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CN115584372B - Method for smelting metalliferous raw material - Google Patents

Method for smelting metalliferous raw material Download PDF

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Publication number
CN115584372B
CN115584372B CN202211062663.7A CN202211062663A CN115584372B CN 115584372 B CN115584372 B CN 115584372B CN 202211062663 A CN202211062663 A CN 202211062663A CN 115584372 B CN115584372 B CN 115584372B
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furnace
smelting
gas
feed material
smelting furnace
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CN115584372A (en
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F·P·格雷林
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27FURNACES; KILNS; OVENS; RETORTS
    • F27BFURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B19/00Combinations of different kinds of furnaces that are not all covered by any single one of main groups F27B1/00 - F27B17/00
    • F27B19/04Combinations of different kinds of furnaces that are not all covered by any single one of main groups F27B1/00 - F27B17/00 arranged for associated working
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/0006Making spongy iron or liquid steel, by direct processes obtaining iron or steel in a molten state
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/0006Making spongy iron or liquid steel, by direct processes obtaining iron or steel in a molten state
    • C21B13/0013Making spongy iron or liquid steel, by direct processes obtaining iron or steel in a molten state introduction of iron oxide into a bath of molten iron containing a carbon reductant
    • C21B13/002Reduction of iron ores by passing through a heated column of carbon
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/0073Selection or treatment of the reducing gases
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/008Use of special additives or fluxing agents
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/10Making spongy iron or liquid steel, by direct processes in hearth-type furnaces
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/12Making spongy iron or liquid steel, by direct processes in electric furnaces
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/14Multi-stage processes processes carried out in different vessels or furnaces
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B13/00Making spongy iron or liquid steel, by direct processes
    • C21B13/14Multi-stage processes processes carried out in different vessels or furnaces
    • C21B13/143Injection of partially reduced ore into a molten bath
    • F27D17/001
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B2100/00Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/40Gas purification of exhaust gases to be recirculated or used in other metallurgical processes
    • C21B2100/44Removing particles, e.g. by scrubbing, dedusting
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B2100/00Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/60Process control or energy utilisation in the manufacture of iron or steel
    • C21B2100/62Energy conversion other than by heat exchange, e.g. by use of exhaust gas in energy production
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21BMANUFACTURE OF IRON OR STEEL
    • C21B2100/00Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/60Process control or energy utilisation in the manufacture of iron or steel
    • C21B2100/64Controlling the physical properties of the gas, e.g. pressure or temperature
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/10Reduction of greenhouse gas [GHG] emissions
    • Y02P10/122Reduction of greenhouse gas [GHG] emissions by capturing or storing CO2
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/20Recycling

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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 Of Iron (AREA)
  • Vertical, Hearth, Or Arc Furnaces (AREA)

Abstract

The invention relates to a smelting process. The method comprises the steps of (1) charging agglomerates containing fine particles of metalliferous feed material, fine particles of reductant, and fine particles of fluxing agent into a smelting furnace to form a packed bed of agglomerates in the smelting furnace; (2) Passing a first portion of carbon monoxide (CO) off-gas through the packed bed of agglomerates to partially reduce the particulates of the metalliferous feed material; (3) Combusting a second portion of carbon monoxide (CO) off-gas as a fuel gas through a burner of the smelting furnace to heat agglomerates in the smelting furnace to more than 1000 ℃ to melt the agglomerates in the smelting furnace to form a molten product; (4) charging the molten product to a reduction furnace; (5) Smelting the molten product to form a liquid metal product, a liquid slag product, and carbon monoxide (CO) off-gas that is conveyed to a burner of a smelting furnace.

Description

Method for smelting metalliferous raw material
Technical Field
The present invention relates to a method of smelting metalliferous feed material, in particular a method of smelting metalliferous feed material by using carbon monoxide (CO) off-gas of a reduction furnace as a reducing gas and a fuel gas.
Background
Metals are typically refined from ores by a smelting process. During smelting, heat and chemical reducing agents together reduce metal oxides in the ore to release oxygen that combines with the metal. Oxygen released from the metal oxide combines with carbon to form carbon monoxide (CO) exhaust.
Carbon monoxide (CO) off-gas is typically burned in a flare stack and carbon dioxide (CO 2) is generated for release to the atmosphere. In this case, all of the energy associated with the carbon monoxide (CO) exhaust gas is lost.
The energy associated with carbon monoxide (CO) exhaust gases has been used as much as possible. For example, carbon monoxide (CO) exhaust gas has been used for general plant heating and power generation. However, the thermal efficiency of both of the above uses is relatively low and most of the energy associated with carbon monoxide (CO) exhaust gas is wasted.
