WO2022262812A1 - 一种基于带式焙烧机的预还原球团制备装置及方法 - Google Patents

一种基于带式焙烧机的预还原球团制备装置及方法 Download PDF

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Publication number
WO2022262812A1
WO2022262812A1 PCT/CN2022/099170 CN2022099170W WO2022262812A1 WO 2022262812 A1 WO2022262812 A1 WO 2022262812A1 CN 2022099170 W CN2022099170 W CN 2022099170W WO 2022262812 A1 WO2022262812 A1 WO 2022262812A1
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Prior art keywords
pellets
hydrogen
shaft furnace
gas
based shaft
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PCT/CN2022/099170
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English (en)
French (fr)
Inventor
李建
毛晓明
徐万仁
熊林
许海法
沈海嘉
刘思阳
刘峰
尤益峰
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Baoshan Iron and Steel Co Ltd
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Baoshan Iron and Steel Co Ltd
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Priority to BR112023026315A priority Critical patent/BR112023026315A2/pt
Priority to EP22824285.5A priority patent/EP4335940A4/en
Publication of WO2022262812A1 publication Critical patent/WO2022262812A1/zh
Anticipated expiration legal-status Critical
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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
    • C21B13/14—Multi-stage processes processes carried out in different vessels or 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
    • C21B13/0046—Making spongy iron or liquid steel, by direct processes making metallised agglomerates or iron oxide
    • 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
    • C21B13/02—Making spongy iron or liquid steel, by direct processes in shaft 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
    • C21B13/02—Making spongy iron or liquid steel, by direct processes in shaft furnaces
    • C21B13/029—Introducing coolant gas in the shaft furnaces
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/16—Sintering; Agglomerating
    • C22B1/20—Sintering; Agglomerating in sintering machines with movable grates
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/16—Sintering; Agglomerating
    • C22B1/22—Sintering; Agglomerating in other sintering apparatus
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C22B1/2406—Binding; Briquetting ; Granulating pelletizing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C22B1/2413—Binding; Briquetting ; Granulating enduration of pellets
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C22B1/242—Binding; Briquetting ; Granulating with binders
    • C22B1/243—Binding; Briquetting ; Granulating with binders inorganic
    • 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
    • F27B19/00—Combinations of different kinds of furnaces that are not all covered by any single one of main groups F27B1/00 - F27B17/00
    • 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
    • F27B19/00—Combinations of different kinds of furnaces that are not all covered by any single one of main groups F27B1/00 - F27B17/00
    • F27B19/04—Combinations 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
    • 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
    • F27B21/00—Open or uncovered sintering apparatus; Other heat-treatment apparatus of like construction
    • F27B21/06—Endless-strand sintering machines
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/20—Increasing the gas reduction potential of recycled exhaust gases
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/40—Gas purification of exhaust gases to be recirculated or used in other metallurgical processes
    • C21B2100/44—Removing particles, e.g. by scrubbing, dedusting
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/60—Process control or energy utilisation in the manufacture of iron or steel
    • C21B2100/66—Heat exchange
    • 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
    • Y02P10/143—Reduction of greenhouse gas [GHG] emissions of methane [CH4]

Definitions

  • the disclosure belongs to the pretreatment technology of ferrous metallurgical raw materials in the field of iron and steel smelting, and in particular relates to a pre-reduction pellet preparation device and method.
  • Chinese patent CN103261446B discloses a production of direct reduction with a reducing gas source containing hydrogen and CO Iron method and device, using the reduction gas containing CO and hydrogen and high oxidation (CO 2 and H 2 O) prepared by coal gas to produce DRI (direct reduced iron), breaking through the previous gas-based direct reduction shaft furnace using natural gas limit.
  • Chinese patent CN 103608468B discloses a system and method for reducing iron oxide to metallic iron by using coke oven gas and oxygen steelmaking furnace gas, so that the gas inside long-process iron and steel enterprises can be used to produce direct reduced iron, which solves the problem of natural gas shortage areas The bottleneck of developing direct reduced iron.
  • Publication No. CN105408500A discloses a method of using natural gas to reduce iron oxide to metallic iron, converting purified or raw natural gas, purified or polluted coke oven gas, etc. Reducing gas/synthesis gas; hydrocarbons etc. are converted to H2 and CO due to reduction. Its typical feature is that iron oxide is added to the shaft furnace at room temperature, and the gas is converted and heated as reducing gas, and the high temperature required for the reaction is provided. In order to solve the problem of low utilization rate, the circulation method is adopted, and the purification, heating and circulation are repeated. .
  • Chinese patent CN103898265B discloses a coke oven gas upgrading direct reduction iron ore system device and method, using the coke oven gas produced in the coking process to transform it into hydrogen-rich reducing gas ( H2 and CO), and then Introduce it into the shaft furnace to directly reduce iron ore; this technology can reduce carbon dioxide emissions in the iron ore reduction process, which is different from the route of natural gas for direct reduction of iron, and can better adapt to the characteristics of China's energy resources.
  • H2 and CO hydrogen-rich reducing gas
  • Publication No. CN110484672A discloses a method for producing direct reduced iron in a gas-based shaft furnace.
  • the method for producing direct-reduced iron in a gas-based shaft furnace utilizes the budol reaction of crushed coke and CO under the blast furnace sieve to absorb heat, which can effectively reduce The temperature in the shaft furnace can reduce the thermal junction of the charge, and at the same time effectively use the reduction exothermic energy to improve the overall energy utilization rate.
  • the generated CO increases the reduction potential in the furnace and promotes the reduction of iron ore, which is conducive to promoting the direct production of gas-based shaft furnace.
  • the application of iron ore reduction technology; its iron ore is pellet or lump ore, and a mixture of both.
  • the above-mentioned technology uses a shaft furnace as the reduction device, which has the advantages of large processing capacity and high efficiency.
  • the iron ore After the iron ore is added to Luding at room temperature, it exchanges heat with the high-temperature reducing gas, raises the temperature and reaches the temperature required for reduction, and gradually reduces to a higher temperature.
  • Metallization rate and then used as the raw material of electric furnace, with scrap steel, to obtain molten steel; but this kind of processing method has inherent thermodynamic limitations, mainly because of the large specific heat capacity of iron oxide, and after reforming with natural gas or coke oven gas, mainly with hydrogen As a reducing agent, a large amount of heat is absorbed during the reduction process, and it is difficult to maintain the reduction temperature.
  • the gas needs to be heated and circulated for many times.
  • the utilization rate of hydrogen is relatively low, usually about 30%, so that the gas base can
  • the reduction process is difficult to promote worldwide, and it has only developed in countries such as the Middle East and South America where natural gas is cheap.
  • Chinese patent CN107304460B discloses a method and device for pre-reduction sintering of iron ore, which is improved by adopting traditional sintering process. 1) Prepare traditional mixture: iron ore Stone powder, flux and fuel are used for raw material batching, mixing, and granulation to obtain traditional mixture; 2) Preparation of pre-reduced mixture: mix iron ore powder, additives and fuel and then pelletize to obtain pellets with internal carbon; The pellets with carbon inside are placed in a cylinder mixer, and fuel fine powder and quicklime or slaked lime are added to coat and granulate to obtain a pre-reduced mixture; The obtained pre-reduction mixture is placed on the sintering machine trolley in advance, and the traditional mixture prepared in step 1) is placed on the pre-reduction mixture; 4) sintering: ignition, the traditional mixture and the pre-reduction mixture are placed on the sintering machine Carry out flue gas circulation sintering.
  • Chinese patent CN103290159B discloses a method for producing direct reduction iron powder by microwave heating, using 60-73% of iron raw material, 22-30% of coal coke reducing agent, 3-7% of desulfurizer, and 2-3% of bentonite; mixed with water , pelletizing, and sieving to obtain raw pellets with a diameter of 10-15mm; after drying, send them to a microwave heating furnace to heat up to 1050-1150°C, and reduce for 160-180min to obtain metallized pellets; after crushing and grinding Fine powder with a particle size of less than 0.2mm; direct reduced iron powder obtained by magnetic separation; this technology overcomes the long reduction time, difficult control of product quality, and large investment in the production of direct reduced iron by the coal-based tunnel kiln canned external carbon method. Large floor area and other shortcomings, but the industrial microwave oven in this technology is for charging trays, intermittent production, and production efficiency has not been introduced.
  • Publication No. CN112159880A discloses a hydrogen ironmaking method and device, using iron-containing raw pellets in a hydrogen or hydrogen-rich gas atmosphere, using microwave irradiation to achieve hydrogen-rich or pure hydrogen smelting of iron-containing ores to obtain direct reduced iron.
  • microwaves are used to provide the heat source
  • pure hydrogen or hydrogen-rich gas is used as the reducing agent
  • the sample is placed in the crucible.
  • the kg-scale microwave oven is used as the core equipment, and the processing scale is limited.
  • These technologies use cloth or microwaves as heat sources, which can solve the disadvantages of mutual interference between heating and reduction and difficult control in the traditional reduction process.
  • these solutions still achieve the above two functions on the same set of equipment, the process reliability and production There are still relatively large challenges in terms of scale and continuity, which affect the implementation and application of the above-mentioned schemes.
  • the purpose of the present disclosure is to provide a pre-reduced pellet preparation device and method, by organically combining the roasting of iron-containing raw pellets with the reduction of the pellets, canceling the cooling process of the pellets after roasting and
  • the heating process before the reduction of the pellets uses the physical heat of the pellets after roasting to meet the heat required for the reduction process, which solves the problem of low hydrogen utilization in the traditional direct reduction process and the energy loss of the pellets during the oxidation roasting and direct reduction processes. Due to the high energy consumption, the pellets in the upper and lower layers of the traditional oxidized pellet belt roasting machine have technical problems such as uneven heat under high temperature conditions, resulting in uneven pellet quality.
  • the prepared pre-reduced pellets are used as blast furnace/converter/electric furnace The furnace charge can greatly reduce the fuel consumption and carbon emissions of the traditional steel process, and create favorable conditions for the green development of the traditional process.
  • the first aspect of the present disclosure provides a pre-reduced pellet preparation device, including a belt roaster system and a hydrogen-based shaft furnace reduction system;
  • the belt roaster system is sequentially provided with a drying section I, a drying section II, a preheating section I, a preheating section II and a roasting section along the moving direction of the green pellets containing iron.
