WO2024200095A1 - Procédé d'exploitation d'un système de réduction directe - Google Patents

Procédé d'exploitation d'un système de réduction directe Download PDF

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Publication number
WO2024200095A1
WO2024200095A1 PCT/EP2024/057240 EP2024057240W WO2024200095A1 WO 2024200095 A1 WO2024200095 A1 WO 2024200095A1 EP 2024057240 W EP2024057240 W EP 2024057240W WO 2024200095 A1 WO2024200095 A1 WO 2024200095A1
Authority
WO
WIPO (PCT)
Prior art keywords
gas
iron ore
fed
reactor
oxygen
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2024/057240
Other languages
German (de)
English (en)
Inventor
Dr. Nils JÄGER
Dr. Daniel SCHUBERT
Dr. Matthias Weinberg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ThyssenKrupp Steel Europe AG
Original Assignee
ThyssenKrupp Steel Europe AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ThyssenKrupp Steel Europe AG filed Critical ThyssenKrupp Steel Europe AG
Priority to EP24714410.8A priority Critical patent/EP4689196A1/fr
Publication of WO2024200095A1 publication Critical patent/WO2024200095A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/004—Making spongy iron or liquid steel, by direct processes in a continuous way by reduction from ores
    • 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
    • C21B7/00—Blast furnaces
    • C21B7/002—Evacuating and treating of 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
    • 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
    • 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
    • C21B2100/62—Energy conversion other than by heat exchange, e.g. by use of exhaust gas in energy production
    • 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
    • C21B2100/80—Interaction of exhaust gases produced during the manufacture of iron or steel with other processes

