US2928730A - Iron ore reduction process - Google Patents

Iron ore reduction process Download PDF

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Publication number
US2928730A
US2928730A US634282A US63428257A US2928730A US 2928730 A US2928730 A US 2928730A US 634282 A US634282 A US 634282A US 63428257 A US63428257 A US 63428257A US 2928730 A US2928730 A US 2928730A
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Prior art keywords
zone
gas
reducing gas
ash
reducing
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US634282A
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Frank W Luerssen
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Inland Steel Co
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Inland Steel Co
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Priority to US634282A priority Critical patent/US2928730A/en
Priority to CH5454558A priority patent/CH378921A/de
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    • 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
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/10—Reduction of greenhouse gas [GHG] emissions
    • Y02P10/122—Reduction of greenhouse gas [GHG] emissions by capturing or storing CO2
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/10—Reduction of greenhouse gas [GHG] emissions
    • Y02P10/134—Reduction of greenhouse gas [GHG] emissions by avoiding CO2, e.g. using hydrogen

Definitions

  • This invention relates to the direct reduction of iron oxide, particularly iron oxide ores, by the use of a reducing gas comprising principally carbon monoxide.
  • a primary object of the invention is to provide a novel and improved process for the direct reduction of iron ore.
  • a further object of. the invention is to provide a novel process of the foregoing character which utilizes a reducing gas obtained from the combustion of coalor like solid carbonaceous fuel.
  • Another object of the invention is to provide an iron ore reduction process utilizing a reducing gas obtained by the combustion of coal or the like and including novel means for overcoming coal ash and related problems which arise from such combustion.
  • Fig. 1 is a block flow diagram illustrating a preferred method of practicing the invention.
  • Fig. 2 is a generally diagrammatic fiow sheet illustrating the process in somewhat more detail.
  • my invention involves three principal process stages as applied to an integrated reduction and melting process: (1) a combined melting and gas generator zone wherein a fuel is burned in order to melt and separate the iron from the reduced ore and at the same time producing combustion gases, (2) an upgrading or gas enrichment zone wherein the combustion gases from the first zone are treated to increase their reducing capacity, and (3) a reduction zone wherein subdivided iron ore is contacted with the enriched reducing gases from the second zone and from which the resultant reduced iron ore is passed to the first zone.
  • iron oxide ore is introduced through a line 10 to a reduction zone 11 and contacted with CO-r'ich reducing gases introduced to the zone 11 through a line 12.
  • the ores which may be used in the process comprise any of the well known ironoxide ores including hematite, magnetite, and others which may contain at least about 5 wt. percent and as much as 45 wt. percent gangue materials, particularly silica and alumina. Other ores similar to iron ore such as iron-manganese ores may also be used. It is also within the scope of the invention to charge to the reduction zone 11 other iron oxide materials such as mill scale, etc.
  • the well known reduction reactions of iron oxide with CO (and'H take place with the heat of reaction being supplied by the sensible heat of the reducing gases which are at a temperature of from about 900 F. to about 1800 F. as hereinafter described.
  • Effluent reducing gases of depleted CO content are discharged through a line 13 from the reduction zone 11.
  • the resultant ore particles comprising reduced iron
  • gangue, and a certain amount of unreduced iron oxide pass from the reduction zone 11 through a line ,14 to a hearth zone 16 which comprises a combined melting and gas generator zone.
  • a solid carbonaceous fuel is introduced in admixture with a high oxygen content gas through a line 17 and combustion of the fuel with the oxygen takes place within the hearth zone 16.
  • the combustion of the fuel in the hearth zone 16 must be sufficiently complete so that an excess of CO is produced with the result that the combustion gases in the hearth zone 16 are oxidizing to iron.
  • the preferred solid carbonaceous fuel burned in the hearth zone 16 is coal such as anthracite, bituminous or sub-bituminous coal in pulverized form.
  • the oxygen-rich gas introduced'with the fuel must contain at least oxygen, e.g. a commercial grade of straight oxygen which may be 98-99% pure, or oxygen enriched air;
  • oxygen e.g. a commercial grade of straight oxygen which may be 98-99% pure, or oxygen enriched air;
  • the relative quantities of coal and oxygen and the other combustion conditions in the hearth zone 16 are regulated so that the exit combustion gases from the hearth zone are oxidizing in character with a CO :CO ratio of at least about 1.