  • the iron green pellets are dried and preheated in sequence to obtain preheated pellets, and in the roasting section, the preheated pellets are roasted at a temperature of 1170-1270° C. to obtain roasted pellets;
  • the roasting section adopts microwave electric heating;
  • the hydrogen-based shaft furnace reduction system includes a hydrogen-based shaft furnace, a feeding system, a reducing gas system, a cooling system, and a discharging system;
  • the roasted pellets of the machine system are directly transported to the feeding system;
  • the reducing gas system processes the flue gas from the hydrogen-based shaft furnace, and provides the hydrogen-based shaft furnace with the reducing gas required for reduction treatment;
  • the cooling system is used to cool the pre-reduced pellets of the hydrogen-based shaft furnace to obtain cooled pre-reduced pellets;
  • the discharge system is arranged at the bottom of the hydrogen-based shaft furnace to discharge the cooled pre-reduced pellets.
  • the preheating section II is heated by fuel and communicated with the drying section II through a first reheating fan;
  • the preheating stage I is connected to the tube heat exchanger of the reducing gas system, and is connected to the preheating stage II through a combustion-supporting fan, and the preheating stage I is also connected to the drying Section I connection;
  • Both the drying section I and the drying section II are connected to the bag filter through the main exhaust fan.
  • the feeding system includes an upper hopper, a middle hopper and a lower hopper; a valve is provided between the upper hopper, the middle hopper and the lower hopper; and/or
  • the reducing gas system includes a tube heat exchanger, a waste heat boiler, a first scrubber, a circulation fan and a pressurized fan;
  • the tube heat exchanger is provided with a flue gas inlet, a flue gas outlet, an air inlet and an air outlet , the flue gas inlet is connected to the flue gas port on the top of the hydrogen-based shaft furnace, the flue gas outlet is connected to the waste heat boiler, the air inlet is connected to the heat exchange fan, and the air outlet is connected to the belt
  • the preheating section I of the type roaster system is connected; the gas outlet of the waste heat boiler is connected to the air inlet of the first scrubber; one end of the circulating fan is connected to the gas outlet of the first scrubber, and the other end is communicate with the annular tuyere in the middle of the hydrogen-based shaft furnace; the pressurized fan pressurizes the reducing gas from the circulating fan; and/or
  • the cooling system includes a supplementary oxygen combustion unit, a waste heat recovery unit, a second scrubber and a cooling fan; the supplementary oxygen combustion unit is connected to the gas outlet at the lower part of the hydrogen-based shaft furnace; one end of the waste heat recovery unit is connected to the The oxygen-supplementing combustion unit is connected, and the other end is connected with the air inlet of the second scrubber; one end of the cooling fan is connected with the gas outlet of the second scrubber, and the other end is connected with the inlet of the lower part of the hydrogen-based shaft furnace.
  • the air port is connected; the air outlet is arranged on the upper part of the air inlet.
  • the upper hopper is provided with an air duct; the middle hopper is provided with a pressure equalizing device; and the lower hopper is provided with a universal distributor.
  • the second aspect of the present disclosure provides a method for preparing pre-reduced pellets.
  • the pre-reduced pellet preparation method uses the pre-reduced pellet preparation device described in the first aspect of the present disclosure.
  • the pellets are roasted at a temperature of 1170-1270°C in the belt roaster system to obtain roasted pellets, and then the roasted pellets are directly sent to the hydrogen-based shaft furnace reduction of the pre-reduced pellet preparation device Reduction is carried out in the system to obtain pre-reduced pellets.
  • the method for preparing pre-reduced pellets comprises the following steps:
  • the iron ore raw material is selected from one or more of magnetite, hematite and limonite; and/or
  • the dosage of the bentonite is 0.7-1.5wt% of the iron ore raw material; and/or
  • the binary alkalinity of the mixed material is 0.3-0.5 or 0.8-1.2; and/or
  • the particle size of the iron-containing raw pellets is 8-20mm; and/or
  • the belt roaster system is covered with a bottom material, the thickness of the bottom material is 80-100 mm, and after loading the iron-containing green balls, a material with a total height of 300-400 mm is formed. layers; and/or
  • the blast drying is carried out in the drying section I of the belt roaster system, the blast drying temperature is 170-240°C, the wind speed is 0.8-1.4m/s, and the drying time is 1.5-2.5min; and/or
  • the draft drying is carried out in the drying section II of the belt roaster system, the draft drying temperature is 300-400°C, the wind speed is 0.8-1.4m/s, and the drying time is 4-6min; and/or
  • the first-level preheating is carried out in the preheating section I of the belt roaster system, the first-level preheating temperature is 600-800°C, the wind speed is 0.8-1.4m/s, and the first-level preheating time is 4-6min ;and / or
  • the secondary preheating is carried out in the preheating section II of the belt roaster system, the secondary preheating temperature is 900-1100°C, the wind speed is 0.8-1.4m/s, and the secondary preheating time is 4-6min ;and / or
  • the fuel for the secondary preheating includes natural gas, coke oven gas, cracked gas, pyrolysis oil, biomass oil or biomass carbon; and/or
  • the secondary preheating adopts hot air to support combustion, and the hot air comes from a mixed gas composed of air and hot exhaust gas from the preheating section I; and/or
  • step (1) when the iron ore raw material contains magnetite, air is added above the mixed material to control the oxygen content to be greater than 14%; and/or
  • the calcination temperature is 1170-1270°C, and the calcination time is 8-12min; and/or
  • the pressure of the hydrogen-based shaft furnace of the hydrogen-based shaft furnace reduction system is 200-250kPa; and/or
  • the reducing gas adopts pure hydrogen or coke oven gas
  • the reduction gas consumption is 800-1200m 3 /t, and the reduction reaction time is 40-100min; and/or
  • the cooling gas adopts nitrogen and natural gas; and/or
  • the cooling air flow rate is 1200-1800m 3 /t; and/or
  • the discharge temperature of the pre-reduced pellets is lower than 150°C; and/or
  • the metallization ratio of the pre-reduced pellets is ⁇ 40%.
  • the blast drying temperature is 190-210°C, and the wind speed is 0.9-1.2m/s; and/or
  • the air drying temperature is 330-350°C, and the wind speed is 0.9-1.2m/s; and/or
  • the wind speed is 0.9-1.2m/s.
  • the wind speed is 0.9-1.2m/s.
  • the metallization rate of the pre-reduced pellets is 40-66%;
  • the reducing gas is pure hydrogen, and the hydrogen utilization rate reaches more than 50% during the reduction reaction process.
  • the reducing gas is pure hydrogen, and the hydrogen utilization rate reaches more than 60% during the reduction reaction; and/or
  • the roasted pellets are transported to the feeding system of the hydrogen-based shaft furnace reduction system through a high-temperature resistant material tank, and then distributed through the feeding system into the hydrogen-based shaft furnace of the hydrogen-based shaft furnace reduction system , participating in the reduction reaction in the middle of the hydrogen-based shaft furnace;
  • the reducing gas enters the hydrogen-based shaft furnace through the reducing gas system to participate in the reduction reaction, and the flue gas after the reaction enters the reducing gas system from the flue gas outlet at the top of the hydrogen-based shaft furnace, and undergoes heat exchange, waste heat recovery, After washing, enter the middle part of the hydrogen-based shaft furnace to participate in the reduction reaction;
  • the cooling gas enters the hydrogen-based shaft furnace through the cooling system to participate in the cooling treatment, and the treated mixed gas enters the cooling system from the gas outlet at the lower part of the hydrogen-based shaft furnace, and after oxygen-supplementing combustion, waste heat recovery and washing, Then enter the lower part of the hydrogen-based shaft furnace to participate in cooling treatment.
  • the distributing method of the feeding system is:
  • the roasted pellets After the roasted pellets enter the feeding system, they pass through the upper hopper, middle hopper and lower hopper of the feeding system in turn, and then are distributed into the hydrogen-based shaft furnace through a universal distributor;
  • the valve below the upper hopper is opened, and the roasted pellets Completely enter the middle hopper, close the valve below the upper hopper, and use the same gas composition as the hydrogen-based shaft furnace inner top gas to complete the pressure equalization process.
  • the pressure equalization is completed, open the middle hopper
  • the valve below the middle hopper close the valve below the middle hopper, open the valve at the lower part of the lower hopper, and distribute the roasted pellets into the hydrogen base In the shaft furnace.
  • the device and method for preparing pre-reduced pellets organically combines the roasting of iron-containing raw pellets with the reduction of pellets, cancels the cooling process of pellets after roasting and the heating process of pellets before reduction, and utilizes the The physical heat of the pellets meets the heat required for the reduction process, which solves the problem of low hydrogen utilization rate in the traditional direct reduction process and high energy consumption of the pellets in the process of oxidative roasting and direct reduction, and the traditional belt-type oxidized pellets
  • the pellets in the upper and lower material layers of the roasting machine have technical problems such as uneven heat due to uneven heat at high temperature.
  • the prepared pre-reduced pellets can be used as the charge of blast furnace/converter/electric furnace, which can greatly reduce the cost of traditional steel process. Fuel consumption and carbon emissions, creating favorable conditions for the green development of traditional processes;
  • the device and method for preparing pre-reduced pellets organically combines the roasting process of iron-containing raw pellets with pellet reduction, cancels the pellet cooling process and the heating process of reduction, and uses pure hydrogen or hydrogen-rich gas to cool Reduction, the process is more concise, and the energy utilization efficiency is improved;
  • the device and method for preparing pre-reduced pellets utilizes the physical heat of the pellets after roasting to meet the heat required for hydrogen reduction and gas temperature rise, making the thermodynamic conditions for hydrogen reduction more reasonable and greatly improving hydrogen utilization. ;
  • the device and method for preparing pre-reduced pellets utilizes the characteristics of large microwave penetration depth, good temperature uniformity, and overall heating, and is used for pellet roasting, so that the kinetic conditions of hydrogen reduction of pellets are better , which is conducive to improving the quality of pre-reduced pellets and increasing the speed of reduction reaction;
  • the device and method for preparing pre-reduced pellets uses microwave electric heating to realize the roasting of iron-containing pellets, which can reduce the roasting temperature of pellets and reduce the generation of NO X pollutants during the preparation of pre-oxidized pellets.
  • the environment is more friendly;
  • the device and method for preparing pre-reduced pellets uses non-fossil energy such as pyrolysis gas, pyrolysis oil, and biomass oil for combustion in the whole process, microwave electric heating generated by green electricity, and reduction of pure hydrogen or hydrogen-rich gas. way, which can realize the production of pre-reduced pellets in a carbon-free or low-carbon process;
  • non-fossil energy such as pyrolysis gas, pyrolysis oil, and biomass oil for combustion in the whole process, microwave electric heating generated by green electricity, and reduction of pure hydrogen or hydrogen-rich gas.
  • the device and method for preparing pre-reduced pellets uses the physical heat of the pellets after roasting to meet the heat required for hydrogen reduction and heating, simplifies the roasting and reduction process of iron-containing pellets, and improves the hydrogen utilization rate.
  • the prepared pre-reduced pellets are used as blast furnace charge, which can greatly reduce blast furnace fuel consumption and carbon emissions. It is a new low-carbon and green pre-reduced pellet preparation process.