It is well known that metallurgical processes or methods for preheating a feed can be used with carbon monoxide (CO) off-gas. However, these processes and methods do not fully utilize the energy associated with carbon monoxide (CO) exhaust gases.
Such a method is described as a first example in International publication No. WO 2017/089651 A1. The invention relates to a method for preheating and smelting manganese ore sinter. The method includes the step of combusting carbon monoxide (CO) off-gas exiting the submerged arc furnace to form carbon dioxide (CO 2) gas. Carbon dioxide (CO 2) gas is then delivered to the pretreatment bin to heat the feed mixture containing the manganese ore sinter prior to feeding the feed mixture to the submerged arc furnace. The method further comprises the step of adjusting the temperature of the carbon dioxide (CO 2) gas to be lower than the melting temperature of the calcite manganese ore sinter described in examples 1 to 4 of the invention. Thus, in the method described in this invention, carbon monoxide (CO) off-gas from an electric submerged arc furnace is combusted to form carbon dioxide (CO 2) gas to preheat but not melt the calcite manganese ore sinter.
Outokumpu Oyj has preheated the sintered chromite pellets in the preheating bin to a temperature of 700 ℃ using the method described above, but without melting. This reduces the electrical energy required to melt and reduce ferrochrome pellets in an electric arc furnace by 6-8%. Thus, although this process utilizes carbon monoxide (CO) off-gas to provide a more energy efficient ore smelting process, the energy associated with carbon monoxide (CO) off-gas is not optimally utilized.
A second example of the use of carbon monoxide (CO) off-gas to improve energy efficiency is described in european patent publication No. EP 2937429 A1. This patent describes an application in which carbon monoxide (CO) off-gas from a smelting furnace is partially combusted and passed through a preheating furnace to heat but not melt scrap steel fed into the preheating furnace. After passing through the scrap, a portion of the carbon monoxide (CO) off-gas is fed to a reduction furnace where it is combusted in a reducing atmosphere to partially reduce the lower iron oxides at 800-1300 c (i.e., below the iron scale melting temperature). Thus, in the reduction furnace, the low grade scale is heated and partially reduced in the solid state. The partially reduced low grade iron scale is then fed into a smelting furnace and melted and further reduced by electrical energy. Although the application described in this application does use some of the energy associated with carbon monoxide (CO) off-gas, it is not suitable for melting and reducing metalliferous ore. The application is only suitable for melting scrap steel and reducing low-grade iron scales.
A third example of the use of carbon monoxide (CO) exhaust gas to improve energy efficiency is described in U.S. patent publication number 3186830. The invention described in this patent relates to a method of continuously melting cast iron. The apparatus for carrying out the method comprises a vertical combustion furnace connected to a forehearth. The method includes the steps of feeding a metal-solid lump fuel into a vertical combustion furnace and melting the metal-solid lump fuel by using energy obtained by burning coke in the vertical combustion furnace. Carbon monoxide (CO) off-gas is combusted in the forehearth to heat the liquid metal in the forehearth to the casting temperature. Furthermore, while this approach does utilize some of the energy associated with carbon monoxide (CO) exhaust gas, optimal utilization is not achieved.
As is evident from the above, the energy associated with carbon monoxide (CO) exhaust gas is still underutilized.
The purpose of the invention is that:
It is an object of the present invention to provide a method for smelting metalliferous feed material using carbon monoxide (CO) off-gas from a reduction furnace with which the applicant believes that energy associated with the carbon monoxide (CO) off-gas may be better utilized or which may provide a method of utilizing energy closely associated with the carbon monoxide (CO) off-gas than existing smelting methods and systems.
Disclosure of Invention
In a first aspect the invention provides a method of smelting metalliferous feed material that includes the steps of:
Charging agglomerates containing fine particles of a metalliferous feed material, fine particles of a reducing agent and fine particles of a fluxing agent into a smelting furnace to form a packed bed of agglomerates in the smelting furnace;
delivering carbon monoxide (CO) off-gas of the reduction furnace to a burner of the smelting furnace;
passing a first portion of carbon monoxide (CO) off-gas through the packed bed of agglomerates to partially reduce at least some of the particulates of the metalliferous feed material;
Delivering a source of oxygen (O2) to a burner of a smelting furnace;
combusting a second portion of carbon monoxide (CO) off-gas as a fuel gas through a burner of the smelting furnace to heat agglomerates in the smelting furnace to more than 1000 ℃ to melt the agglomerates in the smelting furnace to form a molten product;
Feeding the molten product into a reduction furnace;
Smelting the molten product to form a liquid metal product, a liquid slag product, and carbon monoxide (CO) off-gas that is conveyed to a burner of a smelting furnace.