Definitions

  • the invention relates to a method for operating a direct reduction plant.
  • a shaft furnace In the direct reduction process, a shaft furnace is traditionally used as a reactor with a reduction zone, through which the iron ore passes from top to bottom and against the direction of the reducing gas. Such shaft furnaces enable a good flow of reducing gas through the iron ore due to the underlying chimney effect.
  • CH 4 , CO or H 2 or a mixed gas comprising CO and H 2 can be used as the reducing gas.
  • This reducing gas (mixture) is fed to the shaft furnace, where it reduces the iron ore.
  • the main reaction products are CO 2 , water vapor (H 2 O) and sponge iron; when 100% H 2 is used, essentially no CO 2 is produced.
  • CO 2 , water vapor and unused reducing gas are mixed with fresh gas and fed back into the process.
  • the production of sponge iron can involve two basic steps.
  • the first and necessary step is the reduction of iron ore to sponge iron in a reduction zone with a suitable hot reducing gas.
  • a reducing gas essentially comprises compounds or mixtures of carbon and hydrogen (for example CH 4 ), compounds or mixtures of carbon and oxygen (for example CO) and/or hydrogen (H 2 ) at temperatures in the range of 700 °C to 1100 °C.
  • the hot reducing gas not only reacts chemically with the iron ore, but also heats it by contact as it flows through it.
  • the sponge iron produced can be cooled in a cooling zone by means of a cooling gas to temperatures that are typically below 100 °C. Corresponding processes are known in the art.
  • the object of the present invention is to further develop a generic method in such a way that the existing energetically and materially valuable process gases can be used in an economically optimized manner.
  • the teaching relates to a method for operating a direct reduction plant, wherein iron ore carriers pass through a reduction zone located in a reactor of the direct reduction plant for reducing the iron ore carriers to sponge iron from one side of the reactor to the other, wherein the reduction zone is fed with a reduction gas at a temperature of at least 700 °C, which flows through the reduction zone in the opposite direction to the flow of the iron ore carriers, wherein the hot reduction gas heats and reduces the iron ore carriers, wherein reaction gas is discharged from the reactor. At least part of the discharged reaction gas is fed to a gas power plant and/or an electric smelter.
  • the standard process provides that the reaction gas discharged from the reactor is in particular processed and then mixed with fresh gas to provide new gas for direct reduction and/or at least a portion of the discharged reaction gas is burned as fuel gas or in combination with a fuel gas and an oxygen-containing gas in order to bring the new gas to temperature for direct reduction.
  • the inventors have discovered that other utilization possibilities are possible.
  • the discharged reaction gas can be fed to a gas power plant, with the other part being fed to the standard process, for example.
  • the discharged reaction gas can be fed in its entirety to a gas power plant.
  • the gas power plant uses the discharged reaction gas as fuel gas for gas-fired power generation.
  • the energy of the reaction gas is converted, for example, directly in an internal combustion engine into mechanical drive energy and then into electrical energy using a coupled generator.
  • the gas power plant is preferably designed for the maximum volume of the discharged reaction gas from the reactor of the direct reduction plant. Since the direct reduction plant can also comprise two or more reactors, the gas power plant must be scaled accordingly.
  • the structure, principle and functioning of gas power plants, including in different designs, are known to experts.
  • At least part of the discharged reaction gas can also be fed to an electric melter, with the other part being fed to the standard process, for example.
  • the discharged reaction gas can preferably be fed in its entirety to an electric melter.
  • Thermal utilization of the reaction gas, in particular with the addition of an oxygen-containing gas, in an electric melter has the advantage that part of the heating energy required to melt the feedstocks in the melter can be contributed via the reaction gas, thereby reducing the power requirement for the electrodes.
  • a combination is also conceivable, i.e. at least part of the discharged reaction gas is fed to a gas power plant and an electric melter, with the other part being fed to the standard process, for example.
  • the discharged reaction gas can preferably be fed in its entirety to a gas power plant and an electric melter, with the appropriate division being possible as required.
  • the reducing gas is heated to a temperature between 700 and 1100 °C.
  • the temperature can in particular be reduced to a maximum of 1050 °C, preferably to a maximum of 1010 °C, and preferably to a maximum of 990 °C.
  • the reducing gas Before being fed into a reduction zone of the reactor, the reducing gas is heated to a temperature of between 700 and 1100 °C in order to heat the iron ore carriers and to carry out the necessary reduction work to produce sponge iron.
  • the heating takes place in at least one heating unit, which can be designed as a process gas heater or reformer.
  • a process gas heater or reformer In the reformer, for example, carbon dioxide serves as the oxygen source and reforming is an endothermic process and therefore relies on heat input.
  • the functional principle of process gas heaters and reformers is known to experts, in particular the heating units for the reducing gas in direct reduction plants.
  • the temperature of the reducing gas can be in particular 720 °C, preferably at least 750 °C, preferably at least 800 °C.