  • FIG. 1 is a schematic structural diagram of a pre-reduced pellet preparation device based on a belt roaster of the present disclosure.
  • the pre-reduction pellet preparation device includes a belt roaster system 1 and a hydrogen-based shaft furnace reduction system 2;
  • the belt roaster system 1 is used to dry, preheat, and roast iron-containing green balls in sequence; the belt roaster system 1 is provided with drying section I, Drying stage II, preheating stage I, preheating stage II and roasting stage A; wherein the roasting stage A is heated by microwave electric heating, and in a further preferred scheme, the preheating stage II is heated by fuel, and the preheating stage II passes through the first
  • the reheating fan 14 is connected to the drying section II; the preheating section I is connected to the tubular heat exchanger 235 of the reducing gas system 23, the preheating section I is connected to the preheating section II through the combustion-supporting fan 16, and the preheating section I passes through
  • the second heat recovery fan 15 is connected to the drying section I; the drying section I and the drying section II are connected to the bag filter 12 through the main exhaust fan 11 .
  • the roasted pellets obtained after roasting in the belt roaster system 1 are transported to the feeding system 21 of the hydrogen-based shaft furnace reduction system 2 through the high
  • the hydrogen-based shaft furnace reduction system 2 includes a hydrogen-based shaft furnace 22, a feeding system 21, a reducing gas system 23, a cooling system 24, and a discharge system, which are used to roast the belt roaster system 1 to obtain The roasted pellets are reduced;
  • the feeding system 21 is located on the top of the hydrogen-based shaft furnace 22, and receives the roasted pellets from the high-temperature resistant material tank 3;
  • the reducing gas system 23 provides the hydrogen-based shaft furnace 22 with the required gas Reducing gas, in addition, the reducing gas system 23 can also handle the flue gas produced by the reduction reaction in the hydrogen-based shaft furnace 22; in the hydrogen-based shaft furnace 22, the calcined pellets from the feeding system 21 are reduced to obtain Pre-reduced pellets;
  • the cooling system 24 provides cooling gas required for cooling treatment, used for cooling the pre-reduced pellets to obtain cooled pre-reduced pellets, and can also process the mixed gas generated after cooling; discharge The system is located at the bottom of the hydrogen-based shaft furnace 22 for dischar
  • the feeding system 21 includes an upper hopper 211, a middle hopper 212 and a lower hopper 213; in order to maintain a closed environment in each part of the hopper, a valve is provided between the upper hopper 211, the middle hopper 212 and the lower hopper 213.
  • a valve is provided between the upper hopper 211, the middle hopper 212 and the lower hopper 213.
  • the upper hopper 211 is also provided with ventilation Pipelines are convenient for introducing steam (preferably high temperature and high pressure) or nitrogen (preferably high temperature and high pressure) to replace the oxygen in the air.
  • the middle hopper 212 is equipped with a pressure equalization device, and the gas with the same composition as the top gas in the shaft furnace can be used to complete the pressure equalization process.
  • the bottom of the lower hopper 213 is provided with a universal distributor.
  • the reducing gas system 23 is used to provide the hydrogen-based shaft furnace 22 with the reducing gas required for the reduction reaction, which includes a tubular heat exchanger 235, a waste heat boiler 231, a first scrubber 232, and a circulating fan 233 And pressurized fan 234;
  • Tube heat exchanger 235 is provided with flue gas inlet, flue gas outlet, air inlet and air outlet, wherein the flue gas inlet is connected with the flue gas port on the top of the hydrogen-based shaft furnace 22, and the flue gas outlet It is connected to the waste heat boiler 231;
  • the air inlet is connected to the heat exchange fan 236, and the air outlet is connected to the preheating section I of the belt roaster system 1;
  • the other end of the waste heat boiler 231 is connected to the air inlet of the first scrubber 232, and the circulation
  • One end of the fan 233 is connected to the gas outlet of the first scrubber 232, and the other end is connected to the annular tuyere in the middle of the hydrogen
  • the cooling system 24 includes an oxygen-supplementing combustion unit 241, a waste heat recovery unit 242, a second scrubber 243, and a cooling fan 244;
  • the oxygen-supplementing combustion unit 241 is connected to the gas outlet at the bottom of the hydrogen-based shaft furnace 22; waste heat recovery One end of the unit 242 is connected with the supplementary oxygen combustion unit 241, and the other end is connected with the air inlet of the second scrubber 243;
  • the air inlet is connected; wherein the air outlet is arranged on the upper part of the air inlet; in specific use, the cooling gas enters from the air inlet at the bottom of the hydrogen-based shaft furnace 22, and the pre-reduced balls after the reduction reaction are placed in the lower part of the hydrogen-based shaft furnace 22
  • the mixed gas after the cooling treatment passes through the oxygen-supplementing combustion unit 241, the waste heat recovery unit 242 recovers waste heat, and the second scrubber 243 washes, and then passes through the lower part of the hydrogen-based shaft furnace 22 under the action of
  • the discharge system is used to discharge the cooled pre-reduced pellets.
  • the belt roaster-based pre-reduction pellet preparation method uses the above-mentioned pre-reduction pellet preparation device, the method is: put iron-containing raw pellets into the belt roaster system In 1, after roasting by microwave electric heating, it is directly sent to the hydrogen-based shaft furnace reduction system for reduction; specifically, the following steps are included:
  • the specific process is as follows: mix one or more of magnetite, hematite and limonite with Blaine specific surface area ⁇ 1500cm 2 /g after pretreatment by ball mill or high pressure roller mill to obtain iron ore raw material, and then mix Add bentonite, add finely ground limestone or slaked lime to obtain a mixed material with a binary alkalinity (CaO/SiO 2 ) of 0.3-0.5 or 0.8-1.2, wherein the amount of bentonite is 0.7-1.5wt% of the iron ore raw material, The binary alkalinity of the mixed material is adjusted by finely ground limestone or slaked lime, which needs to be determined according to the actual use; then an appropriate amount of water is added, and the particle size is 8-20mm obtained by pelletizing with a disc pelletizer or a cylinder pelletizer of iron-containing green balls.
  • Add bentonite add finely ground limestone or slaked lime to obtain a mixed material with a binary alkalinity (CaO/
  • the iron-containing green balls prepared in step (1) are placed on the trolley of the belt roaster system 1 where the bottom material is laid, the thickness of the bottom material is controlled to be 80-100mm, and the iron-containing green balls are loaded into Finally, a material layer with a total height of 300-400mm is formed; then it passes through the drying section I, drying section II, preheating section I, and preheating section II of the belt roaster system 1 in sequence, and is dried by blasting, exhausting, and a
  • the first-stage preheating and the second-stage preheating are used to obtain preheated pellets, and then roasted by microwave electric heating in the roasting section A of the belt roaster system 1;
  • the blast drying is carried out in the drying section I, and the hot waste gas from the preheating section I is used to blast the iron-containing green balls from the bottom of the material layer through the second reheating fan 15, and the blast drying temperature is controlled at 170-240°C , preferably 190-210°C; the wind speed is 0.8-1.4m/s, preferably 0.9-1.2m/s, and the drying time is 1.5-2.5min;
  • Suction drying is carried out in the drying section II.
  • the hot exhaust gas from the preheating section II is used to guide it above the material surface through the first reheating fan 14.
  • the ventilation drying temperature is adjusted according to the bursting temperature of the green pellets, and is controlled below the pellet bursting temperature. Below the temperature, the air drying temperature is 300-400°C, preferably 330-350°C, the wind speed is 0.8-1.4m/s, preferably 0.9-1.2m/s, and the drying time is 4-6min;
  • the first-level preheating is carried out in the preheating stage I.
  • the hot air comes from the heat exchange fan 236 and is obtained by heat exchange through the tube heat exchanger 235 of the reducing gas system 23.
  • the first-level preheating temperature is 600-800°C, and the wind speed is 0.8- 1.4m/s, preferably 0.9-1.2m/s, the primary preheating time is 4-6min;
  • Secondary preheating is carried out in the preheating section II, and the hot air is obtained by burning fuel, which can be combustible oil or gas, including natural gas, coke oven gas, pyrolysis gas, pyrolysis oil, biomass oil or biomass carbon,
  • the fuel is preferably pyrolysis gas, pyrolysis oil or gas from non-fossil energy sources such as biomass oil.
  • hot air is used to support the combustion.
  • the hot air comes from the mixed gas composed of air and hot exhaust gas from the preheating stage I. Control the secondary preheating temperature to 900-1100°C, the wind speed to 0.8-1.4m/s, preferably 0.9-1.2m/s, and the preheating time to 4-6min.
  • High-temperature roasting is carried out in the roasting section A. Microwave electric heating is used. There is no air flow through the material layer to maintain a high temperature state in the material layer. If magnetite is added to the iron-containing green balls, in order to ensure its complete oxidation, the material layer A small amount of air needs to be added to the top to make the oxygen content greater than 14%.
  • the iron-containing green balls can be heated rapidly during the roasting process, and the iron-containing pellets are inside and outside, and on the material layer. , The temperature uniformity of the middle and lower parts is better, the roasting temperature is controlled at 1170-1270°C, and further at 1250-1270°C, and the roasting time is 5-10min.
  • the pellets After roasting, the pellets enter the hydrogen-based shaft furnace reduction system 2, undergo a reduction reaction with the reducing gas, and then cool the cooling gas to obtain the cooled pre-reduced pellets: after roasting, the pellets enter through the high-temperature resistant material tank
  • the feeding system 21 of the hydrogen-based shaft furnace reduction system 2 enters the hydrogen-based shaft furnace 22 of the hydrogen-based shaft furnace reduction system 2 through the feeding system 21, and the reduction reaction is carried out in the middle of the hydrogen-based shaft furnace 22.
  • the reduction reaction Perform cooling treatment at the lower part of the hydrogen-based shaft furnace 22 to obtain cooled pre-reduced pellets; wherein the flue gas after the reduction reaction enters the reducing gas system 23 from the flue gas outlet at the top of the hydrogen-based shaft furnace 22, and undergoes heat exchange and waste heat recovery After washing, enter the middle part of the hydrogen-based shaft furnace 22 through the reducing gas system 23 to participate in the reduction reaction; the mixed gas after cooling treatment enters the cooling system 24 from the gas outlet at the bottom of the hydrogen-based shaft furnace 22, and undergoes oxygen-supplementing combustion, waste heat recovery, After washing, enter the bottom of the hydrogen-based shaft furnace 22 through the cooling system 24 to participate in cooling treatment: the specific process is as follows:
  • step (2) the calcined pellets prepared in step (2) enter the feeding system 21 of the hydrogen-based shaft furnace reduction system 2 through the high-temperature resistant material tank, and enter the upper hopper 211, the middle hopper 212 and the upper hopper of the feeding system 21 in turn.