The fine particles of the metalliferous feed material may be ore fines or metal oxide fines.
The agglomerates may take the form of chunks, granules, and extrudates.
It will be appreciated that the term "fine" refers to very small particles, which allow intimate contact between the particles when aggregated, in accordance with metallurgical industry standards. The diameter of the particles is generally < 0.1mm.
In one embodiment, the reductant particles are fed to the smelting furnace separately from the agglomerates, the reductant particles typically having a diameter of 6mm or less.
Those skilled in the art will appreciate that: exhaust gas is a gas that is emitted as a by-product of a chemical process.
The method comprises the additional steps of: reducing agent is dosed to the smelting furnace independently of the agglomerates. The reducing agent may be selected from anthracite, coal, coke, and combinations thereof.
The method comprises the additional steps of: the volume (i.e., flow rate) of the oxygen (O 2) source supplied to the furnace burner is controlled to ensure that oxygen (O 2) is the limiting reactant in the combustion reaction with the carbon monoxide (CO) off-gas supplied to the burner.
The oxygen (O 2) source needs to be preheated before being fed to the burner. The oxygen (O 2) source may be preheated to 800 ℃. The source of oxygen (O 2) is typically combustion air.
As an alternative to, or in combination with, combustion air, relatively pure oxygen (O 2) may be fed into the burner of the smelting furnace for combustion of oxygen (O 2) in the smelting furnace together with a second portion of carbon monoxide (CO) off-gas of the reduction furnace.
The fine particles of metalliferous feed material in the agglomerates may be partially reduced in the smelting furnace in the solid state.
The molten product formed in the smelting furnace may contain solids entrained in the liquid. Further, the molten product may comprise a component of the metalliferous feed material, a component of the partially reduced metalliferous feed material, an unreacted reductant component, and a flux component.
The reduction furnace may be any one of a direct current brush arc furnace, an alternating current brush arc furnace, and a direct current arc furnace.
An electric arc furnace is an electric furnace whose electrodes produce an electric arc at the top of the contents of the furnace, the arc being short, typically not exceeding 100mm in length.
Preferably, the method may comprise the additional step of supplying a reducing agent to the reduction furnace. The reductant may be one of anthracite, coal, coke, and combinations thereof.
The smelting furnace can be a gas cupola furnace (i.e. a coke-free cupola furnace) or a vertical combustion furnace.
The method may comprise the additional step of: particulate matter is removed from carbon monoxide (CO) off-gas of a reduction furnace by a wet scrubber prior to feeding the CO off-gas to a burner of a smelting furnace.
In a second aspect the invention provides a method of smelting metalliferous feed material that includes the steps of:
Charging agglomerates containing fine particles of a metalliferous feed material, fine particles of a reducing agent and fine particles of a fluxing agent into a smelting furnace to form a packed bed of agglomerates in the smelting furnace;
delivering carbon monoxide (CO) off-gas of the reduction furnace to a burner of the smelting furnace;
passing a first portion of carbon monoxide (CO) off-gas through the packed bed of agglomerates to partially reduce at least some of the particulates of the metalliferous feed material;
Delivering a source of oxygen (O 2) to a burner of a smelting furnace;
combusting a second portion of carbon monoxide (CO) off-gas as a fuel gas through a burner of the smelting furnace to heat agglomerates in the smelting furnace to more than 1000 ℃ to melt the agglomerates in the smelting furnace to form a molten product;
Feeding the molten product into a reduction furnace;
Smelting the molten product to form a liquid metal product, a liquid slag product, and carbon monoxide (CO) off-gas that is conveyed to a burner of a smelting furnace.
In a third aspect the invention provides a method of smelting metalliferous feed material that includes the steps of:
Charging agglomerates containing fine particles of a metalliferous feed material, fine particles of a reducing agent and fine particles of a fluxing agent into a smelting furnace to form a packed bed of agglomerates in the smelting furnace;
delivering carbon monoxide (CO) off-gas of the reduction furnace to a burner of the smelting furnace;
passing a first portion of carbon monoxide (CO) off-gas through the packed bed of agglomerates to partially reduce at least some of the particulates of the metalliferous feed material;
Delivering a source of oxygen (O 2) to a burner of a smelting furnace;
delivering a second portion of carbon monoxide (CO) off-gas of the reduction furnace to a burner of the smelting furnace;
combusting a second portion of carbon monoxide (CO) off-gas as a fuel gas through a burner of the smelting furnace to heat agglomerates in the smelting furnace to more than 1000 ℃ to melt the agglomerates in the smelting furnace to form a molten product;
Feeding the molten product into a reduction furnace;
smelting the molten product to form a liquid metal product, a liquid slag product, and carbon monoxide (CO) off-gas that is fed to the smelting furnace and to a burner of the smelting furnace.
