WO2024252435A1 - Procédé de production d'acier et installation correspondante - Google Patents

Procédé de production d'acier et installation correspondante Download PDF

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Publication number
WO2024252435A1
WO2024252435A1 PCT/IT2024/050104 IT2024050104W WO2024252435A1 WO 2024252435 A1 WO2024252435 A1 WO 2024252435A1 IT 2024050104 W IT2024050104 W IT 2024050104W WO 2024252435 A1 WO2024252435 A1 WO 2024252435A1
Authority
WO
WIPO (PCT)
Prior art keywords
plant
furnace
carbon
steel
recarburization
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/IT2024/050104
Other languages
English (en)
Inventor
Paolo Burin
Alessandra Primavera
Gianfranco Marconi
Gianpietro Benedetti
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.)
Danieli and C Officine Meccaniche SpA
Original Assignee
Danieli and C Officine Meccaniche SpA
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 Danieli and C Officine Meccaniche SpA filed Critical Danieli and C Officine Meccaniche SpA
Priority to KR1020257041597A priority Critical patent/KR20260037064A/ko
Priority to CN202480037863.8A priority patent/CN121712911A/zh
Priority to EP24739741.7A priority patent/EP4724613A1/fr
Publication of WO2024252435A1 publication Critical patent/WO2024252435A1/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
    • C21B13/14—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
    • C21B13/0006—Making spongy iron or liquid steel, by direct processes obtaining iron or steel in a molten state
    • 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
    • C21B13/14—Multi-stage processes processes carried out in different vessels or furnaces
    • C21B13/143—Injection of partially reduced ore into a molten bath
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C1/00—Refining of pig-iron; Cast iron
    • C21C1/02—Dephosphorising or desulfurising
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C1/00—Refining of pig-iron; Cast iron
    • C21C1/04—Removing impurities other than carbon, phosphorus or sulfur
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/28—Manufacture of steel in the converter
    • C21C5/285—Plants therefor
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/0025—Adding carbon material
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/0056—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00 using cored wires
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/0056—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00 using cored wires
    • C21C2007/0062—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00 using cored wires with introduction of alloying or treating agents under a compacted form different from a wire, e.g. briquette, pellet