  • the lower hopper 213 is then put into the hydrogen-based shaft furnace 22.
  • Cooling treatment After the pellets undergo reduction reaction after roasting, cooling gas is used in the lower part of the hydrogen-based shaft furnace 22 for cooling treatment, and the mixed gas after the cooling treatment enters the cooling system 24 from the gas outlet at the lower part of the hydrogen-based shaft furnace 22, Participate in the cooling process through the cooling system 24 through the lower air inlet of the hydrogen-based shaft furnace 22 after oxygen-enriched combustion, waste heat recovery, and washing; in the cooling process, nitrogen and natural gas (preferably a small amount) are used, and while cooling,
  • the reduced material contains sponge iron (DRI), which can catalyze the cracking of CH 4 and form a small amount of Fe 3 C to complete the carburizing process to prevent the re-oxidation of DRI; in the above process, the cooling air flow is 1200-1800m 3 / t.
  • DRI sponge iron
  • the cooling gas will bring out a small amount of H 2 .
  • the mixed gas is burned with supplementary oxygen, and then the waste heat is utilized. After that, the H 2 O is removed by the scrubber, and the mixture containing N 2 and Mixed gas with a small amount of CO 2 , the mixed gas is recycled; the final output of the hydrogen-based shaft furnace 22 is the cooled pre-reduced pellets, and the output temperature is lower than 150°C, and the metallization rate of the product is determined according to the requirements of the subsequent process .
  • the device and method for preparing pre-reduced pellets based on belt roaster of the present disclosure will be further introduced in conjunction with specific examples below; the device and method for preparing pre-reduced pellets based on belt roaster in the following embodiments adopt the above-mentioned device and method ;
  • the iron ore raw materials in Examples 1-5 are as shown in Table 1. Add bentonite and finely ground limestone to obtain a mixed material, add water to mix, and pelletize to obtain iron-containing green pellets, and then transfer them to the belt roaster system through sequential Blast drying, draft drying, primary preheating, secondary preheating, and calcination to obtain calcined pellets, the processing parameters of which are shown in Table 1;
  • the roasted pellets were transferred to a hydrogen-based shaft furnace reduction system for reduction, and after reduction with pure hydrogen or coke oven gas, pre-reduced pellets were obtained by cooling with nitrogen and methane and carburizing.
  • the reduction parameters are shown in Table 2 ;
  • Example 1 the binary alkalinity of the iron-containing raw pellets is 1.0, and the processing parameters in Table 1 are used to obtain high cold compressive strength of the pellets after roasting. After roasting, the pellets are cooled and reduced by pure hydrogen, and the hydrogen utilization The metallization rate of pre-reduced pellets obtained after cooling can reach 66%.
  • Example 2 the binary alkalinity of iron-containing raw pellets is 0.3, and the processing parameters in Table 1 are adopted. Because the ratio of magnetite is high, the preheating and roasting temperatures can be appropriately reduced, and the pellets are pure after roasting. Hydrogen cooling reduction has a hydrogen utilization rate of 62%, and the metallization rate of the pre-reduced pellets obtained after cooling can reach 55%.
  • Example 3 the binary basicity of iron-containing raw pellets is 0.9, and the processing parameters in Table 1 are adopted. After roasting, the pellets are cooled and reduced by pure hydrogen, and the hydrogen utilization rate is 65%. The pre-reduced pellets obtained after cooling The metallization rate can reach 62%.
  • Example 4 the binary alkalinity of the iron-containing raw balls is 0.4, and the processing parameters in Table 1 are adopted. Due to the reduction in the amount of alkaline flux (finely ground limestone powder), the preheating and roasting temperatures can be appropriately reduced, and the roasting After the pellets are cooled and reduced by pure hydrogen, the hydrogen utilization rate is 56%, and the metallization rate of the pre-reduced pellets obtained after cooling can reach 58%.
  • alkaline flux finely ground limestone powder
  • Example 5 the binary alkalinity of the iron-containing green pellets is 1.0, and the processing parameters in Table 1 are used to obtain high cold compressive strength of the pellets after roasting. CO and CH 4 react with H 2 O in water gas, and the hydrogen utilization rate is relatively lower than that of pure hydrogen. In this example, the hydrogen utilization rate is only 43%, and the metallization rate of pre-reduced pellets can reach 52%.
  • the device and method for preparing pre-reduced pellets based on a belt roaster organically combines the roasting of iron-containing raw pellets with the reduction of pellets, canceling the cooling process of pellets after roasting and the reduction of pellets.