Drawings
Fig. 1 is a schematic diagram of the system of the present invention.
Detailed Description
Referring to FIG. 1, a system for smelting metalliferous feed material in accordance with the process of the present invention is indicated generally by the reference numeral 10.
The system 10 includes a smelting furnace 20 having burners 22. The system 10 also includes a reduction furnace 30. A conduit 40 extends between the reduction furnace 30 and the burner 22 of the smelting furnace 20 for delivering carbon monoxide (CO) exhaust gas of the reduction furnace 30 as a reducing gas and a fuel gas to the burner 22 of the smelting furnace 20.
Agglomerates (not shown) comprising fine particles of metalliferous feed material, fine particles of reductant, and fine particles of flux are fed into smelting furnace 20 to form a packed bed (not shown) of agglomerates in smelting furnace 20. Agglomerates are typically fed into smelting furnace 20 through a sluice (not shown). Process stream (I) in fig. 1 represents the step of charging the agglomerates to smelting furnace 20. The flux is used to promote the melting of the fine particles of the metalliferous feed material in the agglomerates. Agglomerates fed into the smelting furnace 20 typically take the form of nuggets, granules and extrudates.
The diameter of the particles of the agglomerates is generally less than or equal to 0.1mm.
The reducing agent is also fed into the smelting furnace 20 separately from the agglomerates. The reducing agent is typically coke, coal or anthracite.
The diameter of the reducing agent is less than or equal to 6mm.
The fine particles of the metalliferous feed material are typically fine ore particles or fine metal oxide particles.
The packed bed of agglomerates is typically located at the top of a bed of refractory material (not shown). The refractory bed is in turn positioned on top of the water cooled grate 24 of the furnace 20. The water cooled grate 24 is covered with a refractory material to reduce heat loss and protect the water cooled grate 24. The combustion chamber 26 of the smelting furnace 20 is located below the refractory covered water cooled grate 24. The burner 22 combusts a second portion of the carbon monoxide (CO) exhaust of the reduction furnace 30 with combustion air in the combustion chamber 26 of the smelting furnace 20 to heat the agglomerates to above 1000 ℃ to melt the agglomerates to form a molten product. As shown by process stream (II) in fig. 1, combustion air is fed to the burner 22 of the smelting furnace 20. Normally the combustion air needs to be preheated in a preheater 70 before being fed to the burner 22 of the smelting furnace 20. The combustion air is typically heated to 800 c in the preheater 70. As an alternative to, or in combination with, combustion air, oxygen may be fed to the burners 22 of the smelting furnace 20.
As a further alternative, or in any combination with the foregoing, an external fuel gas in the form of synthesis gas or natural gas may be provided to the burner 22 from the source 72 in the event additional external energy is required to achieve the desired temperature and maintain a reducing atmosphere within the smelting furnace 22. It has been found that such external fuel gas may be required when the agglomerates comprise ferrochrome.
Such external fuel gas may also provide assistance during the start-up phase of the process.
A first portion of the carbon monoxide (CO) off-gas of the reduction furnace 30 is passed through the packed bed of agglomerates to partially reduce at least some of the fine particles of the metalliferous feed material of the solid agglomerates.
Thus, the fine particles of metalliferous feed material in the agglomerates are first partially reduced to a solid state in the smelting furnace 20 and then melted to form a molten product. The molten product includes a component of the metalliferous feed material, a component of the partially reduced metalliferous feed material, an unreacted reductant component, and a flux component.
Valve arrangement 90 is used to control the flow rate of combustion air or oxygen (O 2) to the burners 22 of smelting furnace 20. The flow rate of combustion air or oxygen (O 2) to the burner 22 is controlled to ensure that oxygen (O 2) is the limiting reactant in the combustion reaction of the second portion of carbon monoxide (CO) exhaust. That is, the flow of combustion air or oxygen (O2) is controlled to be less than the stoichiometric ratio required for complete combustion of carbon monoxide (CO) exhaust gas that is delivered from the reduction furnace 30 to the smelting furnace 20.
An outlet (not shown) is provided in the operable top region of the smelting furnace 20 for withdrawing from the smelting furnace 20 waste gases formed in the smelting furnace 20. The step of extracting the offgas formed in the smelting furnace 20 from the smelting furnace 20 refers to process stream (VI) in fig. 1. The flue gas formed in the smelting furnace 20 and exiting the smelting furnace 20 is typically carbon dioxide (CO 2). Carbon dioxide (CO 2) off-gas formed in smelting furnace 20 and extracted from smelting furnace 20 is passed through a bag filter 60 to remove particulate matter from the off-gas before it is released into the atmosphere.
