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United States Patent |
6,254,663
|
Kepplinger
,   et al.
|
July 3, 2001
|
Process for the production of liquid pig iron or liquid steel pre-products
Abstract
In the process for the production of liquid pig iron 943) or liquid steel
pre-products from charging substances comprising iron ore (5) and fluxes
and at least partially containing a portion of fines, the iron ore is
directly reduced to sponge iron in at least two reduction stages (1, 2) by
the fluidized bed method, the sponge iron is melted in a melt-down
gasifying zone (39) under the supply of carbon carriers and an
oxygen-containing gas, and a CO- and H.sub.2 -containing reducing gas is
produced which is injected into reduction zones of the reduction stages
(1, 2), is reacted there, is withdrawn as a top gas and optionally is
supplied to a consumer. To achieve uniform reduction of the iron ore at
optimum exploitation of the reducing gas, the iron ore (5) in a first
reduction stage (1) by aid of the reducing gas is fractionated into at
least two fractions having different grain size distributions each, each
fraction is reduced by the reducing gas in a separate fluidized bed (6,
15), wherein the reducing gas maintains a first fluidized bed (6)
containing the coarse-grain fraction and separates the fine-grain fraction
from the same, and wherein, further, reducing gas is additionally
introduced into the further fluidized bed (15) directly reduced iron ore
(5) is discharged both from the first and from the further fluidized bed
(6, 15) and the fine- and the coarse-grain fraction reduced in the first
reduction stage (1) are further reduced in at least one further reduction
stage (2) operating in the same manner as the first reduction stage (1)
and from the last reduction stage (2) the fine-grain fraction is
introduced into the melt-down gasifying zone (39) while being agglomerated
by provision of oxygen, and the coarse-grain fraction is fed directly into
the melt-down gasifying zone (39) gravitationally (FIG. 1).
Inventors:
|
Kepplinger; Werner Leopold (Leonding, AT);
Wallner; Felix (Linz, AT);
Schenk; Johannes (Linz, AT);
Lee; Il-Ock (Pohang, KR);
Kim; Yong-Ha (Pohang, KR);
Park; Moon Duk (Pohang, KR)
|
Assignee:
|
Voest-Alpine Industrieanlagenbau GmbH (Linz, AT);
Pohang Iron & Steel Co., Ltd. (Kyong Sang Book-Do, KR);
Research Institute of Industrial Science & Technology, Incorporated (Pohang, KR)
|
Appl. No.:
|
221494 |
Filed:
|
December 28, 1998 |
Foreign Application Priority Data
| Jun 28, 1996[AT] | 1154/96 |
| Jun 26, 1997[WO] | PCT/AT97/00143 |
Intern'l Class: |
C21B 013/14 |
Field of Search: |
75/446
266/160,172
|
References Cited
U.S. Patent Documents
3264096 | Aug., 1966 | Agarwal et al. | 75/446.
|
5919281 | Jul., 1999 | Park et al. | 75/450.
|
5948139 | Sep., 1999 | Kepplinger et al. | 75/445.
|
Foreign Patent Documents |
4240194 | Jul., 1994 | DE.
| |
0316819 | May., 1989 | EP.
| |
0594557 | Apr., 1994 | EP.
| |
63-011611 | Jan., 1988 | JP.
| |
01184211 | Jul., 1989 | JP.
| |
08060215 | Mar., 1996 | JP.
| |
9414825 | Jul., 1994 | KR.
| |
Primary Examiner: Andrews; Melvyn
Attorney, Agent or Firm: Ostrolenk, Faber, Gerb & Soffen, LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of International Application PCT/AT97/00143,
with an International filing date of Jun. 26, 1997.