  • the physical heat of the pellets after roasting is used to meet the heat required for the reduction process, which solves the problems of low hydrogen utilization rate and high energy consumption of pellets in the process of oxidation roasting and direct reduction in the traditional direct reduction process.
  • the prepared pre-reduced pellets are used as the charge of blast furnace/converter/electric furnace , can greatly reduce the fuel consumption and carbon emissions of the traditional iron and steel process, and create favorable conditions for the green development of the traditional process; organically combine the roasting process of iron-containing green pellets with pellet reduction, cancel pellet cooling and direct reduction of pellets During the heating process, pure hydrogen or hydrogen-rich gas is used for cooling and reduction, the process is more concise, and the energy utilization efficiency is improved; the physical heat of the pellets after roasting is used to meet the heat required for hydrogen reduction and gas temperature rise, making the thermodynamic conditions of hydrogen reduction more reasonable.
  • the use of microwave electric heating to realize iron-containing pellet roasting can reduce the roasting temperature of pellets, reduce the generation of NO X pollutants in the pre-oxidation pellet preparation process, and make the environment more friendly; the whole process adopts Combustion of non-fossil energy such as pyrolysis gas, pyrolysis oil, and biomass oil, microwave electric heating generated by green electricity, and reduction of pure hydrogen or hydrogen-rich gas can realize the production of pre-reduced pellets in a carbon-free or low-carbon process; after roasting The physical heat of pellets satisfies the heat required for hydrogen reduction and heating, simplifies the roasting and reduction process of iron-containing pellets, improves the utilization rate of hydrogen, and uses the prepared pre-reduced pellets as blast furnace charge, which can greatly reduce blast furnace fuel consumption and carbon It is a new low-carbon, green pre-reduced pellet preparation process.
  • non-fossil energy such as pyrolysis gas, pyrolysis oil, and biomass oil

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Abstract

本公开提供了一种预还原球团制备装置及方法，其中预还原球团制备装置包括带式焙烧机系统和氢基竖炉还原系统；该预还原球团制备方法通过将含铁生球的焙烧过程与还原过程有机结合，取消焙烧后球团冷却过程和球团还原前的升温过程，利用焙烧后球团的物理热满足加热和还原过程所需的热量，解决了传统的直接还原过程中，氢利用率偏低以及球团在氧化焙烧、直接还原过程中能耗偏高、传统的氧化球团带式焙烧机上下料层球团因高温状态下热量不均匀，带来的球团质量不均匀等技术难题，制备的预还原球团作为高炉炉料，可大幅度降低传统钢铁流程的燃料消耗和碳排放，为传统流程的绿色发展创造有利的条件。

Description

一种基于带式焙烧机的预还原球团制备装置及方法 技术领域
本公开属于钢铁冶炼领域的黑色金属冶金原材料预处理技术，尤其涉及一种预还原球团制备装置及方法。
背景技术
我国钢铁生产以高炉—转炉长流程工艺为主，受工艺特征限制，需使用大量以煤为主的化石能源，从而排放大量的温室气体；据统计，中国钢铁生产二氧化碳排放占社会排放总量的15％，是温室气体排放量较大的行业；随着全球工业化的发展，因温室气体集中排放带来的气候问题日益引人关注，中国作为《巴黎协定》的签署国，一直重视气候变化；近期习近平总书记于2020年9月22日在第七十五届联合国大会一般性辩论上向国际社会作出“碳达峰、碳中和”郑重承诺，12月12日，在气候雄心峰会上提出中国力争2030年碳达峰，2060年实现碳中和。
作为全流程重要的工序，炼铁的能源消耗和碳排放占全流程70-80％因此，如何降低炼铁流程的碳排放是解决钢铁行业绿色发展的关键；业内普遍认为，采用氢还原代替碳还原，是降低碳排放的重要技术方向，由于高炉内氢利用率偏低(≤30％)，采用富氢气体直接还原成为重点发展的技术方向。
根据米德雷克斯公司统计，2019年，全球直接还原铁产量首次突破1亿吨，达到1.081亿吨，比2018年增长7.3％；其中气基竖炉工艺产量占比74.1％，煤基回转窑工艺占比24％，其它工艺占比1.9％；现有的直接还原工艺通常采用氧化球团作为铁原料，煤、天然气或钢厂煤气作为还原剂和加热剂，将氧化球团加热至820-1050℃，然后进行还原，得到金属化球团或热压铁块，供电炉、转炉或高炉使用，相关专利如下：中国专利CN103261446B公开了一种用含氢和CO的还原气体源生产直接还原铁的方法和装置，使用煤制气制备的含有CO和氢的高氧化(CO 2和H 2O)的还原气体生产DRI(直接还原铁)，突破了以往气基直接还原竖炉使用天然气的限制。
中国专利CN 103608468B公开了一种使用焦炉气和氧气炼钢炉气将氧化铁还 原为金属铁的系统和方法，使得长流程钢铁企业内部的煤气可用于生产直接还原铁，解决了天然气匮乏区域发展直接还原铁的瓶颈。
公开号CN105408500A公开了一种使用天然气将氧化铁还原为金属铁的方法，将净化的或原料天然气、净化的或污染的焦炉气等以最低限度的处理或净化，转化为适用于直接还原的还原气/合成气；烃类等被转化为H 2和CO，由于还原。其典型特征为氧化铁为常温加入竖炉，气体通过转化、加热作为还原气，并提供反应所需的高温，为解决利用率偏低的难题，采用循环的方式，多次净化、加热、循环。
中国专利CN103898265B公开了一种焦炉煤气改质直接还原铁矿石系统装置及方法，利用炼焦过程产生的焦炉煤气，将其改质转化制成富氢还原气(H 2和CO)，然后将其引入竖炉直接还原铁矿石；该技术可以减少铁矿石还原过程中的二氧化碳排放，与天然气进行直接还原铁的路线不同，可更好的适用中国的能源资源特点。
公开号CN110484672A公开了一种气基竖炉生产直接还原铁的方法，采用气基竖炉生产直接还原铁的方法，利用高炉筛下碎焦与CO 2的布多尔反应吸收热量，可有效降低竖炉内温度，减少炉料热结产生，同时有效利用还原放热能量，提高了整体能量利用率，生成的CO提高了炉内还原势，促进了铁矿还原，有利于促进气基竖炉直接还原铁矿技术的应用；其铁矿石为球团或块矿，及两者的混合物。上述技术以竖炉作为还原装置，具有处理量大、效率高等优点，铁矿石常温加入泸定后，与高温还原气进行热交换、升温并达到还原所需的温度，逐步还原至较高的金属化率，然后作为电炉的原料，搭配废钢，得到钢水；但是此类处理方法存在固有的热力学限制环节，主要在于氧化铁的比热容大，加之以天然气或焦炉煤气重整后，主要以氢为还原剂，还原过程中大量吸热，其维持还原温度比较困难，因此需要对气体进行多次加热、循环，整个流程中，氢的利用率比较低，通常在30％左右，使得气基直接还原流程难以在世界范围内推广，只在天然气价格便宜的中东、南美等国家有一定发展。
也有一些研究者在布料、加热方式方面进行了创新：中国专利CN107304460B公开了一种铁矿石预还原烧结方法及其装置，采用传统的烧结工艺进行改进，1)制备传统混合料：将铁矿石粉、熔剂和燃料进行原料配料，混合，制粒，得到传统混合料；2)制备预还原混合料：将铁矿石粉、添加剂和燃料混匀后造球而获得内配碳的球团；将内配碳的球团放置在圆筒混合机中，加入燃料细粉和生石灰或消石灰， 进行裹覆制粒，得到预还原混合料；3)布料：采用双层布料方式，将步骤2)制得的预还原混合料预先放置在烧结机台车上，将步骤1)制得的传统混合料放置在预还原混合料上；4)烧结：点火，传统混合料和预还原混合料在烧结机上进行烟气循环式烧结。解决高CO烟气难以处理的问题，减少了预还原烧结矿还原过程的再次氧化，改善了料层间的燃烧气氛，提高物料的温度和加速了铁矿物料还原反应的发生。中国专利CN103290159B公开了一种微波加热生产直接还原铁粉的方法，采用铁原料60～73％，煤焦类还原剂22～30％，脱硫剂3～7％，膨润土2～3％；加水混合、造球、筛分，得球径为10～15mm的生球；干燥后，送入微波加热炉中升温至1050～1150℃，还原160～180min，得金属化球团；经破碎、磨细成粒度小于0.2mm的细粉；经磁选得直接还原铁粉；该技术克服煤基隧道窑罐装外配碳法生产直接还原铁工艺存在的还原时间长、产品质量难以控制、投资大，占地面积大等不足，但是该技术中的工业微波炉为料盘装料，间断生产，生产效率方面未介绍。