  • Degree of metallization [%] 100 * Fe elemental [%] / Fe to tai [%] ⁇ Due to the contact of the iron ore carrier surface with the hot reducing gas, the reaction processes and ultimately the metallization begin from the outside in. A complete reduction, i.e. a degree of metallization of 100%, is theoretically possible, but in practice economics plays an important role and thus the time for reduction, so that a degree of metallization of up to 100%, in particular up to 98%, is aimed for. A degree of metallization of at least 80%, in particular at least 85%, preferably at least 88%, preferably at least 92% and particularly preferably at least 95% is aimed for in the direct reduction process.
  • Iron ore carriers can be provided in the form of sinter, pellets and/or iron lump ores.
  • the discharged reaction gas can first be dedusted in a dedusting unit before it is fed to the gas power plant and/or the electric melter. This means that, for example, solids that are entrained from the reactor by the discharged reaction gas can be removed from the reaction gas in order to avoid damaging and/or clogging other units to which the reaction gas is fed for further use/processing.
  • the structure, principle and functioning of dedusting units are well known in the specialist world.
  • the reaction gas supplied to the gas power plant can be burned with an oxygen-containing gas.
  • an oxygen-containing gas it is necessary to supply an oxygen-containing gas to the reaction gas so that the oxygen content in the oxygen-containing gas reacts with reactive parts in the reaction gas that do not react in the direct reduction process, releasing heat.
  • the combustion produces a carbon dioxide-rich combustion gas, which leaves the gas power plant.
  • nitrogen and/or nitrogen compounds in particular undesirable nitrogen oxides, remain in the combustion gas, which result from the nitrogen content of the air introduced.
  • the combustion gas from the gas power plant would thus be rich in nitrogen, so that the yield of carbon dioxide from the combustion gas for preferred carbon use, also known as CCU (Carbon Capture Use), or alternatively and less preferably carbon storage, also known as CCS (Carbon Capture Storage), would be low.
  • the oxygen-containing gas consists of oxygen, which is produced and made available by decomposing water by means of electrolysis in an electrolysis unit, see for example EP 3 425 070 Bl .
  • the structure, principle and functioning of (water) electrolysis units are known in the specialist world. This not only improves the efficiency of the electrolysis unit by additionally removing and utilizing oxygen in addition to hydrogen, but also further processes the combustion gas from the gas power plant with a high carbon dioxide content, which can promote, among other things, the economical operation of carbon dioxide separators and/or reformers.
  • At least part of the discharged reaction gas can be converted into electricity in a gas-fired power plant, if preferably the fed-in reaction gas essentially comprises components contains or consists of fuels that do not have a fossil origin, so that “green electricity” can also be generated in the gas-fired power plant, particularly for internal use.
  • At least part of the discharged reaction gas can be temporarily fed to the gas power plant, for example if other consumers are unable to take delivery and the power supply must be ensured at short notice.
  • the advantage of gas power plants is that they can be switched on and off quickly.
  • the electricity generated in the gas power plant can supply units in the direct reduction plant, at least temporarily, as long as the gas power plant is supplied with at least part of the discharged reaction gas.
  • Other systems can also be operated with electricity from the gas power plant, for example an electric melter, so that the external electricity requirement and/or peak loads can be reduced. If, for example, high power is required for the electrodes to temporarily melt the feedstock, part of the required electricity requirement could be met by feeding the electricity generated in the gas power plant.
  • the reaction gas fed to the electric melter can be enriched with an oxygen-containing gas.
  • Enrichment or “boosters” as it is known in specialist circles, burns in situ the oxygen content in the oxygen-containing gas and the parts of the reaction gas that are reactive and that do not react in the direct reduction process, releasing heat, which can contribute to an improved heat balance of the melter.
  • At least part of the process gas discharged from the electric melter, which is optionally dedusted, can be fed to the gas-fired power plant for electricity generation.
  • the oxygen-containing gas consists of oxygen, which is produced and provided by the decomposition of water by means of electrolysis in an electrolysis unit. This not only improves the efficiency of the electrolysis unit through additional removal and utilization of oxygen in addition to hydrogen, but also the efficiency of the melter.
  • At least a portion of the discharged reaction gas can be temporarily fed to the electric melter, for example when high powers are required for the electrodes for temporary melting of the feedstocks would be required and part of the required heat input can be compensated by thermal utilization of the discharged reaction gas.
  • the supply or supply can be carried out quickly and flexibly.
  • Iron ore carriers (io) pass through a reduction zone (11) located in a reactor (10) of the direct reduction plant (100) for reducing the iron ore carriers (io) to sponge iron (si) from one side of the reactor (10) to the other.
  • the reactor (10) is preferably designed as a shaft furnace which is charged with iron ore carriers (io) from above.
  • the reduction zone (11) is fed with a reduction gas (12) which is at least 700 °C hot and flows through the reduction zone (11) against the direction of flow of the iron ore carriers (io).