Claims
What is claimed is:
1. A process for the production of liquid pig iron or liquid steel
pre-products from charging substances comprising iron ore and fluxes and
at least partially containing a portion of fines, wherein the iron ore is
directly reduced to sponge iron in at least two reduction stages by the
fluidized bed method, the sponge iron is melted in a melt-down gasifying
zone under the supply the carbon carriers and an oxygen-containing gas,
and a CO--H.sub.2 -containing reducing gas is produced which is injected
into the reduction zones of the reduction stages, is reacted there, is
withdrawn as a top gas and optionally is supplied to a consumer, wherein:
in the first reduction stage the iron ore by aid of the reducing gas is
fractionated into at least one coarse-grain fraction and at least one
fine-grain fraction,
each fraction is reduced by the reducing gas in a separate fluidized bed,
wherein
the reducing gas maintains said first fluidized bed containing the
coarse-grain fraction and separates the fine-grain fraction from the
coarse-grain fraction,
and wherein reducing gas is additionally introduced into said second
fluidized bed directly, in an amount and/or chemical composition such that
reduction of the fine-grain fraction in this fluidized bed to
metallization takes place, and
a reduced iron ore is discharged both from first said first fluidized bed
and from said second fluidized bed and
the fine- and the coarse-grain fractions reduced in the first reduction
stage are further reduced in at least one further reduction stage and from
the last reduction stage the fine-grain fraction is introduced into the
melt-down gasifying zone while being agglomerated by treatment with
oxygen, and the coarse-grain fraction is fed directly into the melt-down
gasifying zone gravitationally.
2. A process according to claim 1, characterized in that in both reduction
stages the grain size distribution of the separated fine-grain fraction is
adjusted by adjusting the amount of reducing gas supplied to the first
fluidized bed per time unit and, at the same time, the degree of reduction
of the fine-grain fraction is adjusted by adjusting the amount of
secondary reducing gas which is directly supplied to this fraction.
3. A process according to claim 1, wherein the fine- and the coarse-grain
fractions reduced in the first reduction stage are further reduced in a
first fluidized bed of the second reduction stage together and the
fine-grain fraction is once again separated and supplied to a second
fluidized bed of the second reduction stage and there is further reduced.
4. A process according to claim 1, wherein the fine-grain fraction is
introduced into the melt-down gasifying zone in close proximity to an
oxygen feeding means opening into the melt-down gasifying zone.
5. A process according to claim 1, wherein the fine-grain fraction is
introduced into the melt-down gasifying zone by means of a burner.
Description
The invention relates to a process for the production of liquid pig iron or
liquid steel pre-products from charging substances comprising iron ore and
fluxes and at least partially containing a portion of fines, wherein the
iron ore is directly reduced to sponge iron in at least two reduction
stages by the fluidized bed method, the sponge iron is melted in a
melt-down gasifying zone under the supply of carbon carriers and an
oxygen-containing gas, and a CO- and H.sub.2 -containing reducing gas is
produced which is injected into reduction zones of the reduction stages,
is reacted there, is withdrawn as a top gas and optionally is supplied to
a consumer, and a plant for carrying out the process.
A process for the reduction of ore with subsequent melting is known for
example from EP-A-0 594 557. With this known process, in accordance with a
preferred embodiment, reduction is carried out in two locally separated
reduction zones connected in series, wherein the reducing gas exiting the
first reduction zone is supplied to the second reduction zone, which is
connected to precede the first reduction zone in the direction of flow of
the fine ore, hence in counter-flow, and from there under compression is
supplied to a preheating zone. Each of the two reduction zones has an
upper section in which fine solid particles are reduced in a fluidized bed
and a lower section to which coarser solid particles descend and in which
they are reduced in a flown-through fixed bed.
Hereby, advantages result as compared to single-stage direct reduction,
i.e. to direct reduction utilizing only a single reduction zone, said
advantages consisting above all in a low consumption of reducing gas,
namely for the following reason: technical reduction processes require a
reduction temperature of at least 750.degree. C., so that there inevitably
results a minimum temperature of the reducing gas--when exiting the
reduction zone--of 750.degree..
Since for technical reasons it is not admissible for the reducing gas from
the melter gasifier to have temperatures in excess of 950.degree. C., only
a temperature gradient of roughly 200.degree. C. is available, meaning
that only roughly 1/3 of the sensible heat of the reducing gas can be
utilized. To be able to maintain the above-indicated temperature level, it
would be necessary with a single-stage reduction process to utilize
reducing gas in an amount several times the amount required for reduction.
This would result in insufficient exploitation of the reducing gas and
hence in a high level of coal consumption in the melter gasifier.