公开号CN112159880A公开了一种氢气炼铁的方法及装置，采用含铁生球在氢气或富氢气体气氛下，采用微波照射实现含铁矿石的富氢或纯氢冶炼，得到直接还原铁。该方案以微波提供热源，以纯氢或富氢气体为还原剂，将样品置于坩埚中，采用kg级规模的微波炉作为核心装备，处理规模有限。这些技术利用布料或以微波为热源，能解决传统还原过程中，加热和还原互相干扰，控制困难的弊端，但由于这些方案仍然在同一套装备上实现上述2个功能，过程的可靠性、生产规模、连续性方面仍存在比较大的挑战，影响上述方案的实施和应用。
鉴于上述情况，业界亟待研究新的球团烧结还原技术，能够解决传统的球团直接还原氢利用率偏低以及球团在氧化焙烧、直接还原过程中，加热(～1250℃)、冷却(～25℃)、再加热(820～1050℃)反复加热带来的能耗偏高、传统的氧化球团带式焙烧机上下料层球团因高温状态下热量不均匀，带来的球团质量不均匀等技术难题。
发明内容
针对现有技术中存在的上述缺陷，本公开的目的是提供一种预还原球团制备装置及方法，通过将含铁生球的焙烧与球团还原有机结合，取消焙烧后球团冷却过程和球团还原前的升温过程，利用焙烧后球团的物理热满足还原过程所需的热量，解决了传统的直接还原过程中，氢利用率偏低以及球团在氧化焙烧、直接还原过程中 能耗偏高、传统的氧化球团带式焙烧机上下料层球团因高温状态下热量不均匀，带来的球团质量不均匀等技术难题，制备的预还原球团作为高炉/转炉/电炉的炉料，可大幅度降低传统钢铁流程的燃料消耗和碳排放，为传统流程的绿色发展创造有利的条件。
为实现上述目的，本公开采用如下技术方案：
本公开的第一方面提供了一种预还原球团制备装置，包括带式焙烧机系统和氢基竖炉还原系统；
所述带式焙烧机系统沿含铁生球运动方向依次设有干燥Ⅰ段、干燥Ⅱ段、预热Ⅰ段、预热Ⅱ段和焙烧段，在所述带式焙烧机系统中，对含铁生球顺序进行干燥、预热，获得预热后的球团，以及在所述焙烧段中，在1170-1270℃的温度下对预热后的球团进行焙烧，获得焙烧后球团；所述焙烧段采用微波电加热；
所述氢基竖炉还原系统包括氢基竖炉、上料系统、还原气系统、冷却系统以及出料系统；所述上料系统设于所述氢基竖炉上部，来自所述带式焙烧机系统的焙烧后球团被直接输送到上料系统中；所述还原气系统处理来自所述氢基竖炉的烟气，以及为所述氢基竖炉提供还原处理所需的还原气；在所述氢基竖炉中对来自所述上料系统的焙烧后球团进行还原，获得预还原球团；所述冷却系统用于对所述氢基竖炉的预还原球团进行冷却处理，获得冷却后的预还原球团；所述出料系统设于所述氢基竖炉底部，排出冷却后的预还原球团。
优选地，所述预热Ⅱ段采用燃料加热，并通过第一回热风机与所述干燥Ⅱ段相连通；
所述预热Ⅰ段与所述还原气系统的管式换热器连接，并通过助燃风机与所述预热Ⅱ段连接，所述预热Ⅰ段还通过第二回热风机与所述干燥Ⅰ段连接；
所述干燥Ⅰ段、干燥Ⅱ段均通过主抽风机与布袋除尘器连接。
优选地，所述上料系统包括上部料斗、中部料斗以及下部料斗；所述上部料斗、中部料斗以及下部料斗之间均设有阀门；和/或
所述还原气系统包括管式换热器、余热锅炉、第一洗涤器、循环风机以及加压风机；所述管式换热器上设有烟气入口、烟气出口、空气入口和空气出口，所述烟气入口与所述氢基竖炉顶部的烟气口连接，所述烟气出口与所述余热锅炉连接，所述空气入口与换热风机连接，所述空气出口与所述带式焙烧机系统的预热Ⅰ段连接； 所述余热锅炉的出气口与所述第一洗涤器的进气口连接；所述循环风机一端与所述第一洗涤器的出气口连接，另一端与所述氢基竖炉中部的环形风口连通；所述加压风机为所述循环风机出来的还原气加压；和/或
所述冷却系统包括补氧燃烧单元、余热回收单元、第二洗涤器以及冷却风机；所述补氧燃烧单元与所述氢基竖炉下部的出气口连接；所述余热回收单元一端与所述补氧燃烧单元连接，另一端与所述第二洗涤器的进气口连接；所述冷却风机一端与所述第二洗涤器的出气口连接，另一端与所述氢基竖炉下部的进气口连通；所述出气口设于所述进气口上部。
优选地，所述上部料斗上设有通气管道；所述中部料斗上设有均压装置；所述下部料斗上设有万向布料器。
本公开的第二方面提供了一种预还原球团制备方法，该预还原球团制备方法使用本公开第一方面所述的预还原球团制备装置，在所述预还原球团制备装置的带式焙烧机系统中在1170-1270℃温度下对球团进行焙烧，获得焙烧后球团，然后将所述焙烧后球团直接送入所述预还原球团制备装置的氢基竖炉还原系统中进行还原，获得预还原球团。
优选地，所述预还原球团制备方法包括以下步骤：
(1)向铁矿石原料中配入膨润土和细磨石灰石/消石灰得到混合物料，然后加水混合，经造球制得含铁生球；
(2)将所述含铁生球置入所述带式焙烧机系统内，形成含铁生球料层，对含铁生球料层依次进行鼓风干燥、抽风干燥、一级预热、二级预热得到预热球团，然后使用微波电加热对所述预热球团在1170-1270℃的温度下进行焙烧，得到焙烧后球团；
(3)将所述焙烧后球团送入氢基竖炉还原系统中，使焙烧后球团与还原气发生还原反应，再经冷却气冷却处理后得到预还原球团。
优选地，所述步骤(1)中，所述铁矿石原料选自磁铁矿、赤铁矿和褐铁矿的一种或以上；和/或
铁矿石原料的勃氏比表面积≥1500cm 2/g；和/或
所述膨润土的配入量为所述铁矿石原料的0.7-1.5wt％；和/或
所述混合物料的二元碱度为0.3-0.5或0.8-1.2；和/或
所述含铁生球的粒度为8-20mm；和/或
所述步骤(2)中，所述带式焙烧机系统铺有底料，所述底料的厚度为80-100mm，装入所述含铁生球后，形成总高度为300-400mm的料层；和/或
所述鼓风干燥在所述带式焙烧机系统的干燥Ⅰ段进行，鼓风干燥温度为170-240℃，风速为0.8-1.4m/s，干燥时间为1.5-2.5min；和/或
所述抽风干燥在所述带式焙烧机系统的干燥Ⅱ段进行，抽风干燥温度为300-400℃，风速为0.8-1.4m/s，干燥时间为4-6min；和/或
所述一级预热在所述带式焙烧机系统的预热Ⅰ段进行，一级预热温度为600-800℃，风速为0.8-1.4m/s，一级预热时间为4-6min；和/或
所述二级预热在所述带式焙烧机系统的预热Ⅱ段进行，二级预热温度为900-1100℃，风速为0.8-1.4m/s，二级预热时间为4-6min；和/或
所述二级预热的燃料包括天然气、焦炉煤气、裂解气、热解油、生物质油或生物质碳；和/或
所述二级预热采用热风助燃，所述热风来自于空气和来自于预热I段的热废气所组成的混合气体；和/或
所述步骤(1)中，所述铁矿石原料中含有磁铁矿时，在所述混合物料上方补入空气，控制氧含量大于14％；和/或
所述焙烧过程中，焙烧温度为1170-1270℃，焙烧时间为8-12min；和/或
所述步骤(3)中，所述氢基竖炉还原系统的氢基竖炉的压力为200-250kPa；和/或
所述还原气采用纯氢或焦炉煤气；和/或
所述还原反应过程中，所述还原气的消耗量为800-1200m 3/t，还原反应时间为40-100min；和/或
所述冷却气采用氮气和天然气；和/或
所述冷却处理过程中，所述冷却气流量为1200-1800m 3/t；和/或
所述预还原球团的出料温度低于150℃；和/或
所述预还原球团的金属化率≥40％。
优选地，所述步骤(2)中，所述鼓风干燥过程中，鼓风干燥温度为190-210℃，风速为0.9-1.2m/s；和/或
所述抽风干燥过程中，抽风干燥温度为330-350℃，风速为0.9-1.2m/s；和/或
所述一级预热过程中，风速为0.9-1.2m/s；和/或
所述二级预热过程中，风速为0.9-1.2m/s；和/或
所述步骤(3)中，所述预还原球团的金属化率为40-66％；和/或
所述还原气为纯氢，所述还原反应过程中，氢利用率达到50％以上。
优选地，所述步骤(3)中，所述还原气为纯氢，所述还原反应过程中，氢利用率达到60％以上；和/或
所述焙烧后球团通过耐高温料罐输送至所述氢基竖炉还原系统的上料系统中，再经所述上料系统布料进入所述氢基竖炉还原系统的氢基竖炉中，在所述氢基竖炉的中部参与还原反应；
所述还原气通过还原气系统进入所述氢基竖炉中参与还原反应，反应后的烟气从所述氢基竖炉顶部的烟气出口进入还原气系统中，经换热、余热回收、洗涤后，再进入所述氢基竖炉的中部参与还原反应；
所述冷却气通过冷却系统进入所述氢基竖炉中参与冷却处理，处理后的混合气体从所述氢基竖炉下部的出气口进入冷却系统，经补氧燃烧、余热回收、洗涤后，再进入所述氢基竖炉的下部参与冷却处理。
优选地，所述步骤(3)中，所述上料系统的布料方式为：
所述焙烧后球团进入所述上料系统后，依次通过上料系统的上部料斗、中部料斗和下部料斗后，再通过万向布料器布入所述氢基竖炉中；
所述焙烧后球团装入所述上部料斗后，通入蒸汽或氮气进行置换，确保所述上部料斗内的氧含量≤1％后，打开所述上部料斗下方的阀门，所述焙烧后球团完全进入所述中部料斗中，关闭所述上部料斗下方的阀门，采用与所述氢基竖炉内顶煤气成分相同的煤气完成均压过程，所述均压完成后，打开所述中部料斗下方的阀门，所述焙烧后球团完全进入所述下部料斗后，关闭所述中部料斗下方的阀门，打开所述下部料斗下部的阀门，将所述焙烧后球团布入到所述氢基竖炉中。
本公开的有益效果为：
1、本公开所提供的预还原球团制备装置及方法，通过将含铁生球的焙烧与球团还原有机结合，取消焙烧后球团冷却过程和球团还原前的升温过程，利用焙烧后球团的物理热满足还原过程所需的热量，解决了传统的直接还原过程中，氢利用率 偏低以及球团在氧化焙烧、直接还原过程中能耗偏高、传统的氧化球团带式焙烧机上下料层球团因高温状态下热量不均匀，带来的球团质量不均匀等技术难题，制备的预还原球团作为高炉/转炉/电炉的炉料，可大幅度降低传统钢铁流程的燃料消耗和碳排放，为传统流程的绿色发展创造有利的条件；
2、本公开所提供的预还原球团制备装置及方法，将含铁生球的焙烧过程与球团还原有机结合，取消球团冷却过程和还原的升温过程，利用纯氢或富氢气体冷却还原，流程更简洁，能源利用效率提高；
3、本公开所提供的预还原球团制备装置及方法，利用焙烧后球团的物理热，满足氢还原和气体升温所需热量，使得氢还原热力学条件更合理，能大幅度提高氢利用率；
4、本公开所提供的预还原球团制备装置及方法，利用微波穿透深度大、温度均匀性好、整体加热的特点，用于球团焙烧，使得球团的氢还原动力学条件更优，有利于改善预还原球团的质量、提高还原反应的速度；
5、本公开所提供的预还原球团制备装置及方法，利用微波电加热实现含铁球团焙烧，可降低球团的焙烧温度，减少预氧化球团制备过程NO X类污染物的产生，环境更为友好；
6、本公开所提供的预还原球团制备装置及方法，全流程采用裂解气、热解油、生物质油等非化石能源燃烧，绿电产生微波电加热，纯氢或富氢气体还原的方式，可以实现无碳或低碳工艺生产预还原球团；
7、本公开所提供的预还原球团制备装置及方法，采用焙烧后球团物理热满足氢气还原和加热所需的热量，简化含铁球团焙烧和还原过程，提高了氢气利用率，将制备的预还原球团作为高炉炉料，可大幅度降低高炉燃料消耗和碳排放，是一种低碳、绿色的预还原球团制备新工艺。
附图说明
通过阅读参照以下附图对非限制性实施例所作的详细描述，本公开的其它特征、目的和优点将会变得更明显：
图1为本公开的基于带式焙烧机的预还原球团制备装置的结构示意图。
具体实施方式
为了能更好地理解本公开的上述技术方案，下面结合附图和实施例进一步说明本公开的技术方案。
结合图1所示，结合图1所示，本公开所提供的预还原球团制备装置，包括带式焙烧机系统1和氢基竖炉还原系统2；