Smelting furnace 20 is in fluid communication with reduction furnace 30 via conduit 50. The conduit 50 generally extends between an operable bottom region of the smelting furnace 30 (e.g., a tapping region and a tapping port of the smelting furnace 20) and the reduction furnace 30. Conduit 50 is used to convey molten products (not shown) formed in smelting furnace 20 to reduction furnace 30. Conduit 50 is used to convey molten products (not shown) formed in smelting furnace 20 to reduction furnace 30. The molten product includes a component of the metalliferous feed material, a component of the partially reduced metalliferous feed material, an unreacted reductant component, and a flux component. Conduit 50 is typically a closed conduit and is thermally insulated to prevent heat loss from the molten product as it is transported from smelting furnace 20 to reduction furnace 30.
The reduction furnace 30 may be selected from any one of a direct current brush arc furnace, an alternating current brush arc furnace, and a direct current arc furnace. A brushed electric arc furnace is an electric furnace in which the electrodes produce an electric arc at the top of the furnace contents in a short arc length, typically no longer than 100mm. Exemplary embodiments of brushed arc furnaces are provided in international patent application number PCT/IB2011/052428, south african patent application number 2012/04751, and south african provisional patent application number 2019/07850. The contents of these three documents are incorporated herein by reference.
As shown in fig. 1, the reduction furnace 30 takes the form of a brushed arc furnace having two electrodes 32a and 32b, the electrodes 32a and 32b extending from the roof 31 of the reduction furnace 30 or through the roof 31. Electrodes 32a and 32b are arranged to form arcs 33a and 33b on top of the smelting furnace contents 34. As shown in process stream (III) in fig. 1, a reducing agent (not shown) for reducing fine particles of partially reduced metalliferous feed material in the molten product is fed into reduction furnace 30. The reducing agent is typically anthracite, coal, coke, or a combination thereof.
The smelting furnace contents 34 include a liquid slag product 34a and a liquid metal product 34b. The smelting furnace contents 34 are formed by a smelting reaction. During the smelting reaction, the partially reduced metalliferous feed material fine particle constituents of the molten product are reduced to form a liquid slag product 34a and a liquid metal product 34b. Carbon monoxide (CO) off-gas is emitted during the smelting reaction.
As shown in process stream (IV) of fig. 1, a tap (not shown) is provided in reduction furnace 30 to convey liquid slag product 34a out of reduction furnace 30. As shown in process stream (V) of fig. 1, there is another outlet (not shown) in the reduction furnace 30 to convey the liquid metal product 34b out of the reduction furnace 30.
As described above, the conduit 40 extends between the reduction furnace 30 and the burner 22 of the smelting furnace 20 for delivering carbon monoxide (CO) off-gas of the reduction furnace 30 as fuel gas and reducing gas to the smelting furnace 20. Carbon monoxide (CO) off-gas may be fed directly to the burner 22 of the smelting furnace 20. More specifically, conduit 40 extends between an operable top region of reduction furnace 30 and burners 22 of smelting furnace 20. That is, the conduit 40 has an opening in the reduction furnace 30 that is located above the contents 34 of the reduction furnace 30.
Or a first portion of the carbon monoxide (CO) off-gas may be supplied to the smelting furnace 20 and a second portion of the carbon monoxide (CO) off-gas may be supplied to the burner 22 of the smelting furnace 20.
As shown in fig. 1, a wet scrubber 80 is used to remove contaminants from carbon monoxide (CO) off-gas of the reduction furnace 30. In particular, wet scrubber 80 is used to remove particulate matter from carbon monoxide (CO) off-gas of reduction furnace 30 prior to delivering the carbon monoxide (CO) off-gas as fuel gas to burner 22 of smelting furnace 20.
In use, agglomerates (not shown) comprising fine particles of metalliferous feed material, fine particles of reductant, and fine particles of fluxing agent are fed through a sluice (not shown) into smelting furnace 20. This step is shown in process flow (I) of fig. 1. The agglomerates are conveyed into the smelting furnace 20 to form a packed bed of agglomerates (not shown) on a packed bed of refractory material. The refractory packed bed is supported on a refractory covered water cooled grate 24 of the smelting furnace 20.
The scrubbed carbon monoxide (CO) off-gas of the reduction furnace 30 is fed to the smelting furnace 20 as fuel gas and reducing gas through a conduit 40.