Although this known process has proved its value, different degrees of
reduction may result with the fine-grain fraction and the coarse-grain
fraction of the iron ore when processing ores of different grain sizes,
that is, when processing ores having a slightly higher portion of fine ore
(e.g. run-of-mine ore). Remediation is difficult, as it is not possible
with this known process to adjust the retention time of the fine-grain
fraction independently of the retention time of the coarse-grain fraction
of the iron ore in the reactor vessels.
With the known process, the completely reduced fine ore portion from the
reduction zone arranged to immediately precede the melt-down gasifying
zone is charged to the melt-down gasifying zone separately from the coarse
ore portion, namely at the height of the fluidized bed forming above the
fixed bed of the melt-down gasifying zone. Hereby, conveying-out of the
fine-grain fraction along with the reducing gas generated in the melt-down
gasifying zone is avoided. If the fluidized bed becomes overloaded with
the charged fine-grain fraction, breakdown of the fluidized bed and
subsequently damming-up of gas may ensue. This results in eruptive
outbreaks of gas. Hereby, the gasification process for the carbon carriers
and the melt-down process for the reduced iron ore, that is the sponge
iron, is markedly disturbed. Uncontrollable fluctuations in the pressure
and quantity of the generated reducing gas and formation of a reducing gas
having a reductant composition which is disadvantageous to the reduction
process may ensue.
From KR patent application 94-38980, a process of the initially described
kind is known in which in the reduction zone arranged to imnmediately
precede the melt-down gasifying zone the prereduced fine ore portion is
discharged by means of the reducing gas and supplied to a separate fine
ore reduction zone. From the latter, the completely reduced fine ore is
also conducted to the fluidized bed zone in the melter gasifier, as
according to EP-A - 0 594 557, so that, here, the disturbances already
described above may occur in the melter gasifier.
In accordance with KR patent application 94-38980, the ore is prereduced in
a first reduction zone, with the fine ore portion and the coarse ore
portion being reduced together in a single reduction zone. This results in
the disadvantages described in connection with EP-A - 0 594 557, namely in
nonuniform degrees of reduction of the fine ore portion and of the coarse
ore portion in this reduction zone.
The invention aims at avoiding these disadvantages and difficulties and has
as its object to provide a process of the initially described kind as well
as a plant for carrying out the process, by which not only a uniform
reduction of the fine portion and coarse portion of the ore is feasible,
namely in a reduction process which, in order to achieve good gas
exploitation of the reducing gas, is a multiple-stage, i.e. at least
two-stage, reduction process. In particular, disturbances of the melt-down
process and of the production process for the reducing gas in the
melt-down gasifying zone are also to be avoided herein.
With a process of the initially described kind, this object is achieved in
accordance with the invention in that:
each of the two reduction stages is provided with two separate fluidized
beds, wherein in a first reduction stage the iron ore by aid of the
reducing gas is fractionated into at least two fractions having different
grain size distributions each, namely into at least one coarse-grain
fraction and at least one fine-grain fraction,
each fraction is reduced by the reducing gas in a separate fluidized bed,
wherein
the reducing gas maintains a first fluidized bed containing the
coarse-grain fraction and separates the fine-grain faction from the same,
and wherein, further, reducing gas is additionally introduced into the
further fluidized bed directly, in an amount and/or chemical composition
such that reduction of the fine-grain fraction in this fluidized bed to a
predetermined degree of metallization within a predetermined period of
time is ensured, and
reduced iron ore is discharged both from the first and from the further
fluidized bed and
the fine- and the coarse-grain fraction reduced in the first reduction
stage are further reduced in a further reduction stage operating in the
same manner as the first reduction stage and from the last reduction stage
the fine-grain fraction is introduced into the melt-down gasifying zone
while being agglomerated by provision of oxygen, preferably by means of a
burner, and the coarse-grain fraction is fed directly into the melt-down
gasifying zone gravitationally.