结合图1所示，带式焙烧机系统1用于对含铁生球顺序进行干燥、预热、焙烧；该带式焙烧机系统1沿含铁生球运动方向上依次设有干燥Ⅰ段、干燥Ⅱ段、预热Ⅰ段、预热Ⅱ段和焙烧段A；其中焙烧段A采用微波电加热，在进一步的优选方案中，预热Ⅱ段采用燃料加热，该预热Ⅱ段通过第一回热风机14与干燥Ⅱ段相连通；预热Ⅰ段与还原气系统23的管式换热器235连接，该预热Ⅰ段通过助燃风机16与预热Ⅱ段连接，预热Ⅰ段通过第二回热风机15与干燥Ⅰ段连接；干燥Ⅰ段、干燥Ⅱ段通过主抽风机11与布袋除尘器12连接。带式焙烧机系统1焙烧后得到的焙烧后球团通过耐高温料罐3输送至氢基竖炉还原系统2的上料系统21中。
结合图1所示，氢基竖炉还原系统2包括氢基竖炉22、上料系统21、还原气系统23、冷却系统24以及出料系统，用于将经带式焙烧机系统1焙烧得到的焙烧后球团还原；上料系统21设于氢基竖炉22上部，接收来自耐高温料罐3的焙烧后球团；还原气系统23为氢基竖炉22提供还原反应中所需的还原气，另外该还原气系统23还可处理氢基竖炉22中还原反应所产生的烟气；在氢基竖炉22中对来自所述上料系统21的焙烧后球团进行还原，获得预还原球团；冷却系统24提供冷却处理所需的冷却气，用于对预还原球团进行冷却处理，获得冷却后的预还原球团，另外还可处理冷却后产生的混合气体；出料系统设于氢基竖炉22底部，用于排出冷却后的预还原球团。
结合图1所示，上料系统21包括上部料斗211、中部料斗212以及下部料斗213；为了便于各个部分料斗内保持封闭环境，上部料斗211、中部料斗212以及下部料斗213之间均设有阀门；在具体实施例中，上部料斗211内装入焙烧后球团(1170-1270℃之间，例如约1200℃)后，为了确保上部料斗211内氧含量≤1％，上部料斗211还设有通气管道，便于通入蒸汽(优选高温高压)或氮气(优选高温高压)置换空气中的氧气。为了保证中部料斗内压力均衡，中部料斗212上设有均压装置，可采用与竖炉内顶煤气成分相同的煤气完成均压过程。为了方便将焙烧后球团布入 氢基竖炉22中，下部料斗213的下方设有万向布料器。
结合图1所示，还原气系统23用于为氢基竖炉22提供提供还原反应所需的还原气，其包括管式换热器235、余热锅炉231、第一洗涤器232、循环风机233以及加压风机234；管式换热器235上设有烟气入口、烟气出口、空气入口和空气出口，其中烟气入口与与氢基竖炉22顶部的烟气口连接，烟气出口与余热锅炉231连接；空气入口与换热风机236连接，空气出口与带式焙烧机系统1的预热Ⅰ段连接；余热锅炉231的另一端与第一洗涤器232的进气口连接，循环风机233一端与第一洗涤器232的出气口，另一端与氢基竖炉22中部的环形风口连通；加压风机234为循环风机233出来的还原气加压；在具体使用时，还原气从氢基竖炉22的环形风口进入，在氢基竖炉22中部与来自上料系统21的焙烧后球团接触，还原气一边被焙烧后球团加热(吸收焙烧后球团的温度，将焙烧后球团冷却)，一边与焙烧后球团发生还原反应，反应后从氢基竖炉22顶部的烟气出口经管式换热器235换热、余热锅炉231回收余热、第一洗涤器232洗涤后，再在循环风机233和加压风机234作用下通过环形风口参与还原反应。
结合图1所示，冷却系统24包括补氧燃烧单元241、余热回收单元242、第二洗涤器243以及冷却风机244；补氧燃烧单元241与氢基竖炉22下部的出气口连接；余热回收单元242一端与补氧燃烧单元241连接，另一端与第二洗涤器243的进气口连接；冷却风机244一端与第二洗涤器243的出气口连接，另一端与氢基竖炉22下部的进气口连通；其中出气口设于进气口上部；在具体使用时，冷却气从氢基竖炉22下部的进气口进入，在氢基竖炉22下部将还原反应后的预还原球团冷却，冷却处理后的混合气体经补氧燃烧单元241补氧燃烧、余热回收单元242回收余热、第二洗涤器243洗涤后，再在冷却风机244的作用下通过氢基竖炉22下部的进气口参与冷却处理。
出料系统，将冷却后的预还原球团进行出料。
结合图1所示，本公开所提供的基于带式焙烧机的预还原球团制备方法，使用上述的预还原球团制备装置，该方法为：将含铁生球装入带式焙烧机系统1中，通过微波电加热进行焙烧后，直接送入氢基竖炉还原系统进行还原；具体包括以下步骤：
(1)向铁矿石原料中配入膨润土和细磨石灰石/消石灰得到混合物料，然后加 水混合，经造球后得到含铁生球；
具体过程如下：将球磨或高压辊磨预处理后的勃氏比表面积≥1500cm 2/g的磁铁矿、赤铁矿和褐铁矿中一种或以上进行混合得到铁矿石原料，然后配入膨润土，加入细磨石灰石或消石灰得到二元碱度(CaO/SiO 2)为0.3-0.5或0.8-1.2的混合物料，其中膨润土的配入量为铁矿石原料的0.7-1.5wt％，混合物料的二元碱度通过细磨石灰石或消石灰进行调节，需根据实际使用情况而定；然后加入适量水，通过圆盘造球机或圆筒造球机造球得到粒级为8-20mm的含铁生球。
(2)将含铁生球装入带式焙烧机系统1内，对含铁生球依次进行鼓风干燥、抽风干燥、一级预热、二级预热得到预热球团，然后对预热球团使用微波电加热在1170-1270℃的高温下焙烧后得到焙烧后球团；
具体过程如下：将步骤(1)中制备的含铁生球置于铺好底料的带式焙烧机系统1的台车上，控制底料的厚度为80-100mm，装入含铁生球后，形成总高度为300-400mm的料层；然后依次通过带式焙烧机系统1的干燥Ⅰ段、干燥Ⅱ段、预热Ⅰ段、预热Ⅱ段，通过鼓风干燥、抽风干燥、一级预热、二级预热得到预热球团，然后在带式焙烧机系统1的焙烧段A利用微波电加热进行焙烧；
其中鼓风干燥在干燥Ⅰ段中进行，利用来自预热Ⅰ段的热废气，通过第二回热风机15从料层底部鼓入含铁生球中，控制鼓风干燥温度为170-240℃，优选为190-210℃；风速为0.8-1.4m/s，优选为0.9-1.2m/s，干燥时间为1.5-2.5min；
抽风干燥在干燥Ⅱ段中进行，利用来自预热Ⅱ段的热废气，通过第一回热风机14引到料面上方，其中抽风干燥温度根据生球爆裂温度调节，控制在低于球团爆裂温度以下，抽风干燥温度为300-400℃，优选为330-350℃，风速为0.8-1.4m/s，优选为0.9-1.2m/s，干燥时间为4-6min；
一级预热在预热Ⅰ段中进行，热风来自于换热风机236通过还原气系统23的管式换热器235换热获得，一级预热温度为600-800℃，风速为0.8-1.4m/s，优选0.9-1.2m/s，一级预热时间为4-6min；
二级预热在预热Ⅱ段中进行，热风通过燃料燃烧获得，其中燃料可以是可燃油或可燃气，包括天然气、焦炉煤气、裂解气、热解油、生物质油或生物质碳，燃料优选裂解气、热解油或生物质油类非化石能源来源的气体，为提高燃烧温度，采用热风助燃，其中热风来自于空气和来自于预热Ⅰ段的热废气所组成的混合气体，控 制二级预热温度900-1100℃，风速0.8-1.4m/s，优选0.9-1.2m/s，预热时间为4-6min。
高温焙烧在焙烧段A中进行，采用微波电加热，料层中无气流穿透，以保持料层中高温状态，若含铁生球中配入磁铁矿，为保证其完全氧化，料层上方需补入少量空气，使氧含量大于14％；利用铁氧化物强吸波性和微波穿透性，使得含铁生球在焙烧过程中快速升温，且含铁球团内外、料层上、中、下部温度均匀性更好，控制焙烧温度为1170-1270℃，进一步为1250-1270℃，焙烧时间为5-10min，以焙烧后球团(烧结矿或团块)冷态抗压强度≥2200N/个为目标，调节微波功率，从而调节焙烧温度和焙烧时间；在带式焙烧机系统1内，含铁生球经鼓风干燥和抽风干燥后废气通过主抽风机11，经布袋除尘器12和除尘脱硫脱硝系统，满足超低排放标准后，通过烟囱13外排。
(3)焙烧后球团进入氢基竖炉还原系统2中，与还原气发生还原反应，再经冷却气冷却处理后得到冷却后的预还原球团：焙烧后球团通过耐高温料罐进入氢基竖炉还原系统2的上料系统21，然后通过上料系统21进入氢基竖炉还原系统2的氢基竖炉22中，在氢基竖炉22的中部进行还原反应，还原反应后在氢基竖炉22的下部进行冷却处理得到冷却后的预还原球团；其中还原反应后的烟气从氢基竖炉22顶部的烟气出口进入还原气系统23，经换热、余热回收、洗涤后再通过还原气系统23进入氢基竖炉22的中部参与还原反应；冷却处理后的混合气体从氢基竖炉22下部的出气口进入冷却系统24，经补氧燃烧、余热回收、洗涤后再通过冷却系统24进入氢基竖炉22的下部参与冷却处理：具体过程如下：
(3.1)布料：步骤(2)中制备的焙烧后球团通过耐高温料罐进入氢基竖炉还原系统2的上料系统21，依次进入上料系统21的上部料斗211、中部料斗212和下部料斗213后再布入氢基竖炉22中，在此过程中焙烧后球团装入上部料斗211后，通入蒸汽(优选高温高压)或氮气(优选高温高压)进行置换，确保上部料斗211内的氧含量≤1％后，打开上部料斗211下方的阀门，焙烧后球团进入完全中部料斗212后，关闭上部料斗211下方的阀门，采用与氢基竖炉22内顶煤气成分相同的煤气完成均压过程，均压完成后，打开中部料斗212下方的阀门，焙烧后球团完全进入下部料斗213后，关闭中部料斗212下方的阀门，打开下部料斗213下部的阀门，通过万向布料器将焙烧后球团布入到氢基竖炉22中。
(3.2)还原反应：焙烧后球团在氢基竖炉22的中部进行还原反应，其中还原 气采用纯氢或焦炉煤气，优选纯氢；还原气从氢基竖炉22中部的环形风口进入，与500℃左右的热态焙烧后球团接触后，还原气一边被焙烧后球团加热(吸收焙烧后球团的温度，将焙烧后球团冷却)，一边与焙烧后球团发生还原反应，随着气体上升，还原气的浓度逐渐降低，但由于焙烧后球团的温度逐渐升高，故还原反应一直在进行，待还原反应后的烟气从氢基竖炉22顶部的烟气出口排出后，其温度被加热到1000℃以上，通过管式换热器235换热(利用顶煤气中的物理热进行一级预热)、余热锅炉231回收余热，之后再用第一洗涤器232脱出烟气中的H 2O和粉尘，也可根据工艺需要，在第一洗涤器232中喷入少量氨水，脱除烟气中CO 2和SO 2，使得烟气经简单洗涤处理后，变成以H 2和CO为主高还原势气体，该还原气再通过循环风机233，再次参与到还原反应中；在还原反应过程中，还原气的消耗量为800-1200m 3/t，还原反应时间为40-100min，氢基竖炉还原系统2的氢基竖炉22的压力为200-250kPa。
(3.3)冷却处理：焙烧后球团经还原反应后在氢基竖炉22的下部采用冷却气进行冷却处理，冷却处理后的混合气体从氢基竖炉22下部的出气口进入冷却系统24，经补氧燃烧、余热回收、洗涤后再通过冷却系统24通过氢基竖炉22下部进气口参与到冷却处理中；在冷却处理中，采用氮气和天然气(优选少量)，在冷却的同时，还原后的物料中含有海绵铁(DRI)可催化CH 4裂解，并可形成少量Fe 3C，完成渗碳过程，以防止DRI再度氧化；在上述过程中，冷却气流量为1200-1800m 3/t，冷却气在冷却球团过程中，会带出少量H 2，为保证安全，将混合气体进行补氧燃烧，再进行余热利用，之后通过洗涤器脱除H 2O，得到含N 2和少量CO 2的混合气体，混合气体循环利用；最终氢基竖炉22出料为冷却后的预还原球团，其出料温度低于150℃，根据后道工序的要求确定产品的金属化率。
在上述的预还原球团制备方法中，制得的预还原球团的金属化率≥40％，氢利用率达到40％以上。在进一步的方案中，预还原球团的金属化率为40-66％，氢利用率达到50％以上。
下面结合具体的例子对本公开的基于带式焙烧机的预还原球团制备装置及方法进一步介绍；下面所实施例的基于带式焙烧机的预还原球团制备装置及方法采用上述的装置和方法；
实施例1-5
实施例1-5中的铁矿石原料如表1所示，配入膨润土、细磨石灰石得到混合物料，加水混合，造球得到含铁生球，然后转入带式焙烧机系统内依次经鼓风干燥、抽风干燥、一级预热、二级预热、焙烧后制得焙烧后球团，其处理参数如表1所示；
表1铁矿石原料及处理参数
Figure PCTCN2022099170-appb-000001
将焙烧后球团转入氢基竖炉还原系统中进行还原，采用纯氢或焦炉煤气进行还原后，经氮气和甲烷冷却、渗碳得到预还原球团，其中还原参数如表2所示；