A first portion of the carbon monoxide (CO) off-gas is passed through the packed bed of agglomerates to partially reduce at least some of the fine particles of the solid metalliferous feed material.
As shown by process stream (II) in fig. 1, preheated combustion air is fed to the burner 22 of the smelting furnace 20. The burners 22 of the smelting furnace 20 combust a second portion of the carbon monoxide (CO) off-gas and combustion air to heat a packed bed of refractory material in the smelting furnace 20. The refractory material in turn heats the agglomerates to over 1000 ℃ to melt the agglomerates in the smelting furnace 20 to form a molten product (not shown). The molten product includes a component of the metalliferous feed material, a component of the partially reduced metalliferous feed material, an unreacted reductant component, and a flux component.
During the combustion reaction, carbon dioxide (CO 2) off-gas is formed. Carbon dioxide (CO 2) off-gas is extracted from smelting furnace 20 as shown by process stream (VI). The extracted carbon dioxide (CO 2) exhaust gas passes through a bag filter 60 to remove particulate matter therefrom before it is released to the atmosphere.
The molten product flows downwardly and passes through a refractory packed bed and refractory covered water cooled grate 24 before being conveyed through a conduit 50 to a reduction furnace 30.
The molten product is located in the reduction furnace 30 and electrical energy is continuously applied to the reduction furnace 30 and its contents 34 via electrodes 32a and 32 b. Electrodes 32a and 32b are arranged to form arcs 33a and 33b on top of the smelting furnace contents 34. As shown in process stream (III) of fig. 1, a reducing agent (not shown) is also continuously added to the reduction furnace 30.
As electrical energy and reductant are continuously added to the reduction furnace 30 and its contents 34, the fine particles of partially reduced metalliferous feed material and the fine particles of metalliferous feed material that are not partially reduced in the smelting furnace 20 are melted to form the liquid metal product 34b and the liquid slag product 34a. As shown by process stream (V) in fig. 1, liquid metal product 34b periodically or continuously flows from reduction furnace 30 through a tap hole (not shown). As shown by process stream (IV) in fig. 1, liquid slag product 34a periodically or continuously flows from reduction furnace 30 through an outlet (not shown).
During the smelting reaction, off-gas, consisting mainly of carbon monoxide (CO), is discharged. Carbon monoxide (CO) off-gas is extracted from reduction furnace 30 via conduit 40 and sent to wet scrubber 80. Contaminants and particulate matter are removed from the carbon monoxide (CO) off-gas of the reduction furnace 30 by the wet scrubber 80. The scrubbed carbon monoxide (CO) off-gas of the reduction furnace 30 is then fed into the smelting furnace 20 as fuel gas and reducing gas.
It will be appreciated by those skilled in the art that carbon monoxide (CO) exhaust gas from reduction furnace 30 may form a constituent of the fuel gas delivered to burners 22 of smelting furnace 30.
The method of the invention effectively utilizes the energy related to the carbon monoxide (CO) waste gas of the reduction furnace. The applicant found that: by using carbon monoxide (CO) off-gas of the reduction furnace as fuel gas and reducing gas for the smelting furnace burner, the throughput of the reduction furnace can be doubled. In addition, by using carbon monoxide (CO) off-gas of the reduction furnace as fuel gas and reducing gas for the smelting furnace burner, the electrical energy requirements of the reduction furnace are significantly reduced.
Illustrating the advantages of the invention: mass and energy balance
The following is a comparison of two smelting processes:
(i) A first conventional smelting process using a brushed electric arc furnace;
(ii) A second smelting process using the process and system 10 of the present invention.
The first conventional smelting process using a brushed electric arc furnace:
The first conventional process is a smelting process that utilizes a brushed electric arc furnace to smelt the agglomerates. The agglomerates take the form of fused particles and comprise, in weight percent, approximately:
-32.5%Cr2O3
-22.6%FeO;
-13.4%Al2O3
-12.7%CaO;
-8.1%MgO;
-5.5%SiO2
The agglomerates were fed into a brushed electric arc furnace at a rate of 21.3 metric tons per hour. The reducing agent was also fed into the brushed electric arc furnace at a rate of 3.6 metric tons per hour. 30 megawatts was supplied to the brushed electric arc furnace to provide the energy required to smelt the metal oxides located in the agglomerates.
The brushed arc furnace melts the agglomerates to form an alloy liquid product and a slag liquid product.