  • a temperature of from about 2900 F. to about 3500 F. is obtained in the hearth zone so that the heat of combustion is sufficient to insure melting of the iron in the reduced ore particles thereby separating the same from the gangue of the ore.
  • Excessive reoxidation of the molten iron in the hearth 16 is also retarded by the presence of extraneous carbon either in the form of coal fall-out during the combustion of coal in'the hearth or as the result of direct addition of coal or other carbonaceous solid to the surface of the molten iron.
  • the combustion 'zone 16 contain an excess of they must be subjected to an upgrading or enrichment treatment before they can be used for ore reduction purposes.
  • the upgrading or enrichment of the combustion gases is effected by reducing-the CO content by reaction with carbon.
  • the combustion gases pass from the hearth'zone 16 through'a line 21 to a gasifier zone'22 to which oxygen and an excess of coal are also supplied through a line 23;
  • the carbon in part of the coal sup plied at 23 reacts with the CO in the combustion gases supplied at 21, and the endothermic heat requirements for the reduction reaction are furnished by.
  • the sensible heat in the combustion gasessupplemented by additional heat evolved in the gasifier 22 by partial combustion of another part of the coal with the oxygen supplied through the line 23.
  • the high oxygen content gas supplied at 23 may be straight commercial grade oxygen or maybe an oxygen enriched gas containing at least 85% oxygen just as in the hearth 16.
  • reaction of CO with the carbon content of the coal to produce CO is the primary reduction reaction accomplished in the gasifier zone 22, it will also be appreciated that water vapor contained in the combustion gases fed to the gasifier zone 22 will be reduced by reaction with carbon to form H
  • part of the ash- may be removed from the gasifier zone 22 as a semi-solid slag or ash deposit, but the operating condit-ions required in the gasifier zone 22 are such that a troublesome quantity of coal ash necessarily escapes from the gasifier zone 22 as entrained particles in the exit gases.
  • a gas cleaner such as a cyclone separator or an electrostatic precipitator could be used to effect removal of ash from the high temperature gases in the line 24, I have found that the most effective and inexpensive removal may be effected by means of a liquid washing or scrubbing device such as a water scrubber, particularly a venturi scrubber.
  • a water scrubber particularly a venturi scrubber.
  • the hot gases from the line 24 pass through a heat exchanger 26 where the gases are cooled to a temperature on the order to. 500 F. to 600 F. and are thence introduced through a line 27 to a scrubber 28.
  • Water or other liquid cleaning agent is introduced tothe scrubber28 through a line 29 and the effluent scrubbing liquid is removedthrough a line 31.
  • thescrubbing liquid may also comprise a chemical reactant or solvent such as monoethanolamine or the like for selectively removing CO from the gases.
  • the hearth zone 16 be operated at, atmospheric or substantially atmospheric pressure.
  • pump or compressor must be provided in the system for effecting passage of gases through the various stages of the process and particularly through the reduction zone 11.
  • the effluentclean reducing gases from the scrubber 28 pass through a line 32 to a compressor 33, and thence through a line 34 to the heat exchanger 26 wherein the cooled and cleaned gases are reheated to a suitable reaction temperature of from about 900 F. to about 1800" F.
  • a pulsating device 37 which may impart a cyclic pulsating pressure to the gas stream for the purpose. hereinafter described. From the pulsator 37 the reducing gasespass through the line 12 to'the reduction zone 11 as heretofore described. 7
  • the subdivided or granular iron oxide material fed to the reduction zone 11 is preferably within the range of from about /2" to about mesh which includes particles substantially smaller than anything suitable for use in the blast furnace.
  • thefluid velocity of the reducing gases may be Undersuchcircumstances, a gas pulsating effect caused by momentary increases and de-' creases in gas pressure. This scheme effectively avoids mechanical blocking difficulties in the non-fluidized moving bed operation whenever such difiiculties are encountered.
  • the hearth unit in this case comprises a unitary refractory lined enclosure 40 having an upright insulating wall or thermal barrier 41 which devides the enclosure into a melting and gas generation zone 42 at one side of the'wall 41 and an upgrading or gasified zone 43 at the other side.
  • a restricted gas passageway 44 is provided therebetween. Reduced iron ore particles are fed to the melting and slag outlets from the hearth are illustrated at 51 and 52, respectively.
  • the reduction reactions carried out in the gasifier zone 43 are at a significantly lower temperature than the high temperature melting which takes place in the zone 42, and the thermal wall 41 serves to maintain the temperature differential.
  • the CO-rich reducing gases at a temperature of from about 1900 F. to about 2400" F. pass through a line 54 v and thence through the interior of a two-stage heat exchanger 56 and finally through an outlet line 57 to the base of a scrubber 58.
  • Water or other scrubbing liquid is introduced at the top of the scrubber 58 through a line 59 for countercurrentcontacting with the reducing gases to remove ash therefrom.