The charging of a reduced fine-grain fraction to a melt-down vessel by
means of a burner is known per se from KR patent application 92-27502. But
here, reduction by the reducing gas is effected in a single stage and
melting down of the ore that is only prereduced in the single-stage
process takes place by the so-called "in-bath" method. In accordance with
this method, only a metal melt covered by a molten slag, without a fixed
bed and without a fluidized bed, is present in a reactor vessel. The
charged coal gasifies in the slag layer in which the charged prereduced
ore is also completely reduced. However, the reduction process takes a
completely different course than with the process of the initially
described kind and the process in accordance with the invention, as, in
prereduction, reduction of Fe.sub.2 O.sub.3 by means of CO and/or H.sub.2
is, at the most, only carried to the FeO stage and the prereduced ore is
then completely reduced in the melt-down vessel by means of carbon, namely
in accordance with the equation FeO+C=Fe+CO. These "in-bath" melting
processes are therefore fundamentally different from the process of the
initially described kind, because reduction by a reducing gas is effected
only to a slight extent, namely to a degree of reduction of roughly 30%.
For complete reduction in the melt-down reactor, a high percentage of
carbon is required if compared to the process according to the invention,
whereas with the process of the initially described kind and in accordance
with the invention reduction to a degree of reduction of 90% or more is
carried out exclusively by reducing gas. Since with the "in-bath" method
there is no fixed bed and no fluidized bed, the problem underlying the
invention, i.e. overloading of the fluidized bed, does not occur.
In accordance with a preferred embodiment, in both reduction stages the
grain size distribution of the separated fine-grain fraction according to
the invention is adjusted as a function of the overall grain size
distribution by adjusting the amount of reducing gas supplied to the first
fluidized bed per time unit and, at the same time, the degree of reduction
of the fine-grain fraction is adjusted by adjusting the amount of
secondary reducing gas which is directly supplied to this fraction
additionally.
A simplified embodiment of the process according to the invention provides
that the fine- and the coarse-grain fraction reduced in the first
reduction stage are further reduced in the first fluidized bed of the
further reduction stage together and the fine-grain fraction is once again
separated and supplied to the further fluidized bed and there is further
reduced.
Suitably, the fine-grain fraction reduced in the first reduction stage is
supplied to the further fluidized bed of the further reduction stage
directly and is further reduced there.
Another simplified process variant of the process set forth in the
invention is characterized in that instead of via a burner the fine-grain
fraction is introduced into the melt-down gasifying zone in close
proximity to an oxygen feeding means opening into the melt-down gasifying
zone.
A plant for carrying out the process according to the invention comprising
at least two reduction units arranged in series, from which there run into
a first reactor vessel a conveying duct for charging substances containing
iron ore and fluxes, a gas feed duct for a reducing gas and a conveying
duct destined for the reduction product formed in said reactor vessel and
leading to a further reduction unit with a reactor vessel, and a gas
discharge duct for the top gas, wherein the gas feed duct for the reducing
gas forms a gas discharge duct for reducing gas from the further reduction
unit and a further conveying duct for the reduction product formed in the
further reduction unit runs into a melter gasifier provided with supply
ducts for oxygen-containing gases and carbon carriers as well as with a
tap for pig iron or steel prematerial and slag, wherein the reducing-gas
feed duct for reducing gas formed in the melter gasifier which runs into
the further reduction unit departs from the melter gasifier, is
characterized in that each of the reduction units is provided with at
least two reactor vessels arranged in series in the direction of flow of
the iron ore, each reactor vessel having a separate fluidized bed therein,
and with one gas feed duct for the reducing gas leading to each of said
reactor vessels in parallel arrangement, wherein from the reactor vessel
that is first if viewed in the direction of flow of the iron ore a
reducing-gas discharging means runs into the second reactor vessel of the
same reduction unit intended for the fine-grain fraction of the iron ore
to be reduced and a conveying duct for the reduction product departs from
each reactor vessel, and wherein further the two conveying ducts leading
out of the first reduction unit run into the further reduction unit and
the conveying ducts departing from the further reduction unit--in case
this forms the last reduction unit--lead to the melter gasifler
separately, namely a conveying duct departing from the first reactor
vessel of the last reduction unit enters the melter gasifier directly and
a conveying duct departing from the second reactor vessel of the last
reduction unit enters the melter gasifler at an oxygen-enriched site,
preferably via a burner.
According to a preferred embodiment, the two conveying ducts leading out of
the first reduction unit enter the further reduction unit together.
Suitably, the conveying duct leading out of the further reactor vessel of a
reduction unit runs into the further reactor vessel of the subsequently
arranged reduction unit directly.
