DIRECT INTEGRATED IRON REDUCTION SYSTEM
Technical Field This method is applied to the production of iron - cast iron at the direct reduction of iron ore and provides an improvement that the direct reduction of iron ore is effectively halted by the generation of iron ore. Energy Preferably the integration also includes an air separation plant ta! As a cryogenic air separation plan Technique Antecedent Iron oxide or iron oxide is directly educed to metal iron by contacting the mineral ae. -? e ?? c directly with a reductoi The reduction onecía de¡ m •,. The amount of energy used to produce metallic ice consumes significant amounts of energy, but the optimal geographic location of these direct reduction plants is often in years 1, where the increasing energy to operate the power plant is the same. However, it is an object of this invention to provide a process for the production of free-standing iron ore reduction that can be effectively operated in any geographical location regardless of the exogenous availability of C! P energy in said location. Place the JUP e __ io d e_m ve nc? p_n The ante "o es and other objectives that will be relevant to the experts in the field. When reading this description they are mixed with the present intent one aspect of which is a methoco to produce iron comprising (A) generating synthesis gas and passing said synthesis gas to a reaction vessel '(B) supplying iron ore in the reaction vessel and react the iron ore with the synthesis gas center of the container: the reaction to produce iron and second gas or reaction that C D more nde n. carbon dioxide hydrogen gave carbon dioxide and steam (C) recover the iron from the reaction vessel (D) remoe at least some of the secondary gas water vapor from the reactor to produce secondary gas from the dryer and (E) burning the secondary gas of the dryer in a turbo gas to produce energy Another aspect of the invention is Aparate to produce iron comprising (To a synthesis gas generator and means to pass hydrocarbon tiuine in the synthesis gas generator (B) a reaction vessel for direct reduction means for passing the iron ore into the direct reduction reaction vessel and means for passing the synthesis gas of the synthesis gas generator into the vessel direct reduction reaction (C) media for recovering iron: container for direct reduction (D) a dryer and means for passing gas from the direct reduction reaction vessel to the dryer, and (E) A gas turbine and means for passing the gas from the dryer to the gas turbine As used herein, the term synthesis gas means a mixture comprising carbon monoxide and hydrogen. As used herein, the term "ore-O mineral means flax or more iron oxides such as ferric and ferrous oxide. As used herein, the term" dryer "means equipment that can remove moisture in a mixture and Gas The equipment can use a material, such as an absorbent to remove water vapor from the gas mixture or heat exchange media, such as a cooler and a subsequent phase separator to remove the condensed water from the mixture. Gas As used herein, the term "gas turbine" means a unit that combines an air compressor, a burner and a gas expander to generate energy from combustion wells of high pressure level of a suitable fuel. o Normally the components of the air compressor e! expansoi of gases are mounted on the common wells that also. They can derive other fluid components that are consumed by the generator or electric generator. means a mixture comprising principal oxygen and nitrogen such as ambient air. As used herein, the term "air separation plant" means equipment which separates air from separate feed and produces at least one air. Oxygen and Myogen As used herein, the term "piapia" of "cryogenic air" means a separation plant comprising at least one column where at least part of the operation of the column is used. it is carried out atepe >; Atuia er or below 150 degrees Kelvm (K) As used herein the term column means a column or zone of distillation or fraction ation ie a cojmna or contact zone where the liquid and vapor phases are put in countercurrent contact to effect the separation of a mixture of fluids such as by contacting vapor and liquid aids on a series of chai wave or vertically mounted plants vertically mounted on the elements of column V? packaging such as structured packing or alloys As used herein the term "pressure balancing adsorption plurality" means a plant or. air separation to carry out the separation of the feed that comprises the adsorption main passes during which preferably the feed of the absorbent and the regeneration are absorbed, preferably where the absorbed component is absorbed by a reduction in pressure B _.