表2预还原球团及还原参数
Figure PCTCN2022099170-appb-000002
实施例1中，含铁生球的二元碱度为1.0，采用表1中的处理参数，得到焙烧后球团的冷态抗压强度高，焙烧后球团通纯氢冷却还原，氢利用率为51％，冷却后得到的预还原球团金属化率可达66％。
实施例2中，含铁生球的二元碱度为0.3，采用表1中的处理参数，因磁铁矿配比高，预热和焙烧温度都可适当的降低，焙烧后球团通纯氢冷却还原，氢利用率为62％，冷却后得到的预还原球团金属化率可达55％。
实施例3中，含铁生球的二元碱度为0.9，采用表1中的处理参数，焙烧后球 团通纯氢冷却还原，氢利用率为65％，冷却后得到的预还原球团金属化率可达62％。
实施例4中，含铁生球的二元碱度为0.4，采用表1中的处理参数，因碱性熔剂(细磨石灰石粉)配入量减少，可适当降低预热和焙烧温度，焙烧后球团通纯氢冷却还原，氢利用率为56％，冷却后得到的预还原球团金属化率可达58％。
实施例5中，含铁生球的二元碱度为1.0，采用表1中的处理参数，得到焙烧后球团的冷态抗压强度高，焙烧后球团通焦煤气冷却还原，因高温下CO和CH 4与H 2O发生水煤气反应，其氢利用率与采用纯氢时相对降低，本实施例中氢利用率仅为43％，预还原球团金属化率可达52％。
综上所述，本公开所提供的基于带式焙烧机的预还原球团制备装置及方法，通过将含铁生球的焙烧与球团还原有机结合，取消焙烧后球团冷却过程和球团还原前的升温过程，利用焙烧后球团的物理热满足还原过程所需的热量，解决了传统的直接还原过程中，氢利用率偏低以及球团在氧化焙烧、直接还原过程中能耗偏高、传统的氧化球团带式焙烧机上下料层球团因高温状态下热量不均匀，带来的球团质量不均匀等技术难题，制备的预还原球团作为高炉/转炉/电炉的炉料，可大幅度降低传统钢铁流程的燃料消耗和碳排放，为传统流程的绿色发展创造有利的条件；将含铁生球的焙烧过程与球团还原有机结合，取消球团冷却和直接还原球团升温过程，利用纯氢或富氢气体冷却还原，流程更简洁，能源利用效率提高；利用焙烧后球团的物理热，满足氢还原和气体升温所需热量，使得氢还原热力学条件更合理，能大幅度提高氢利用率；利用微波穿透深度大、温度均匀性好、整体加热的特点，用于球团焙烧，使得球团的氢还原动力学条件更优，有利于改善预还原球团的质量、提高还原反应的速度；利用微波电加热实现含铁球团焙烧，可降低球团的焙烧温度，减少预氧化球团制备过程NO X类污染物的产生，环境更为友好；全流程采用裂解气、热解油、生物质油等非化石能源燃烧，绿电产生微波电加热，纯氢或富氢气体还原的方式，可以实现无碳或低碳工艺生产预还原球团；采用焙烧后球团物理热满足氢气还原和加热所需的热量，简化含铁球团焙烧和还原过程，提高了氢气利用率，将制备的预还原球团作为高炉炉料，可大幅度降低高炉燃料消耗和碳排放，是一种低碳、绿色的预还原球团制备新工艺。
本技术领域中的普通技术人员应当认识到，以上的实施例仅是用来说明本公开，而并非用作为对本公开的限定，只要在本公开的实质精神范围内，对以上所述实施 例的变化、变型都将落在本公开的权利要求书范围内。

Claims (10)

  1. 一种预还原球团制备装置，其特征在于，包括带式焙烧机系统和氢基竖炉还原系统；
    所述带式焙烧机系统沿含铁生球运动方向依次设有干燥Ⅰ段、干燥Ⅱ段、预热Ⅰ段、预热Ⅱ段和焙烧段，在所述带式焙烧机系统中，对含铁生球顺序进行干燥、预热，获得预热后的球团，以及在所述焙烧段中，在1170-1270℃的温度下对预热后的球团进行焙烧，获得焙烧后球团；所述焙烧段采用微波电加热；
    所述氢基竖炉还原系统包括氢基竖炉、上料系统、还原气系统、冷却系统以及出料系统；所述上料系统设于所述氢基竖炉上部，来自所述带式焙烧机系统的焙烧后球团被直接输送到上料系统中；所述还原气系统处理来自所述氢基竖炉的烟气，以及为所述氢基竖炉提供还原处理所需的还原气；在所述氢基竖炉中对来自所述上料系统的焙烧后球团进行还原，获得预还原球团；所述冷却系统对所述氢基竖炉的预还原球团进行冷却处理，获得冷却后的预还原球团；所述出料系统设于所述氢基竖炉底部，排出冷却后的预还原球团。
  2. 根据权利要求1所述的预还原球团制备装置，其特征在于，所述预热Ⅱ段采用燃料加热，并通过第一回热风机与所述干燥Ⅱ段相连通；
    所述预热Ⅰ段与所述还原气系统的管式换热器连接，并通过助燃风机与所述预热Ⅱ段连接，所述预热Ⅰ段还通过第二回热风机与所述干燥Ⅰ段连接；
    所述干燥Ⅰ段、干燥Ⅱ段均通过主抽风机与布袋除尘器连接。
  3. 根据权利要求2所述的预还原球团制备装置，其特征在于，所述上料系统包括上部料斗、中部料斗以及下部料斗；所述上部料斗、中部料斗以及下部料斗之间均设有阀门；和/或
    所述还原气系统包括管式换热器、余热锅炉、第一洗涤器、循环风机以及加压风机；所述管式换热器上设有烟气入口、烟气出口、空气入口和空气出口，所述烟气入口与所述氢基竖炉顶部的烟气口连接，所述烟气出口与所述余热锅炉连接，所述空气入口与换热风机连接，所述空气出口与所述带式焙烧机系统的预热Ⅰ段连接； 所述余热锅炉的出气口与所述第一洗涤器的进气口连接；所述循环风机一端与所述第一洗涤器的出气口连接，另一端与所述氢基竖炉中部的环形风口连通；所述加压风机为所述循环风机出来的还原气加压；和/或
    所述冷却系统包括补氧燃烧单元、余热回收单元、第二洗涤器以及冷却风机；所述补氧燃烧单元与所述氢基竖炉下部的出气口连接；所述余热回收单元一端与所述补氧燃烧单元连接，另一端与所述第二洗涤器的进气口连接；所述冷却风机一端与所述第二洗涤器的出气口连接，另一端与所述氢基竖炉下部的进气口连通；所述出气口设于所述进气口上部。
  4. 根据权利要求3所述的预还原球团制备装置，其特征在于，所述上部料斗上设有通气管道；所述中部料斗上设有均压装置；所述下部料斗上设有万向布料器。
  5. 一种预还原球团制备方法，其特征在于，所述预还原球团制备方法包括使用如权利要求1-4中任一项所述的预还原球团制备装置制备预还原球团，在所述预还原球团制备装置的带式焙烧机系统中在1170-1270℃温度下对球团进行焙烧，获得焙烧后球团，然后将所述焙烧后球团直接送入所述预还原球团制备装置的氢基竖炉还原系统中进行还原，获得预还原球团。
  6. 根据权利要求5所述的预还原球团制备方法，其特征在于，所述预还原球团制备方法包括以下步骤：
    (1)向铁矿石原料中配入膨润土和细磨石灰石/消石灰得到混合物料，然后加水混合，经造球制得含铁生球；
    (2)将所述含铁生球置入所述带式焙烧机系统内，形成含铁生球料层，对含铁生球料层依次进行鼓风干燥、抽风干燥、一级预热、二级预热得到预热球团，然后使用微波电加热对所述预热球团在1170-1270℃的温度下进行焙烧，得到焙烧后球团；
    (3)将所述焙烧后球团送入氢基竖炉还原系统中，使焙烧后球团与还原气发生还原反应，再经冷却气冷却处理后得到预还原球团。
  7. 根据权利要求6所述的预还原球团制备方法，其特征在于，所述步骤(1)中，所述铁矿石原料选自磁铁矿、赤铁矿和褐铁矿中的一种或以上；和/或
    铁矿石原料的勃氏比表面积≥1500cm 2/g；和/或
    所述膨润土的配入量为所述铁矿石原料的0.7-1.5wt％；和/或
    所述混合物料的二元碱度为0.3-0.5或0.8-1.2；和/或
    所述含铁生球的粒度为8-20mm；和/或
    所述步骤(2)中，所述带式焙烧机系统为铺有底料的带式焙烧机系统，所述底料的厚度为80-100mm，装入所述含铁生球后，形成总高度为300-400mm的料层；和/或
    所述鼓风干燥在所述带式焙烧机系统的干燥Ⅰ段进行，鼓风干燥温度为170-240℃，风速为0.8-1.4m/s，干燥时间为1.5-2.5min；和/或
    所述抽风干燥在所述带式焙烧机系统的干燥Ⅱ段进行，抽风干燥温度为300-400℃，风速为0.8-1.4m/s，干燥时间为4-6min；和/或
    所述一级预热在所述带式焙烧机系统的预热Ⅰ段进行，一级预热温度为600-800℃，风速为0.8-1.4m/s，一级预热时间为4-6min；和/或
    所述二级预热在所述带式焙烧机系统的预热Ⅱ段进行，二级预热温度为900-1100℃，风速为0.8-1.4m/s，二级预热时间为4-6min；和/或
    所述二级预热的燃料包括天然气、焦炉煤气、裂解气、热解油、生物质油或生物质碳；和/或
    所述二级预热采用热风助燃，所述热风来自于空气和来自于预热I段的热废气所组成的混合气体；和/或
    所述步骤(1)中，所述铁矿石原料中含有磁铁矿时，在所述混合物料上方补入空气，控制氧含量大于14％；和/或
    所述焙烧过程中，焙烧时间为8-12min；和/或
    所述步骤(3)中，所述氢基竖炉还原系统的氢基竖炉的压力为200-250kPa；和/或
    所述还原气采用纯氢或焦炉煤气；和/或
    所述还原反应过程中，所述还原气的消耗量为800-1200m 3/t，还原反应时间为40-100min；和/或
    所述冷却气包含氮气和天然气；和/或
    所述冷却处理过程中，所述冷却气流量为1200-1800m 3/t；和/或
    所述预还原球团的出料温度低于150℃；和/或
    所述预还原球团的金属化率≥40％。
  8. 根据权利要求7所述的预还原球团制备方法，其特征在于，所述步骤(2)中，所述鼓风干燥过程中，鼓风干燥温度为190-210℃，风速为0.9-1.2m/s；和/或
    所述抽风干燥过程中，抽风干燥温度为330-350℃，风速为0.9-1.2m/s；和/或
    所述一级预热过程中，风速为0.9-1.2m/s；和/或
    所述二级预热过程中，风速为0.9-1.2m/s；和/或
    所述步骤(3)中，所述预还原球团的金属化率为40-66％；和/或
    所述还原气为纯氢，所述还原反应过程中，氢利用率达到50％以上。
  9. 根据权利要求6所述的预还原球团制备方法，其特征在于，所述步骤(3)中，所述还原气为纯氢，所述还原反应过程中，氢利用率达到60％以上；和/或
    所述焙烧后球团通过耐高温料罐输送至所述氢基竖炉还原系统的上料系统中，再经所述上料系统布料进入所述氢基竖炉还原系统的氢基竖炉中，在所述氢基竖炉的中部参与还原反应；
    所述还原气通过还原气系统进入所述氢基竖炉中参与还原反应，反应后的烟气从所述氢基竖炉顶部的烟气出口进入还原气系统中，经换热、余热回收、洗涤后，再进入所述氢基竖炉的中部参与还原反应；
    所述冷却气通过冷却系统进入所述氢基竖炉中参与冷却处理，处理后的混合气体从所述氢基竖炉下部的出气口进入冷却系统，经补氧燃烧、余热回收、洗涤后，再进入所述氢基竖炉的下部参与冷却处理。
  10. 根据权利要求9所述的预还原球团制备方法，其特征在于，所述步骤(3)中，所述上料系统的布料方式为：
    所述焙烧后球团进入所述上料系统后，依次通过上料系统的上部料斗、中部料斗和下部料斗后，再通过万向布料器布入所述氢基竖炉中；
    所述焙烧后球团装入所述上部料斗后，通入蒸汽或氮气进行置换，确保所述上部料斗内的氧含量≤1％后，打开所述上部料斗下方的阀门，所述焙烧后球团完全进入所述中部料斗中，关闭所述上部料斗下方的阀门，采用与所述氢基竖炉内顶煤气成分相同的煤气完成均压过程，所述均压完成后，打开所述中部料斗下方的阀门，所述焙烧后球团完全进入所述下部料斗后，关闭所述中部料斗下方的阀门，打开所述下部料斗下部的阀门，将所述焙烧后球团布入到所述氢基竖炉中。
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