Definitions

  • the present invention concerns a method and a corresponding plant for producing steel, preferably starting from iron ore, with lower direct CO2 emissions compared to current integral cycle plants.
  • the present invention is advantageously applied in the temporary and progressive replacement of known plants, that is, blast furnaces, in order to reduce environmental impact, particularly in terms of emissions, guaranteeing the same quality of liquid steel.
  • each blast furnace is fed with iron ore in the form of Sinter and/or pellets and/or lump, with an iron concentration that can be defined as medium-low, typically comprised between 62% and 65%, or even higher.
  • the residual oxides are acid-based (SiO2%>CaO%) or neutral, and the concentration of mixed oxides in the iron ore is typically 5% 10%.
  • This type of plant while allowing a wide production flexibility, produces high direct emissions of CO2 into the atmosphere, due to the use of fossil fuels and the chemical transformations that occur in the decarburization of the cast iron.
  • DRPs direct reduction plants
  • NG natural gas
  • EAF electric arc furnace
  • one purpose of the present invention is to perfect a method and provide a plant for producing steel with lower direct CO2 emissions, and without impacting the quantity and quality of the steel produced.
  • Another purpose of the present invention is to perfect a method and provide a plant for producing steel that can progressively replace current integrated cycle plants, substantially respecting the economic and operational amortization plans of the refractory components of existing blast furnaces, and guaranteeing quality and annual production at least at current values.
  • the Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.
  • a method according to the present invention for producing steel comprises at least a first step of direct reduction in which, by means of a direct reduction plant, a reduction of an iron ore is carried out, by means of direct reduction reactions with the use of a reducing gas of any origin, so as to obtain a ferrous material, preferably with a high metallization.
  • the iron ore can be provided in the form of Sinter and/or pellets and/or lump, with a medium-low iron concentration, typically comprised between 62% and 65%, or higher, in a range comprised between approximately 65% and approximately 68%, while the natural gas used can be a mixture of gases consisting of carbon monoxide, methane, light hydrocarbons, small percentages of other gases, and possibly some contaminants.
  • the gas used comprises a percentage of hydrogen, possibly increasing over time, assuming an increase compared to the state of the art, going from a ratio of 60-40%, reaching a ratio of 80% of H2 and 20% CH4 with other residual gases, or even substantially 100% of H2 content.
  • the method subsequently comprises comprises at least a second step of melting only in which, by means of an electric melting furnace, preferably an electrode or induction furnace, the ferrous material is melted, generating a volume of slag and a volume of liquid metal, the latter having a carbon percentage content of less than or equal to about 1%.
  • an electric melting furnace preferably an electrode or induction furnace
  • oxygen can be injected, with a content for example of between about 5 Nm 3 /t liquid metal and about 15 Nm 3 /t liquid metal, in order to reduce the final carbon content in the tapped liquid metal to below 1% and in order to begin the dephosphorization of the liquid metal.
  • the Applicant has experimented that the slag thus separated has a low concentration of iron oxide FeO, comprised between about 10% and about 15%.
  • the production of liquid metal with carbon less than or equal to approximately 1 % allows to improve production efficiency and the performance of the electric melting furnace. This is combined with advantages linked to the reduction of operating times which lead to a greater balance in energy and overall production costs.
  • the aim of the melting process described here is to separate the slag from the liquid metal, minimizing the addition of additives and producing a liquid metal to be used in the subsequent treatment stages.
  • the method in the presence of at least one blast furnace supplying a portion of material for the production of the steel, the method subsequently comprises at least a third step of recarburization in which, in a recarburization station, a desired quantity of carbon is added to the liquid metal at exit from the electric melting furnace, so as to produce a carburized liquid metal with a desired percentage of carbon, whether this can be classified as a cast iron, or as a steel, depending on requirements.
  • the carbon percentage can be comprised between 1% and 3%.
  • graphite in the third step of recarburization graphite can be used in lumps or flux cored wire, containing graphite or CaC2, which is gradually added to the metal bath.
  • the ferrous metal alloy is produced starting from a direct reduction of ore to obtain a ferrous material, preferably without using fossil fuels and, substantially, with reduced CO2 emissions compared to the blast furnace. Furthermore, by providing to use the electric furnace for melting and slag separation only, it is possible to start from an ore with a medium-low iron concentration, to the advantage of supply and reduced starting costs.
  • the method comprises a fourth step of oxidation, in which by means of at least one oxygen converter furnace (BOF) the previously carburized liquid metal is mixed with a determinate quantity of cast iron produced in the at least one blast furnace, and together they are subjected to at least one desired oxygenation for the oxidation of the excess carbon in order to produce steel, which is subsequently sent to a step of continuous casting. Scrap can possibly be added in this step.
  • BOF oxygen converter furnace