__ ___e_ ._____. Definition of the Dictions Figure 1 is a flowchart of a preferred mode of the invention wherein the Gas Generator Synthesis is a reformer. Figure 2 is a flowchart of another preferred embodiment of the m.- The use of different synthetic gas is shown in Figure 3. Figure 3 is a flowchart of another preferred embodiment of the invention which shows large quantities of recirculated gases of secondary gases. The preferred embodiment of the invention wherein both oxygen and nitrogen are used are produced by the air separation plant. Figure 5 is a still preferred flow diagram of the invention. where a solid or fuel of the heavy vehicle is used to generate the synthesis gas The numbers of the Figures are the same for the common elements Detailed Description The invention employs a byproduct of the direct reation of mineral ore for energy management and preferable ta ^ .c in to recycle the oropio direct reduction process The prcd. The power plant facilitates the location of the direct reduction plant where energy is not readily available and recycling increases this facilitation by reducing the energy requirements of the direct reduction process. More preferably, the system is also integrated with a separation plant. of a'-e tai as a cryogenic air separation plant that also heard me the advantages of air globai The invention will be described in detail with reference to the Drawings Now making Figure 1 the fluid of hicrocarbui or '00 normal and preferably natural gas included pri. c i o a • m e > The methane can be partially or completely comprised of other light hydrocarbons up to and including vaporized naphtha mixed with the recycled secondary gas 105 to form the feed stream 110 which is passed in the synthesis gene 500. In the embodiment illustrated in FIG. Figure 1 the synthesis gas generator 500 is a reformer Within the reformer 500 the carbon dioxide reaction with hydrocarbon Lina endothermic reaction to form synthesis gas The heat can be provided to the reformer 500 to derive the endothermic reactions by gas combustion natural as shown by the element 115 The synthesis gas 120 which includes carbon monoxide and hydrogen generated in the synthesis gas generator 500 as well as carbon monoxide and recirculate acid from the erect reduction reactor is passed pre-e- ? L "ep.enfe co -: • is used in Figure 1 without cooling to the rest, tanded X trans Natural heat, in the fresh water reagent 510. The iron ore 210 is passed in e? -recipient to the direct reduction network 510 and within the network; The iron ion is contacted in contact with the hot synthesis gas which is generally at a temperature within a scale of 76 ° C to 982 ° C. and it reacts with the synthesis gas. The leaction of the synthesis gas with the iron ore reduces the iron ore to metallic iron and produces carbon dioxide and agly vapor. The resulting iron is recovered from the rec.,: direct c on 510 as shown in stream 2 __ C The secondary gas 125 of the direct reduction reaction vessel 510 which comprises carbon dioxide and water vapor from the direct reduction reaction as well as a carbon rponoxide Unreacted and hydrogen is passed to dryer 520 where the secondary gas is cooled and at least some of the water vapor in the secondary gas in reactor 510 condenses. The resultant condensed agglomerate is removed from dryer 520 as shown by the Comment 200 and the secondary gas resulting from the drying is passed in the current 130 from the dryer 520 to the compressor 530 where it is prime in a pressure generally in the range from 2 1 to 21 kg / cm2 abs It should be understood that although the secondary gas 125 is treated to remove a ^ go of its. of ag .. to the secondary gas content of the secacora result 130 of -even still retains some water vapoi) can saturaise to: s = conditions of exit of the dryer 520 A portion 105 of compressed secondary gas 135 of the first Compressor 530 is reluctant In the embodiment of the invention illustrated in Figure 1, the portion 105 is recycled to the reformer 500. Another portion 140 generally comprises about 5 to 70 percent of the secondary gas. The second compressor 540 is passed to the dryer and compressed at a pressure generally within the range of 10 to 35 15 kg cm. abs. The additional secondary dryer gas is then added to the compressor. 