  • the hot reduction gas (12) heats and reduces the iron ore carriers (io).
  • the reaction gas (13) is discharged from the reactor (10).
  • iron ore carriers can be charged into a rotary kiln, whereby the iron ore carriers pass through a reduction zone in the rotary kiln at the side or diagonally downwards to reduce the iron ore carriers to sponge iron, whereby the reduction gas flows through the reduction zone in a countercurrent principle to the direction of flow of the iron ore carriers.
  • the process for operating rotary kilns and the rotary kilns themselves are known in the specialist world.
  • Iron ore carriers in the form of, for example, lump/iron ore (io) are introduced at the upper end of the reactor (10) as shown in Figure 1.
  • the sponge iron (si) produced is removed at the lower end of the reactor (10).
  • a reduction zone (11) is arranged in the reactor (10), optionally also a cooling zone below.
  • the reduction gas (12) is passed through at least one heating unit (20) before being fed in and heated to a temperature of at least 700 and up to 1100 °C.
  • the heating unit (20) can be a process gas heater or a reformer.
  • the heating unit (20) is fed with a fuel gas (5) and an oxygen-containing gas.
  • a fuel gas (5) for example natural gas, but also biomethane or other combustible gases, in particular those available in an integrated steelworks, such as process gases discharged from converters and/or heat treatment furnaces for steel production, and/or from the electric smelter (200) can be provided for firing the at least one heating unit (20).
  • the oxygen-containing gas can consist of oxygen, which is preferably generated and provided by decomposing water by means of electrolysis in an electrolysis unit (50), for example in order to improve the combustion efficiency of the heating unit (20).
  • the yield of carbon dioxide from the combustion gas (6) of the heating unit (20) can, in particular after processing, be fed to, for example, carbon utilization or carbon storage.
  • the reduction gas (12) comprises a fresh gas (1).
  • the fresh gas (1) can consist partly or completely of hydrogen (2), which can be generated and provided by decomposing water by means of electrolysis in an electrolysis unit (50).
  • the fresh gas (1) can also contain a mixture of hydrogen (2), carbon monoxide and/or hydrocarbons.
  • recycled gas is mixed into the fresh gas (1), which corresponds to the reaction gas (13) discharged from the reduction zone (11) of the reactor (10), which has been dedusted in a dedusting unit (14), which has been dried in a dewatering unit (15), which can optionally be freed of carbon dioxide in a carbon dioxide separation unit (16).
  • a compression unit (40) can optionally be provided for compressing the recycled, in particular dedusted and dried gas, preferably before it is mixed with the fresh gas (1).
  • the sponge iron After leaving the reduction zone (11), the sponge iron can enter an optional cooling zone, for example within the reactor (10).
  • the sponge iron (si) finally leaves the reactor (10) at its lower end in Figure 1. It can be fed directly as an iron-containing solid into an electric melter (200) together with other additives such as slag formers and optionally carbon carriers for melting/melting using electrodes to which current is applied to form an iron melt and a liquid slag lying on the iron melt.
  • the discharged reaction gas (13) can, in particular after it has been dedusted in a dedusting unit (14), be fed to at least one gas power plant (30), see line I, and/or an electric melter (200), see line II. According to line I, at least part of the discharged reaction gas (13) can be converted into electricity in a gas power plant (30).
  • the reaction gas (13) supplied to the gas power plant (30) can be burned with an oxygen-containing gas (4).
  • the oxygen-containing gas (4) preferably consists of oxygen, which can be generated and made available by decomposing water by means of electrolysis in an electrolysis unit (50).
  • the electricity generated by the gas power plant (30) can supply units within the direct reduction plant (100), for example the compression unit (40), and/or an electric melter (200), in order to preferably cover high temporary power densities for melting the introduced solids.
  • At least part of the discharged reaction gas (13) can be fed to an electric melter (200).
  • the reaction gas (13) fed to the electric melter can be "boosted” with an oxygen-containing gas (4), wherein the oxygen-containing gas (4) preferably consists of oxygen, which can be generated and provided by decomposing water by means of electrolysis in an electrolysis unit (50).
  • renewable energy from wind, sun and/or water is preferably used.
  • the carbon dioxide can preferably be separated from the combustion gas of the gas power plant (30) (not shown) in order to be fed in part or in full to a CCU.
  • the carbon dioxide preferably separated or provided at least in part or in full from the combustion gas of the gas power plant (30) can, for example, be fed to a reforming process (not shown) in order to produce a gas containing carbon monoxide.
  • the carbon dioxide can also be used as a decarburizing agent in a converter in which carbon monoxide or converter gas is produced by the reverse Bouduard reaction by consuming the carbon from the steel melt to be conditioned in the converter.
  • This carbon monoxide can then be used in an integrated furnace for another use (not shown) or as part of a fresh gas (1) or as fresh gas (1).
  • the following preferably temporary operating modes are possible, either strand I, strand II or strands I and II.
  • Also possible temporarily or permanently is a combination of strand 0 and strand I, strand 0 and strand II or strands 0 to II.
  • at least part of the process gas discharged from the electric melter (200), which is optionally dedusted can be fed to the gas power plant (30) for electricity generation.