Another preferred embodiment is characterized in that the first reduction
unit is preceded by a pre-heating vessel for the iron ore into which there
enters a gas duct conducting a top gas from the first reduction unit.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:
FIGS. 1 to 3 each illustrate an advantageous embodiment of a plant
according to the invention in schematic representation.
FIG. 4 illustrates an exemplary embodiment comprising a melter gasifier
according to a modified embodiment.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
The plant according to the invention according to FIG. 1 is provided with
two reduction stages or reduction units 1 and 2 subsequently connected in
series, wherein iron ore--optionally mixed with fluxes--having at least a
fine portion (hereinafter called fine-grain fraction) and a coarse portion
(hereinafter called coarse-grain fraction) and optionally being already
preheated, via an ore feed duct 3 is supplied to the first reduction unit
1. There, prereduction and--in case the iron ore has not been preheated as
yet--also preheating take place. This first reduction unit 1 is
constructed as follows:
The reduction unit 1 is provided with a first reactor vessel 4 for
receiving a first fluidized bed 6 formed of iron ore 5. The fluidized bed
6 is maintained by a reducing gas which is radially symmetrically supplied
via a gas feed duct 7 departing from a circular duct 8 surrounding the
reactor vessel 4. The ore feed duct 3 enters the reactor vessel 4
laterally.
At the lower end of the frustoconically narrowing reactor vessel 4 a
discharging means 10 for pre-reduced iron ore is provided. At the upper
end of the first reactor vessel 4 suitably exhibiting a circular cross
section 11, at a distance above the fluidized bed 6 a roughly vertically
oriented reducing-gas discharging means 12 is provided having a cross
section 13, preferably also circular cross section 13, that is contracted
as compared to the reactor cross section 11. The discharging means 12 thus
forms a nozzle-like contraction. The vertical disposition of the
discharging means 12 enables recycling of bigger ore particles
accidentally entrained by the upward-flowing reducing gas or of
agglomerates forming during reduction into the fluidized bed 6.
Directly above the first reactor vessel 4 a further reactor vessel 14 is
provided for accommodating a further fluidized bed 15. Into this further
reactor vessel 14, which has a circular cross section 16 that is larger
than the cross section 11 of the first reactor vessel 4, the discharging
means 12 of the first reactor vessel 4 enters via a radially symmetrically
arranged, i.e. here centrally disposed, gas supply opening 17, through
which the reducing gas exiting the first reactor vessel 4, which entrains
part of the iron ore 5, namely the part having a grain size lying in the
lower range of the grain size distribution (fine-grain fraction), enters
the fluidized bed 15 and maintains the same. The lower end of the second
reactor vessel 14 is likewise constructed to be frustoconical in shape,
with the further reactor vessel 14 cantilevering radially outward relative
to the first reactor vessel 4, in the shape of a circular ring, i.e. being
provided with an outwardly extending circularly ring-shaped enlargement
18.
At this enlargement 18, the further reactor vessel 14 is provided with a
radially symmetrically arranged gas distributing bottom 19 for directly
feeding a secondary reducing gas streaming in via a gas feed duct 20,
which then additionally, along with the reducing gas streaming over into
the reactor vessel 14 from the first reactor vessel 4 not only serves for
maintaining the fluidized bed 15 in the further reactor vessel 14 but also
for sufficiently reducing the fine ore 5 present in this fluidized bed 15.
On this occasion, the reduction potential of the reducing gas streaming
out of the first reactor vessel 4 is also utilized. The gas distributing
bottom 19, which may be constructed as a perforated bottom, a sieve
bottom, a valve tray or a bubble plate or the like, is designed to taper
off (roughly frustoconically) toward the centrally disposed gas supply
opening 17, such that bigger ore particles or agglomerates formed by them
fall back into the fluidized bed 6 in the first reactor vessel 4 and are
further reduced there. The gas feed ducts 7 and 20 are provided for gas
flow in parallel arrangement.