560 gas turbine where it is burned to produce energy If desired, additional fuel can be provided tai as natural gas 150 to the gas turbine 560 for the generation of increased energy The energy produced by the gas turbine 560 shown in the form The representation as 155 can be electrical or mechanical It is said that the turbine 560 can be assembled to drive a generator or it can be smoothed to directly impute machinery such as a compiese. Figure 2 illustrates another mode of operation where the additional synthesis gas is generated using either a partial oxidation unit or an autothermal unit as a second synthesis gas generator. The elements of the embodiment of the invention illustrated in FIG. In Figure 2 that correspond to those of the modality illustrated in Figure 1 were enu were equal and ~ c will be described again in detail Making retention now a, a c? The air of a limen with 10 is passed in the air separation plant ~ C0 Preferable "between the air separation plant 700 is a stage of seoarac c- ae cryogenic air even though it can also be an eianta of separation of air from adsorption of rolling of feet Within the air separation plant 700 the supply air is separated into oxygen of product 15 and optionally nitrogen of proaLicto 20 S >; the air separation plant is a cryogenic air separation plant can also produce other products such as argon and / or liquid oxygen represented by the product stream 21 Oxygen 15 produced in the separation plant of a?, e that it has an oxygen concentration of at least 70 ooi cento molar, preferably at least 90 mole percent is passed in the synthesis gas generator 501 together with the hydrocarbon fluid 101 which can be characterized as the characterization of fluid 100 and is generally at the same rate as the hydrocarbon fluid 100 The synthesis gas generator 501 may be a partial oxidation unit or a self-thermal unit In a partial oxidation unit the oxygen reacts with the hydrocarbon to produce carbon monoxide and hydrogen In LUÍ to self-unit, there is also pyrolysis and hydrocarbon monoxide, through the partial oxidation of hydrocarbon with oxygen. e the plant you I? < air separation although to a lesser degree than in the case of partial oxidation and additionally to p e e • e e. apc 'e' "the autothermality to generate monoxide ae carocí adicic - a I e hicirec c via a hydrocarbon reformation process of apor The synthesis gas generated in the synthesizer gas generator s 501 is then passed in the cirecta reduction reaction vessel 510 Preferably as illustrated in Figure 2 the gas and synthesis to generator 501 is passed in stream 118 in stream 120 for formal combined steam 121"for passage in the reaction vessel 510 The remainder of the system illustrated in Fig. 2 is shown in the Figure If a portion of dry gas is desired, it can be absorbed and used anywhere. of the process for example as a source of fuel for generation or to be used in the reformer 500. Figure 3 illustrates a preferred embodiment of the invention wherein the secondary gas is relieved as aipba current as a low current. of the synthesis gas generator The numbers in Figure 3 are the same as those in the other Drawings for the common elements and said elements com Lines will not be treated again in detail. Referring now to Figure 3 the secondary gas comprised 135 is divided in portion 140 and portion 36 A first portion 160 of portion 36 is received in the feed for direct reduction reaction vessel 510 A second portion 137 is fed into the ignited heater 5C0 together: c "e 'fuel 1 .5 The hot secondary gas 3 C 5 of the cale "? On 600, then it is passed on the current 10 _ and the resulting combined heat 110 is passed on to the oxidization unit ca-500 where the synthesis gas is generated. hot synthesis 118 of the oxidation unit caiciai 570 is combined with the current of < E ccording to the gas secunaapo 16C paia foimar the current 320 which is then fed into the reaction vessel 510 The use of the ignited heater optimizes the overall basket of the system The overheating of a portion of reacted gas reduces the amount of Oxygen necessary to sustain the endothermic reforming reactions in the partial oxygenation unit. Figure 4 Mining A preferred mode of the invention in which the synthesis gas generator is a partial oxidation or an autothermal unit. and the air separation plant is a cryogenic air separation plant. The numbers in Figure 1 are the same as here in others. Dio uos for the common elements and these common elements and these common elements will not be treated again in detail Referring now to Figure 4 the hydrocarbon fluid 1010 is passed into the fired heater 600 together with the fuel 115 The hot hydrocarbon fluid 111 d the heated heater 600 and the oxygen 15 produced in the cryogenic air separation plant 700 is passed in the synthesis gas generator 501 which can be a onion unit for:; or an autothermal unit. If the synthesis gas generator _ _ 'is a self-thermal unit. steam is added to prefer .. to a; "Hydrocarbon co_ 100 current arriba or heater on Z J Secondary gas of dryer a105 of the first comcessor