Alloy liquid product was tapped from a brushed electric arc furnace at 1550 c and 7.7 metric tons per hour. The alloy liquid product comprises, in weight percent:
-50.3%Cr;
-38.9%Fe;
-6.5%C;
-4.0%Si。
slag liquid product was tapped from a brushed electric arc furnace at a rate of 10.7 metric tons per hour at a temperature of 1650 ℃. The slag liquid product comprises, in weight percent, about:
-11.6%Cr2O3
-9.0%FeO;
-28.4%Al2O3
-25.3%CaO;
-16.2MgO;
-7.4%SiO2
Exhaust gas was drawn from the brushed electric arc furnace at 8173 standard cubic meters per hour and 10 metric tons per hour. The temperature of the exhaust gas is 1200 ℃, which comprises about:
-51.4%CO;
-7.9%CO2
-26.5%N2
-2.7%H2
-0.1%SO2
-11.4%H2O。
the operating coefficient of the brushed electric arc furnace was 0.92. Brush electric arc furnaces lose 4 megawatts due to heat loss.
The electric arc furnace of this first conventional smelting process has a specific power consumption of 3.81 megawatts per metric ton of molten iron.
A second smelting process using the process and system of the present invention:
The second process is a smelting process that utilizes the process and system 10 of the present invention to smelt agglomerates. The agglomerates take the form of fused particles and comprise, in weight percent, approximately:
-32.5%Cr2O3
-22.6%FeO;
-13.4%Al2O3
-12.7%CaO;
-8.1%MgO;
-5.5%SiO2
The agglomerates are fed into the smelting furnace 20 at a rate of 36.5 metric tons per hour. The agglomerates form a packed bed of agglomerates in the smelting furnace 20. The reducing agent is also fed into the smelting furnace at a rate of 0.6 metric tons per hour.
The off-gas from the reduction furnace 30 is fed through the wet scrubber 80 to the smelting furnace 20 at 50 c and at a rate of 10.88 metric tons/hour. The exhaust gas from the brush electric arc furnace 30 comprises, by weight:
-58.5%CO;
-27.1%N2
-13.6%H2
-0.1%SO2
-0.7%H2O。
The combustion air is preheated to 800 c and fed to the burners 22 of the smelting furnace 20 at a rate of 69.2 metric tons/hour.
A first portion of the carbon monoxide (CO) off-gas is passed through the packed bed of agglomerates to partially reduce at least some of the fine particles of the metalliferous feed material.
A second portion of the carbon monoxide (CO) in the flue gas is combusted by the burner 22 and the packed bed of agglomerates is heated to 1500 ℃ in the smelting furnace 20 to form a molten product and a smelting furnace flue gas. The molten product was at a temperature of 1500 c and was fed from the melting furnace 20 to the brushed electric arc furnace 30 at a rate of 33.8 metric tons per hour. The molten product contained 50% solids, in weight percent, approximately comprising:
-35.2%Cr2O3
-7.3%%FeO;
-13.3%Fe;
-14.6%Al2O3
-13.7%CaO;
-8.8%MgO;
-6%SiO2
The smelting furnace waste gas is discharged from smelting furnace 20 at a flow rate of 34233 standard cubic meters per hour and 47.4 metric tons per hour. The smelting furnace off-gas is extracted from smelting furnace 20 at 500 c and comprises, in weight percent:
-21.7%CO2
-4.8%O2
-66.5N2
-6.9%H2O。
As described above, the molten product is delivered from the melting furnace 20 to the brushed electric arc furnace 30 at a rate of 33.8 metric tons per hour. The reducing agent is also fed into the brushed electric arc furnace 30 at a rate of 6.3 metric tons per hour. 30 megawatts of electrical energy is supplied to the brushed electric arc furnace 30 to provide the energy required to smelt the metal oxides located in the molten product.
The brushed electric arc furnace 30 melts the molten product to form an alloy liquid product and a slag liquid product.
Alloy liquid product flows from the brushed electric arc furnace 30 at 1550 c at a rate of 14.2 metric tons per hour. The alloy liquid product comprises, in weight percent:
-50.3%Cr;
-40.5%Fe;
-8%C;
-1%Si。
Liquid slag product flows from the brushed electric arc furnace 30 at 1650 c at a rate of 17.8 metric tons per hour. The slag liquid product comprises, in weight percent, about:
-8%Cr2O3
-5%FeO;
-29.5%Al2O3
-26.1%CaO;
-16.7%MgO;
-12.6%SiO2。
Exhaust gas is discharged from the brushed electric arc furnace 30 at a flow rate of 12460 standard cubic meters per hour and 13.6 metric tons per hour. The temperature of the exhaust gas was 1400 ℃, comprising, in weight percent:
-58.5%CO;
-27.1%N2
-13.6%H2
-0.1%SO2
-0.7%H2O。
80% by weight of the off-gas of the brushed electric arc furnace 30 is supplied as fuel gas and reducing gas into the smelting furnace 20 and used as described above.