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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)

Abstract

L'invention concerne un procédé d'exploitation d'un système de réduction directe (100) selon la revendication 1.
PCT/EP2024/057240 2023-03-30 2024-03-19 Procédé d'exploitation d'un système de réduction directe Ceased WO2024200095A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP24714410.8A EP4689196A1 (fr) 2023-03-30 2024-03-19 Procédé d'exploitation d'un système de réduction directe

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023108158.6A DE102023108158A1 (de) 2023-03-30 2023-03-30 Verfahren zum Betreiben einer Direktreduktionsanlage
DE102023108158.6 2023-03-30

Publications (1)

Publication Number Publication Date
WO2024200095A1 true WO2024200095A1 (fr) 2024-10-03

Family

ID=90482353

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2024/057240 Ceased WO2024200095A1 (fr) 2023-03-30 2024-03-19 Procédé d'exploitation d'un système de réduction directe

Country Status (3)

Country Link
EP (1) EP4689196A1 (fr)
DE (1) DE102023108158A1 (fr)
WO (1) WO2024200095A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT387038B (de) * 1986-11-25 1988-11-25 Voest Alpine Ag Verfahren und anlage zur gewinnung von elektrischer energie neben der herstellung von fluessigem roheisen
US6986800B2 (en) * 2003-05-15 2006-01-17 Hylsa, S.A. De C.V. Method and apparatus for improved use of primary energy sources in integrated steel plants
EP3425070B1 (fr) 2017-07-03 2022-01-19 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé de fonctionnement d'une installation de production d'acier ou de fer

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102015218502A1 (de) 2015-09-25 2017-03-30 Siemens Aktiengesellschaft Dampfturbinenkraftwerk mit Wasserstoffverbrennung unter Einbindung einer Vergasungseinrichtung
EP3736347A1 (fr) 2019-10-14 2020-11-11 Primetals Technologies Austria GmbH Utilisation d'oxygène de l'électrolyse de l'eau dans la production de fer et / ou d'acier
US11788159B2 (en) 2020-03-24 2023-10-17 Midrex Technologies, Inc. Integration of DR plant and electric DRI melting furnace for producing high performance iron
DE102020116425A1 (de) 2020-06-22 2021-12-23 Salzgitter Flachstahl Gmbh Verfahren zur Herstellung von Rohstahl mit niedrigem N-Gehalt
DE102021112208A1 (de) 2021-05-11 2022-11-17 Thyssenkrupp Steel Europe Ag Verfahren zur Direktreduktion von Eisenerz

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT387038B (de) * 1986-11-25 1988-11-25 Voest Alpine Ag Verfahren und anlage zur gewinnung von elektrischer energie neben der herstellung von fluessigem roheisen
US6986800B2 (en) * 2003-05-15 2006-01-17 Hylsa, S.A. De C.V. Method and apparatus for improved use of primary energy sources in integrated steel plants
EP3425070B1 (fr) 2017-07-03 2022-01-19 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé de fonctionnement d'une installation de production d'acier ou de fer

Also Published As

Publication number Publication date
DE102023108158A1 (de) 2024-10-02
EP4689196A1 (fr) 2026-02-11

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