  • the efiluent scrubbing liquid is removed from the scrubber 58 through a line 61 for discard, recirculation, or recovery treatment as the case may be.
  • additional cooling of the gases takes place in the scrubber 58 so that the effiuent ash.- free reducing gases may be removed from the top of the scrubber at a temperature of from about 100 F. to about 200 F.
  • the gases from the scrubber 58 pass through a line 62 to a compressor 63 and thence through a line 64 to a gas storage device or holder 66.
  • a by-pass line 67 is provided around the compressor 63.
  • the pressurized reducing gas is fed from the holder 66 through a valve controlled line 68 to a header 69 at the inlet side of the first stage of the heat exchanger 56, and the gases are reheated by passage through the first stage of the heat exchanger to a common header 71 and thence through the second stage of the heat exchanger to an outlet header 72 communicating with the discharge line 73.
  • a by-pass line 74 is also provided around the heat exchanger 56, and a valve-controlled vent line 75 extends from the discharge line 73.
  • the pulsating device is in this instance located in the line 73 and comprises a rotary valve mechanism 74 which is adapted to be opened and partially closed for cyclically restricting and enlarging the flow passage through the line 73 whereby to impart desired pulsations in the gas flow for the rea- Dependent upon the particle size of sons heretofore described.
  • a rotary valve mechanism 74 which is adapted to be opened and partially closed for cyclically restricting and enlarging the flow passage through the line 73 whereby to impart desired pulsations in the gas flow for the rea- Dependent upon the particle size of sons heretofore described.
  • the pulsator 74 may be operated either continuously or only as required when. mechanical flow ditficulties are encountered in the reduction zone.
  • the reducing gas stream from the line 73 is fed into the bottom of a refractory lined reduction column 76 having an upper portion 77 of relatively enlarged diameter and a lower portion 78 of reduced diameter.
  • Subdivided ore particles are fed into the enlarged upper portion 77 of the reduction column through a screw conveyor mechanism 79 from a supply source or ore preheating source (not shown).
  • a screw conveyor mechanism 79 from a supply source or ore preheating source (not shown).
  • the ore thus introduced forms a downwardly moving or flowing bed which is supported at its lower end by a cone-shaped partition 81.
  • the partition 81 communicates with one end of another screw conveyor 82 operated by a motor'83 for discharging the reduced ore from the reduction column 76 to the hearth feed line 46.
  • the partition 81 is provided with suitable protected gas passages, such as the bubble cap elements 84, whereby the reducing gas introduced from the line 73 at the bottom of the column 76 may pass upwardly through the partition 81 and thence in countercurrent relation with the downwardly moving bed of ore particles.
  • the depleted or spent reducing gases pass from the top of the reduction column 76 through a line 85 to a cyclone separator 86 or like device wherein entrained .fine ore particles are removed.
  • the oif gases are discharged through a line 87 and ore fines are collected" in a hopper or storage vessel 88 which is connectedby line 89 and a valve 91 to the discharge end of the screw conveyor 82 whereby the ore fines may be intermittently charged to the melting zone 42.
  • the invention as described above relates to an integrated reduction and melting process for making hot metal or molten iron.
  • heat exchange, ash removal, and related features of the invention are equally applicable to a simple reduction process wherein the end productis reduced solid iron ore whichmay be compressed into larger particles without melting and supplied as sponge irOn or so-call'ed synthetic scrap.
  • a gas generator zone for producing a CO-rich reducing gas is required in place of the melting-gas generation-gas enrichment arrangement described herein.
  • the resultant reducing gas contains entrained ash particles, and wherein said reducing gas is contacted with subdivided iron oxide ore at a temperature of from about 900 F. to about 1800" F.; the method of preparing the reducing gas for use in the reduction step which comprises passing the ash-containing reducing gas at an elevated temperature through a heat exchange zone and therein cooling the reducing gas, removing entrained ash from the cooled reducing gas, and passing the ash-free cooled reducing gas through'said heat exchange zone in indirect heat exchange relation with the elevated temperature ashcontaining gas and thereby reheating the ash-free reducing gas to a temperature of fromabout 900 F. to about 1800 F.
  • the resultant reducedv iron 'ore from said reducing zone is passed to said hearth-zone in which the reduced ironis melted by the heat of cornbustiou; the method of. preparing the CO-rich reducing. gas forluse' in the reduction step which comprises passing the ash-containing reducing gas at an elevatedtemperature from said gasifier zone toa heat exchange zone and. therein cooling the reducing gas, scrubbing the cooled reducinglga'swith awashi'ng liquidand thereby removing,