The operating coefficient of the brushed electric arc furnace 30 was 0.92. The brushed electric arc furnace 30 lost 4 megawatts due to heat loss.
The brushed electric arc furnace 30 of the system 10 has a specific power consumption of 2.07 megawatts per metric ton of molten metal.
It will be appreciated by those skilled in the art that the specific power consumption of a brushed electric arc furnace is significantly reduced from 3.81 megawatts per metric ton of molten iron to 2.07 megawatts per metric ton of molten iron. This significant reduction is a direct result of the novel and inventive use of energy associated with the carbon monoxide (CO) off-gas of the reduction furnace.
It will be understood by those skilled in the art that the invention is not limited to the precise details described herein and that many variations are possible without departing from the scope of the invention. Accordingly, the present invention extends to all functionally equivalent processes, methods and uses within the scope thereof.
The description is to be taken in an illustrative manner only and is for the purpose of providing a description that is deemed to be most useful and readily understood in the principles and conceptual aspects of the invention. In this regard, no attempt is made to show more details than is necessary for a fundamental understanding of the invention. The words which have been used herein are words of description and illustration, rather than words of limitation.

Claims (12)

1. A method of smelting metalliferous feed material characterized by: the method comprises the following steps:
Charging agglomerates containing fine particles of a metalliferous feed material, fine particles of a reducing agent and fine particles of a fluxing agent into a smelting furnace to form a packed bed of agglomerates in the smelting furnace;
delivering carbon monoxide (CO) off-gas from the electric arc furnace to a burner of the smelting furnace;
passing a first portion of carbon monoxide (CO) off-gas through the packed bed of agglomerates to partially reduce at least some of the particulates of the metalliferous feed material;
Delivering a source of oxygen (O 2) to a burner of a smelting furnace;
combusting a second portion of carbon monoxide (CO) off-gas as a fuel gas through a burner of the smelting furnace to heat agglomerates in the smelting furnace to more than 1000 ℃ to melt the agglomerates in the smelting furnace to form a molten product;
charging the molten product to an electric arc furnace;
Smelting the molten product to form a liquid metal product, a liquid slag product, and carbon monoxide (CO) off-gas that is conveyed to a burner of a smelting furnace;
the fine particles of the metalliferous feed material are ore fine particles or metal oxide fine particles;
the diameter of the fine particles of the metal-containing raw material is less than or equal to 0.1mm;
The method comprises the additional steps of: the volume of the source of oxygen (O 2) supplied to the smelting furnace burner is controlled to ensure that oxygen (O 2) is the limiting reactant in the combustion reaction with the carbon monoxide (CO) exhaust gas supplied to the burner.
2. A method of smelting metalliferous feed material in accordance with claim 1 in which: the agglomerates are selected from the group consisting of chunks, granules, and extrudates.
3. A method of smelting metalliferous feed material in accordance with any one of claims 1-2 wherein: the method comprises the additional steps of: reducing agent is dosed to the smelting furnace independently of the agglomerates.
4. A method of smelting metalliferous feed material in accordance with claim 1 in which: the fine particles of metalliferous feed material are partially reduced in a smelting furnace in a solid state.
5. A method of smelting metalliferous feed material in accordance with claim 1 in which: the oxygen (O 2) source needs to be preheated before being fed to the burner of the smelting furnace.
6. A method of smelting metalliferous feed material in accordance with claim 5 in which: wherein the oxygen source is preheated to 800 ℃.
7. A method of smelting metalliferous feed material in accordance with claim 1 in which: the arc furnace is any one of a direct current brush arc furnace, an alternating current brush arc furnace and a direct current arc furnace.
8. A method of smelting metalliferous feed material in accordance with claim 1 in which: the method comprises the additional steps of: the reducing agent is delivered to the electric arc furnace.
9. A method of smelting metalliferous feed material in accordance with claim 8 in which: the reducing agent is selected from the group consisting of coal, coke, and combinations thereof.
10. A method of smelting metalliferous feed material in accordance with claim 1 in which: the smelting furnace is a gas cupola furnace.
11. A method of smelting metalliferous feed material in accordance with claim 1 in which: the smelting furnace is a vertical combustion furnace.
12. A method of smelting metalliferous feed material in accordance with claim 1 in which: the method comprises the additional steps of: particulate matter is removed from carbon monoxide (CO) off-gas of a reduction furnace by a wet scrubber prior to feeding the CO off-gas to a burner of a smelting furnace.
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