron |
US20050151307A1 (en) * | 2003-09-30 | 2005-07-14 | Ricardo Viramontes-Brown | Method and apparatus for producing molten iron |
US20210301359A1 (en) * | 2020-03-24 | 2021-09-30 | Midrex Technologies, Inc. | Integration of dr plant and electric dri melting furnace for producing high performance iron |
-
2024
- 2024-02-08 WO PCT/CA2024/050154 patent/WO2024164076A1/fr unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4412858A (en) * | 1982-07-12 | 1983-11-01 | Hylsa, S.A. | Method of converting iron ore into molten iron |
US5946339A (en) * | 1997-07-22 | 1999-08-31 | Itz A Gaz, Inc. | Steelmaking process using direct reduction iron |
CA2340191A1 (fr) * | 1997-08-22 | 1999-03-04 | William Lyon Sherwood | Fabrication directe du fer et de l'acier |
US20050151307A1 (en) * | 2003-09-30 | 2005-07-14 | Ricardo Viramontes-Brown | Method and apparatus for producing molten iron |
US20210301359A1 (en) * | 2020-03-24 | 2021-09-30 | Midrex Technologies, Inc. | Integration of dr plant and electric dri melting furnace for producing high performance iron |
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