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)
US634282A 1957-01-15 1957-01-15 Iron ore reduction process Expired - Lifetime US2928730A (en)

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US634282A US2928730A (en) 1957-01-15 1957-01-15 Iron ore reduction process
CH5454558A CH378921A (de) 1957-01-15 1958-01-10 Verfahren zur Reduktion von Eisenoxyd enthaltenden Stoffen zu Eisen

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3028231A (en) * 1959-01-01 1962-04-03 British Iron Steel Research Processing of metallic ores
US3151973A (en) * 1962-02-23 1964-10-06 Inland Steel Co Production of low sulfur iron
US3163521A (en) * 1961-08-02 1964-12-29 Voest Ag Process and apparatus for the recovery of liquid iron by reacting iron oxide ore
US3700221A (en) * 1968-12-27 1972-10-24 Vyzk Ustav Kovu Cyclone kiln system
US4007034A (en) * 1974-05-22 1977-02-08 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Method for making steel
US4235604A (en) * 1976-12-31 1980-11-25 Didier Engineering Gmbh Method for processing coke oven gas
US4605205A (en) * 1984-06-12 1986-08-12 Korf Engineering Gmbh Arrangement comprising a gasifier and a direct reduction furnace
EP0182992A3 (en) * 1984-10-27 1987-01-21 Man Gutehoffnungshutte Gmbh Low energy process for producing synthesis gas with a high methane content
US20050151307A1 (en) * 2003-09-30 2005-07-14 Ricardo Viramontes-Brown Method and apparatus for producing molten iron
US20110162381A1 (en) * 2010-01-05 2011-07-07 Thacker Pradeep S System and method for cooling syngas produced from a gasifier
US9109171B2 (en) 2013-11-15 2015-08-18 General Electric Company System and method for gasification and cooling syngas

Citations (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1112007A (en) * 1912-06-13 1914-09-29 Karl Albert Fredrik Hiorth Process of producing iron and steel directly from the ore
US1360711A (en) * 1918-10-24 1920-11-30 Basset Lucien Paul Process for the manufacture of iron and steel directly from the ore and improved apparatus therefor
US1401222A (en) * 1919-06-24 1921-12-27 Wiberg Frans Martin Method of and furnace for reducing ores and oxygen compounds utilized as ores
US1591470A (en) * 1922-08-22 1926-07-06 Constant Georges Reduction of ores with continuous regeneration and transformation of the residual gas produced during reduction into fresh reducing gas
US1984727A (en) * 1931-09-29 1934-12-18 Brown William Darke Sponge iron manufacture
US2057554A (en) * 1932-08-03 1936-10-13 James D Bradley Method of and apparatus for the reduction of oxide ores
US2068842A (en) * 1934-10-01 1937-01-26 James A Bradley Method and apparatus for the treatment of ores and the generation of gas
US2107549A (en) * 1933-12-12 1938-02-08 Schmalfeldt Hans Process for the reduction of fine iron ores
US2107980A (en) * 1936-03-16 1938-02-08 Elian John Method for preparing iron and steel
US2142100A (en) * 1936-06-12 1939-01-03 Little Inc A Production of sponge iron
US2243110A (en) * 1935-12-24 1941-05-27 Madaras Corp Method of and apparatus for reducing ores and effecting other chemical reactions
US2526658A (en) * 1943-11-25 1950-10-24 Harman L A Process for smelting iron ore
US2538201A (en) * 1944-08-17 1951-01-16 Inland Steel Co Method of reducing metallic oxides
US2547685A (en) * 1947-11-25 1951-04-03 Brassert & Co Reduction of metallic oxides
US2577730A (en) * 1949-06-24 1951-12-11 Hydrocarbon Research Inc Iron oxide reduction
US2598735A (en) * 1948-07-16 1952-06-03 Hydrocarbon Research Inc Iron oxide reduction
US2650160A (en) * 1949-02-05 1953-08-25 Koppers Co Inc Production of iron sponge from iron ore
US2653088A (en) * 1951-08-09 1953-09-22 Robert D Pike Direct production of steel from oxides of iron
US2750276A (en) * 1952-01-04 1956-06-12 Armco Steel Corp Method and apparatus for smelting fine iron ore
US2750277A (en) * 1951-05-14 1956-06-12 Armco Steel Corp Process and apparatus for reducing and smelting iron