The further reactor vessel 14 is at its upper end provided with an
expansion 21 that is also directed radially outward, i.e. that is
outwardly cantilevering, as a result of which the gas velocity drops
markedly at a distance above the fluidized bed 15, f.i. to approximately
half the velocity within the fluidized bed 15, causing a drastic reduction
in the amount of dust discharged along with the spent reducing gas that is
carried off at the top via the discharge duct 22. The spent reducing gas
is purified in a cyclone 23, from which the fine particles thus separated
are optionally passed back into the fluidized bed 15 of the further
reactor vessel 14 via a recirculating duct 24. The further reactor vessel
14 is provided with a separate discharging means 25, constructed as a
conveying duct, for the fine ore 5 reduced in it.
Inside the reduction unit 1, separation of the charged iron ore 5, which
has a wide grain size range (dimensions ranging for example from 0.01 to 8
mm), is effected by windsifting by means of the reducing gas into a
coarse-grain fraction and into a fine-grain fraction, i.e. into fractions
having different grain size distributions. Hereby it is feasible to
optimally adjust the flow conditions for fluidization and the retention
time of the iron ore to the baking of the grains.
Fine particles carried out of the first lower reactor vessel 4, on account
of the nozzle-like contraction 12 are prevented from streaming back into
said reactor vessel 4, since they are entrained upwards again by the
reducing gas streaming upward through the contraction 12 at an elevated
velocity. Volume controlling devices 26 provided in the reducing-gas feed
ducts 8 and 20 render it feasible to ensure an optimum gas flow and hence
an optimum retention time of the ore particles in the reducing gas for
each of the fractions, i.e. for each of the fluidized beds 6 and 15. It is
thus feasible to precisely adjust a predetermined degree of metallization
of the fine ore, both of the fine-grain and of the coarse-grain fraction,
at the lowest possible. consumption of reducing gas, and within a
predetermined period of time.
The reduced coarse-grain fraction of the iron ore 5, which is carried out
of the first reactor vessel 4 by the discharging means 10, is then
conveyed onwards via a solids discharging means 27 constructed as a
conveying duct. Via the duct 28, which is connected to the cyclone 23, the
purified gas is drawn off along with the residual dust contained in said
drawn-off gas.
The second reduction unit 2, in which a largely complete reduction of the
prereduced iron ore to sponge iron is effected, is provided with two
reactor vessels 29, 30, which, however, are arranged separately, i.e.
separately from one another. Together, the conveying duct 27 for the
coarse-grain fraction and the conveying duct 25 for the fine-grain
fraction enter the first of the two reactor vessels 29 containing a
fluidized bed 6' that are arranged in series and are destined to receive
the material to be reduced, wherein a reducing gas is fed in through the
bottom of said first vessel via a gas feed duct 31. Here, too, windsifting
is effected, and the prereduced fine ore separated herein, that is, the
fine-grain fraction, via a gas discharging means 32 arranged at the upper
end of the first reactor vessel 29 of the second reduction unit 2 is
supplied to a fluidized bed 5' in the second reactor vessel 30 of this
reduction unit 2 along with the reducing gas.
According to a variant, it is also possible to feed the fine-grain fraction
discharged via the discharging means 25 to the second reactor vessel 30 of
the second reduction unit 2 directly, via the conveying duct 25', as
illustrated by the broken lines in FIG. 1.
To this second reactor vessel 30, again via the bottom thereof, reducing
gas is fed via a feed duct 33, which in the upwardly widening dome of this
reactor vessel 30 is fed to the first reduction unit 1 together with the
reducing gas passed over from the first reactor vessel 29 of this second
reduction unit 2 via the gas discharging means 32. Of the gas feed ducts
31 and 33 for the reducing gas, which are arranged for gas flow in
parallel arrangement, each is provided with volume controlling devices 26.
The coarse-grain fraction exiting the first reactor vessel 29 of the second
reduction unit 2 via a conveying duct 34 is conducted to a melter gasifier
35 by means of the influence of gravity. The fine-grain fraction carried
off from the second reactor vessel 30 of the second reduction unit 2 via a
discharge duct 36 is conducted to the melter gasifier 35 via a burner 38
arranged at the dome 37 of the melter gasifier 35. The burner 38 causes
the particles of the fine-grain fraction to agglomerate, so that they pass
into the melt-down gasifying zone 39 gravimetrically.