  • a recarburization can be carried out in the third step up to carbon percentages ranging from about 1.0 to about 3%, to then make the ferrous metal alloy thus obtained flow toward oxygen converter furnaces (BOF), into which the productions of the remaining blast furnaces also flow, so as to keep productivity unchanged.
  • the mixture between the two contributions will have a C concentration in the 2.5% - 4.5% range, with an optimal value in the 3% - 3.5% range.
  • a step of mixing between the two contributions of liquid metal, that is, carburized metal and cast iron, can also optionally take place in a reactor provided in a mixing station that precedes the BOF, so as to promote mixing before the decarburization treatment and/or to optimize the logistics of the plant. Scrap can possibly be added in this step.
  • the concentration of carbon that has to be present in the carburized liquid metal is calculated using the following formula: where: x: fraction of liquid metal coming from the blast furnace, with carbon concentration equal to 4.5%; y: fraction of liquid metal coming from the recarburization process, with carbon concentration to be determined.
  • a second production line according to the present invention can advantageously be provided, and so on until all the blast furnaces have been replaced.
  • the third step of recarburization is eliminated together with the one or more oxygen converter furnaces, and secondary metallurgy processes occur in the recarburization station in order to produce the steel which is subsequently sent to the continuous casting step.
  • the electric melting furnace in the second step of melting only, can also be fed, as well as with the ferrous material from direct reduction, with scrap, the latter in a substantially traditional manner, in baskets or in continuous, hot charging.
  • the present invention also concerns a plant for producing steel comprising at least one direct reduction plant configured to carry out a reduction of an iron ore, by means of natural gas, so as to obtain a ferrous material.
  • the plant for producing steel comprises at least one electric melting furnace, disposed downstream of the at least one direct reduction plant and suitable to subject the ferrous material to melting, so as to generate a volume of slag and a volume of liquid metal, the latter having a carbon percentage content of less than or equal to about 1%.
  • the plant for producing steel comprises at least one recarburization station disposed downstream of the at least one electric melting furnace and suitable to add a desired percentage of carbon to the liquid metal, so as to produce a carburized metal with a desired percentage of carbon, at least one blast furnace suitable to supply a determinate quantity of cast iron for the production of the steel, and at least one oxygen converter furnace suitable to receive, and at least to oxidize the excess carbon contained in, the carburized metal and the cast iron.
  • the at least one electric furnace is also suitable to carry out refining processes on the liquid metal
  • the recarburization station is suitable to carry out secondary metallurgy processes on the refined liquid metal in order to produce the steel to be sent to continuous casting.
  • the plant for producing steel has no blast furnaces and oxygen converter furnaces.
  • - fig. 1 schematically shows a layout of a plant for producing steel according to the present invention, applied to the progressive replacement of a known plant;
  • - fig. 2 schematically shows a layout of the plant of fig.1 once the replacement of the known plant has been completed.
  • a plant 10 according to the present invention is shown, applied as a progressive replacement of a traditional type plant 100.
  • the plant 10 is of the type suitable for the production of a metal alloy, whether this is a cast iron 50a or a steel 50b, starting from iron ore 20.
  • the concentration of iron can be either medium- low or medium-high, depending on the availability of purchase.
  • the traditional type plant 100 is of the integral cycle type, that is, provided with a plurality of blast furnaces 110, for example at least two, which produce cast iron 50a through reduction of the iron ore 20 with carbon-coke, and feed the cast iron
  • a production line of the plant 10 according to the present invention is installed in parallel and as partial replacement, but initially keeping the BOF.
  • the plant 10 essentially comprises a direct reduction plant, or DRP 11, an electric furnace 12 for slag melting and separation only (therefore no possible refining steps are provided in this part of the process, which are delegated to the following steps) and a recarburization station 13, which are disposed in substantial operational sequence to each other.
  • the plant 10 according to the present invention can have a different layout from the one schematically represented.
  • two or more DRPs 11 can be provided operatively in parallel and suitable to feed one or more electric furnaces 12 for melting only; in the same way, it is not excluded that two or more recarburization stations 13 can be provided, also in order to produce different types of cast irons 50a, or steels 50b, in parallel.
  • different layouts can be studied and prepared in advance in order to guarantee the same, if not superior, production conditions as the traditional plant 100 that is being progressively replaced.
  • one of the two blast furnaces 110 is decommissioned, while the other continues to traditionally produce cast iron 50a to be fed to the BOF 120, for the removal of slag impurities 121 and the conversion into steel 50b.
  • the DRP 11 of the plant 10 according to the present invention is installed, which performs a reduction of the iron ore 20 by means of natural gas preferably combined with hydrogen, so as to obtain a ferrous material by direct reduction, or DRI 30, with low, medium or high concentration of iron.