Patent Citations (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1112007A (en) * 1912-06-13 1914-09-29 Karl Albert Fredrik Hiorth Process of producing iron and steel directly from the ore
US1360711A (en) * 1918-10-24 1920-11-30 Basset Lucien Paul Process for the manufacture of iron and steel directly from the ore and improved apparatus therefor
US1401222A (en) * 1919-06-24 1921-12-27 Wiberg Frans Martin Method of and furnace for reducing ores and oxygen compounds utilized as ores
US1591470A (en) * 1922-08-22 1926-07-06 Constant Georges Reduction of ores with continuous regeneration and transformation of the residual gas produced during reduction into fresh reducing gas
US1984727A (en) * 1931-09-29 1934-12-18 Brown William Darke Sponge iron manufacture
US2057554A (en) * 1932-08-03 1936-10-13 James D Bradley Method of and apparatus for the reduction of oxide ores
US2107549A (en) * 1933-12-12 1938-02-08 Schmalfeldt Hans Process for the reduction of fine iron ores
US2068842A (en) * 1934-10-01 1937-01-26 James A Bradley Method and apparatus for the treatment of ores and the generation of gas
US2243110A (en) * 1935-12-24 1941-05-27 Madaras Corp Method of and apparatus for reducing ores and effecting other chemical reactions
US2107980A (en) * 1936-03-16 1938-02-08 Elian John Method for preparing iron and steel
US2142100A (en) * 1936-06-12 1939-01-03 Little Inc A Production of sponge iron
US2526658A (en) * 1943-11-25 1950-10-24 Harman L A Process for smelting iron ore
US2538201A (en) * 1944-08-17 1951-01-16 Inland Steel Co Method of reducing metallic oxides
US2547685A (en) * 1947-11-25 1951-04-03 Brassert & Co Reduction of metallic oxides
US2598735A (en) * 1948-07-16 1952-06-03 Hydrocarbon Research Inc Iron oxide reduction
US2650160A (en) * 1949-02-05 1953-08-25 Koppers Co Inc Production of iron sponge from iron ore
US2577730A (en) * 1949-06-24 1951-12-11 Hydrocarbon Research Inc Iron oxide reduction
US2750277A (en) * 1951-05-14 1956-06-12 Armco Steel Corp Process and apparatus for reducing and smelting iron
US2653088A (en) * 1951-08-09 1953-09-22 Robert D Pike Direct production of steel from oxides of iron
US2750276A (en) * 1952-01-04 1956-06-12 Armco Steel Corp Method and apparatus for smelting fine iron ore

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3028231A (en) * 1959-01-01 1962-04-03 British Iron Steel Research Processing of metallic ores
US3163521A (en) * 1961-08-02 1964-12-29 Voest Ag Process and apparatus for the recovery of liquid iron by reacting iron oxide ore
US3151973A (en) * 1962-02-23 1964-10-06 Inland Steel Co Production of low sulfur iron
US3700221A (en) * 1968-12-27 1972-10-24 Vyzk Ustav Kovu Cyclone kiln system
US4007034A (en) * 1974-05-22 1977-02-08 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Method for making steel
US4235604A (en) * 1976-12-31 1980-11-25 Didier Engineering Gmbh Method for processing coke oven gas
US4605205A (en) * 1984-06-12 1986-08-12 Korf Engineering Gmbh Arrangement comprising a gasifier and a direct reduction furnace
EP0182992A3 (en) * 1984-10-27 1987-01-21 Man Gutehoffnungshutte Gmbh Low energy process for producing synthesis gas with a high methane content
US20050151307A1 (en) * 2003-09-30 2005-07-14 Ricardo Viramontes-Brown Method and apparatus for producing molten iron
US20110162381A1 (en) * 2010-01-05 2011-07-07 Thacker Pradeep S System and method for cooling syngas produced from a gasifier
US8769964B2 (en) * 2010-01-05 2014-07-08 General Electric Company System and method for cooling syngas produced from a gasifier
US9109171B2 (en) 2013-11-15 2015-08-18 General Electric Company System and method for gasification and cooling syngas

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Publication number Publication date
CH378921A (de) 1964-06-30

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