Inside the melter gasifier 35, in a melt-down gasifying zone 39, a CO- and
H.sub.2 -containing reducing gas is produced from coal and
oxygen-containing gas and via the reducing-gas feed duct 40 is conducted
to the two reactor vessels 29, 30 of the second reduction unit 2.
The melter gasifier 35 is provided with a feed duct 41 for solid carbon
carriers, a feed duct 42 for oxygen-containing gases as well as optionally
feed ducts for carbon carriers, such as hydrocarbons, that are liquid or
gaseous at room temperature and for calcined fluxes. Inside the melter
gasifier 35, below the melt-down gasifying zone 39, molten pig iron 43 or
molten steel pre-material respectively and molten slag 44 collect, which
are tapped off through a tap 45.
Above the slag 44, a fixed bed I formed of carbon carriers (coke) will form
and, thereabove, a fluidized bed II of coarse and, thereabove, of fine
particles of carbon carriers (coke particles).
In the reducing-gas feed duct 40 departing from the melter gasifier 35 and
running into the two reactor vessels 29, 30, a dedustifying means 46, such
as a hot gas cyclone, is provided, the dust particles separated in said
hot gas cyclone 46 being fed to the melter gasifier 35 via a return duct
47, with nitrogen as the conveying means and passing via a burner 48 under
the blowing of oxygen. The burner 48 can be arranged on the height level
of the fluidized bed II or above the fluidized bed II.
For adjusting the temperature of the reducing gas, there is preferably
provided a gas recirculating duct 49, which branches off from the
reducing-gas feed duct 40 and via a scrubber 50 and a compressor 51 feeds
back a portion of the reducing gas into the reducing-gas feed duct 40,
namely at a position preceding the hot gas cyclone 46.
In accordance with the embodiment illustrated in FIG. 2, in which the first
reduction unit 1 is connected to be preceded by a preheating stage 52 into
which there are supplied a portion of the top gas exiting the first
reduction unit 1 as a preheating gas and air via an air feed duct 53, the
two reduction units 1, 2 share the same design with each other, namely are
constructed in the same manner as the first reduction unit 1 of the
embodiment illustrated in FIG. 1.
In accordance with FIG. 3, the first reduction unit 1 corresponds to the
second reduction unit 2 of the embodiment according to FIG. 1, and the
second reduction unit 2 to the first reduction unit 1 of the embodiment
according to FIG. 1.
FIG. 4 shows a detail of the plant in accordance with a variant according
to which the completely reduced fine-grain fraction is introduced into the
melter gasifier 35 not via a burner 38, but directly. In the vicinity of
the entry site of the discharge duct 36 into the interior of the melter
gasifier 35 there enters an oxygen supply duct 42', so that even according
to this variant immediate agglomeration of the particles of the fine-grain
fraction can take place and discharging of the same by means of the
reducing gas conducted out of the melter gasifier 35 is prevented. An
entry site of the discharge duct 36 can also be provided in a lower-lying
portion of the melter gasifier 35, as is illustrated in FIG. 4 by the duct
36' drawn in a broken line and by the oxygen supply duct 42" sketched in a
broken line.
In accordance with the invention, advantages in terms of process technology
ensue; among these, an important example is above all the relatively
acutely and precisely adjustable separation into a coarse- and a
fine-grain fraction, whereby it is feasible to directly charge as high a
portion as possible gravimetrically, and only the strictly necessary
portion has to be charged into the melter gasifier 35 via the burner 38 or
an oxygen-enriched site. As a result, a low performance of the burner will
suffice, which in turn leads to a low temperature load in the dome 37 of
the melter gasifier 35, so that total energy consumption is low and only
relatively little cooling of the reducing gas is necessary. This also
reduces the danger of sticking. The fine-grain fraction is melted down
during charging, so that dust enrichment in the melter gasifier is
avoided. The energy for melting the fine-grain fraction is released via
the following chemical reaction, so that the burner can be operated
without additional demands of carbon: 2Fe+O.sub.2 =2FeO
The invention is not limited to the exemplary embodiments represented in
the drawing but can be modified in various respects. As for the number of
the reduction stages or reduction units, this may be chosen freely by
those skilled in the art. They may be chosen according to the desired
process flow and as a function of the charging materials.
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