  • the natural gas used for the direct reduction of the iron ore 20 can be progressively combined with hydrogen, until it is completely replaced by it.
  • the gas used comprises a percentage of hydrogen, possibly increasing over time, from at least 50%, assuming to reach a preferential ratio of about 80% of H2 and 20% of CH4 with other residual gases, although without excluding about 100% (99% plus any residuals).
  • the DRI 30 thus produced is, however, low in carbon, especially if processed by means of hydrogen, and is subsequently fed to the electric furnace 12, which essentially carries out the rapid melting of the DRI 30, preferably by means of prevailing electrical energy, by means of electrodes and/or induction, with the optimized addition of additives (for example CaO-MgO) for slag formation and the safeguarding of the refractory, and with a possible minimum flow of O2 (5-15 Nm 3 /t liquid metai) and addition of coal for the production of liquid metal with C concentration ⁇ 1%.
  • additives for example CaO-MgO
  • the liquid metal 40 thus obtained is then sent to a subsequent recarburization station 13, where the subsequent recarburization takes place at a desired concentration of carbon, by means of, for example, feeding of graphite in lumps or flux cored wire containing graphite or CaC2 into the bath, while not however excluding alternative (although often less efficient) injections of coal in powder/ granules into the bath.
  • This recarburization station 13 can, according to a preferred but not limiting embodiment, be a ladle furnace LF equipped with electrodes for the further heating of the metal and its carbon enrichment up to a preferred, but not exclusive, maximum of 1.0 - 3%.
  • the output of this recarburization station 13 is chosen according to the percentage of carbon to be added to the liquid metal 40 so that the liquid metal to be sent to the BOF has at least 3% - 3.5% C.
  • the output of the recarburization station 13 is a carburized metal 50c which is then fed to the BOF 120, in conjunction with the cast iron 50a produced by the blast furnace 110 still in operation and possibly with some scrap 15, if available at reasonable prices and quantities for the manufacturer.
  • a mixing station 14 can be provided in which the mixing between the carburized metal 50c and the cast iron 50a can take place, if necessary, in a dedicated vessel or reactor disposed upstream of the BOF 120, in order to optimize the mixing of the two metal contributions/or to optimize the logistics of the plant by acting, for example, as a buffer.
  • the BOF 120 receives both the carburized metal 50c from the recarburization station 13, and also the cast iron 50a from the blast furnace 110 still in operation. This metal assembly is then decarburized, similarly to what happens with an integral type process, by the desired percentage in order to obtain a steel 50b with the desired carbon content.
  • the carbon percentage of the carburized metal 50c to be sent to the BOF 120 can be calculated using the following formula: where: x: fraction of liquid metal coming from the blast furnace, with carbon concentration equal to 4.5%; y: fraction of liquid metal coming from the recarburization process, with carbon concentration to be determined.
  • the percentage of carbon present in the carburized metal 50b should be 1.25.
  • the DRP 11 and the electric furnace 12 compensate for the replacement of a blast furnace 110, supplying a liquid metal 40 with a carbon percentage equal to or less than 1%, for the reasons and advantages described above, therefore this metal must then be recarburized, in the recarburization station 13, in order to obtain a carburized metal 50c suitable for treatment in the BOF 120, which was previously fed only by blast furnaces 110.
  • Secondary metallurgy processes will take place in the BOF 120, such as dephosphorization, decarburization, removal of gaseous nitrogen (N gas) by means of the CO bubbles generated by the decarburization process. Scrap can possibly be added in this step.
  • the percentage of carbon of the carburized metal 50c at exit from the recarburization station 13 will have to be within the range 1.0% 3.0%, if mixing the cast iron 50a coming from the blast furnace 110 and that coming from the recarburization station 13, a preferential ratio >1 is maintained.
  • the remaining example blast furnace 110 is also dismantled (in the initial case where there were two) and, consequently, the corresponding BOF 120, effectively eliminating all the equipment of the traditional plant 100. It is clear that, depending on the specific operating conditions, volumes of steel to be produced, quality of the steel itself and other specific factors, the layouts shown can be modified in the design phase, for example by providing that secondary metallurgy processes take place in the recarburization station 13, or providing a single electric furnace 12, or other solutions that go beyond the inventive idea.
  • the electric furnace 12 can be adapted by means of operational modifications, thus being able, in addition to melting, to also proceed with the subsequent refining of the liquid metal 40, operating appropriately in a known manner in terms of injection of coal, 02 (Nm 3 /t liquid metal), power kWh/t liquid metal, slagging agents CaO + MgO (kg/t liquid metal).
  • this step of complete replacement of the traditional plant 100 it is also possible to provide to feed the electric furnace 12 with metal scrap 15, both in baskets and continuously.
  • the liquid steel thus produced will be subjected to the secondary metallurgy path (possibly with further passage in VD/VOD) in order to bring the steel 50b thus produced to the desired chemistry.
  • the secondary metallurgy path is executed in the station 13 which, as mentioned above, no longer has any recarburization functionality.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Botany (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)