530 is combined with the synthesis gas 117 of the synthesis cassette generator 501 to form the synthesis gas stream 120. In the embodiment of the invention illustrated in FIG. 4, the combo containing hydrocarbon 116 is added directly to the and a warm synthesis 120 to make the supply chain '_. to the direct reduction reaction vessel 510. This has the advantage that something is reformed in the stream of hot synthesis gas and the ability of the direct reduction reaction to reduce the hydrocarbon to carbon or hydrogen due to the slow temperature. at 120 and 122, and the presence therein of carbon dioxide from recycle stream 105. will present itself to reformation of hydrocarbons in stream 122 before it enters the reaction vessel 510 into the reaction vessel. 510 The additional reformation will take place as well as the separation of hydrocarbon to carbon and hydrogen. An advantage resulting from the addition of the hydrocarbon fuel 116 to the synthesis gas feed to the reaction vessel 510 is a reduction in the amount of synthesis gas to be produced in the synthesis gas generator 501 thereby reducing its size as the size of the air separation plant In addition because the reforming reaction 1 is endothermic the amount of lecithin in the current 105 can be reduced while o. and even pioe the desired entry temperature to the direct reduction vessel 510. In the m o c a I > of the invention M LI stradae Figure 3 \ 4 is supplied agL.a 190 to the dryer 520 and vap? - ?: a by indirect heat exchange with the hot second gas 125 with the resultant stream 195 that is passes to turbine 560 for use in generating additional energy. The embodiment of the invention illustrated in: Figure 4 also employs nitrogen produced in the separation plant of ai and 700 in the gas turbine. No. 700. It is possible to recover at least some of the nitrogen from the product generally having a concentration of at least 95 percent mole, and it is passed to the nitrogen compressor 710 where it is compressed at a pressure generally within the range of 2 1 to 21 kg / cm "abs The resultant nitrogen stream resulting 30 is then combined with the dry secondary gas stream 140 to form stream 136 which is then further compressed in the second compress r 540 and then pass as comment 146 to the turbine 560 for power generation The nitrogen of the air separation plant serves two purposes The pymeia is to reduce the flame temperature in the gas turbine burner so that reduce the level of nitrogen oxides (NOx) generated in the 1 burner The second addition to addition of nitrogen is for the increase of energy The ad -onal loop associated with the rut'cgenc can be used to ensure that the gas turbine is ope-e ceica of SLI mechanical limit assuring as > The maximum use of gas turbine capital Figure 5 illustrates another mode of the > n enaon where the fuel used to generate the synthesis gas is solid and / or liquid. The numbers in Figure 5 are the same as those in the other drawings for the common elements and these common elements were not treated nine in Detail I'm referring now to Figure 5 e > solium fuel and / or heavy liquid 205 such as vegetable charcoal oil oil is passed in the partial oxidation unit 501? together with oxygen 15 and feed water of the heater 191 The synthesis gas 212 will be released from the unit 501 and if desired, a spent system in amine, or a high temperature unit is passed through the sulfur removal unit 505 which can be a conventional absorption unit. It moves the slags from unit 501 into ia comment 101 and the steam is passed from the unit 501 in the current 196 to the turbine 560 The L. oi to the softened synthesis gas 213 is divided into the current 214 which is passed in the turbine 560 and in the current 217 This is combined with the reaction stream 105 to form the stream 222. This current is heated in the ignited heater 506 which uses the fuel 216 and the resulting stream 224 is passed in the direct reduction reaction vessel 510 as processed. previously Ahoia by the use of this invention isYou can p'Dc. The direct reduction of iron ore through the direct reduction of the metallic gas can be used to generate energy and also to reduce the amount of synthesis gas that must be generated. to carry out the direct reduction The generated energy can be used, among other things, to operate an air separator plant and the products of the separation plant can be used for the generation of synthesis gas and also for the generation of synthesis gas. NOx reduction and for the increase of generation of energy Although the invention has been described in detail with reference to certain preferred embodiments, the subject matter will recognize that there are other embodiments of the invention within the scope and scope of the claims.