Abstract

L'invention concerne un procédé et une installation (10) de production d'acier comprenant au moins une première étape de réduction directe dans laquelle, au moyen d'une installation de réduction directe (11), la réduction d'un minerai de fer (20) est réalisée, de façon à obtenir un matériau ferreux (30), et au moins une seconde étape de fusion uniquement dans laquelle, au moyen d'un four de fusion électrique (12), le matériau ferreux (30) est fondu, générant un volume de laitier (21) et un volume de métal liquide (40), ce dernier ayant une teneur en pourcentage de carbone inférieure ou égale à environ 1 %.
PCT/IT2024/050104 2023-06-06 2024-05-24 Procédé de production d'acier et installation correspondante Ceased WO2024252435A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
KR1020257041597A KR20260037064A (ko) 2023-06-06 2024-05-24 철강 생산 방법 및 해당 플랜트
CN202480037863.8A CN121712911A (zh) 2023-06-06 2024-05-24 用于生产钢的方法和对应设备
EP24739741.7A EP4724613A1 (fr) 2023-06-06 2024-05-24 Procédé de production d'acier et installation correspondante

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT102023000011508A IT202300011508A1 (it) 2023-06-06 2023-06-06 Procedimento per la produzione di acciaio e relativo impianto
IT102023000011508 2023-06-06

Publications (1)

Publication Number Publication Date
WO2024252435A1 true WO2024252435A1 (fr) 2024-12-12

Family

ID=87889471

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IT2024/050104 Ceased WO2024252435A1 (fr) 2023-06-06 2024-05-24 Procédé de production d'acier et installation correspondante

Country Status (5)

Country Link
EP (1) EP4724613A1 (fr)
KR (1) KR20260037064A (fr)
CN (1) CN121712911A (fr)
IT (1) IT202300011508A1 (fr)
WO (1) WO2024252435A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4889323A (en) * 1986-08-07 1989-12-26 Voest-Alpine Aktiengesellschaft Mill arrangement with primary gas mixing means
CA2302244C (fr) * 1997-09-01 2004-08-17 Akira Uragami Procede de fabrication de fer et d'acier
US20230160028A1 (en) * 2020-05-04 2023-05-25 Hybrit Development Ab Process for the Production of Carburized Sponge Iron

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4889323A (en) * 1986-08-07 1989-12-26 Voest-Alpine Aktiengesellschaft Mill arrangement with primary gas mixing means
CA2302244C (fr) * 1997-09-01 2004-08-17 Akira Uragami Procede de fabrication de fer et d'acier
US20230160028A1 (en) * 2020-05-04 2023-05-25 Hybrit Development Ab Process for the Production of Carburized Sponge Iron

Also Published As

Publication number Publication date
CN121712911A (zh) 2026-03-20
EP4724613A1 (fr) 2026-04-15
IT202300011508A1 (it) 2024-12-06
KR20260037064A (ko) 2026-03-17

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