MXPA97003252A - Procedure and apparatus for manufacturing deacero from fie carbide - Google Patents

Abstract

The present invention relates to a process for converting iron carbide to steel comprising melting and dissolving iron carbide contained in a filler material in a liquid iron-carbon bath contained in a first reactor, blowing oxygen into the liquid bath of Carbon-carbon intermediate carbon content between the carbon content of the filler material and the desired carbon content of steel, and refining the intermediate liquid between the iron-carbon-steel alloy of the desired final carbon content in a second reactant

Description

PROCEDURE AND APPARATUS FOR MANUFACTURING STEEL FL OUT OF CARBIDE OF IRON FIELD OF THE INVENTION This application is a continuation in part of the application Series No. 08,359,601, filed on December 20, 1994.

FIELD OF THE INVENTION This invention relates to an apparatus and method for the manufacture of steel from iron carbide in two closely coupled stages which comprise a first stage reactor in which a carbon-carbon alloy of carbon content is produced. i term gave me-gas combustion of high-energy gases, including said gases from a second stage reactor, in addition to the energy-rich gas generated in the first reactor, and said iron-carbon-carbon alloy is used to feed the reactor Second stage in which the desired final carbon content steel is produced.

BACKGROUND OF THE INVENTION Stellung et al., Patent of E.U.A. No. 2,700.53, "describe a method of producing iron carbide and claim that the product can be oxidized to iron in steel furnaces of known construction." Kalling et al., US Patent No. 2,978,310, describe a Continuous feeding of pulverized material containing iron carbide in a rotary inclined kiln type "Kaldo" to produce steel The patent would show that this feedstock provides all the heat required for the reaction and does not introduce sulfur into the process. n and other US Patent No. 3,406,882, teach a process for the continuous production of steel which includes continuously introducing previously reduced steel material into a molten bath contained in a refining vessel and simultaneously introducing terrnogenic material and gaseous oxygen. In the container, the previously reduced steel forrn material is iron ore that has been reduced between 40 and 100%. It translates into the container at an elevated temperature and may contain carbon or other thermogenic elements in sufficient quantity to provide heat requirements necessary for the process. Rouanet Patent of E.U.fi. No. 3,527,598, teaches how to carry out a continuous process of steelmaking in a reactor that uses, for example, those previously reduced, punched and not carburized. The total carbon content of carbonated and non-carbonated pellets is such that the reaction with oxygen produces all the heat required to carry out the process. Btephens Reissue Patent of E.U.fi. No. 32,247, teaches a process for the production of iron carbide from iron ore, using a fluid bed process. The iron carbide product is then fed to a steelmaking furnace, such as a basic oxygen furnace or an electric furnace, for the production of steel. Although the original patent of tephens, patent of E.U.fi. No. 4,503,301, describes the furnace co or a basic oxygen furnace or an electric furnace, the above patent redirection broadly claims a "steel fabrication furnace". The history of the prosecution of the reissuance of the S + ephens patent also states that the type of furnace used in the steelmaking process of the invention is irrelevant to the main novelty of the patent. From the outset, the history of the prosecution of the redispatch of the Tephens patent teaches that the Stephens procedure is not limited to a particular steelmaking furnace, but includes other steelmaking furnaces of the same type. prior art, such as for example a reactor vessel. The Stephens patent redirection teaches, in column 2, lines 20-22, that the formation of iron carbide and its subsequent conversion to steel can be "a continuous operation". Stephens teaches in column 4, ineas 6-21, that when the hot iron carbide is added directly to the furnace, the procedure is "continuous and autothermal". Stephens also teaches that waste gas from the kiln, which contains approximately 90% carbon monoxide, can be collected and burned with oxygen to produce heat. The concept of continuous production of steel, extruded from steel ore, has been discussed by Oueneau in "The OSL Reactor for Lead and its Prospects for Ni, Cu, Fe," Journal of Metals, December 1989, pages 30-35, and also by- Uorner: WORORfl (Cont inuous) Steelmal- ng, Open Hearth Proceedings, 1969, pages 5? -63, and Proceedmgs of the Savard / Lee Enternational Sy psoum on Bath Smelting, Minerals, Metals & amp;; Materials Society, 1992, pages 83-101. The Oueneau or Oueneau-Schunhmann process for continuous production of steel is similar in nature to the procedure called "OSL" for production of non-ferrous metals, for example lead and nickel. See for example US patents U. fi. Nos. 3,941,587, 3,988,148 and 4,005,923 and the aforementioned article of the Journal of Metals. This last publication describes a reactor vessel enclosed for direct and continuous production of steel from iron oxide ores. The OSL reactor is a closed system that is capable of limiting the entry and exit of atmospheric gases and gaseous reaction products. The UORCRfi procedure and similar procedures, such as that described by Rudziki and others in Open Hearth Proceedmgs, 1969, pages 48-56, uses upper oxygen blower or upper or lower combined oxygen blowing to burn CO generated at the top of the molten mixture to generate additional heat for the process. The Rudziki procedure is used to decarp liquid iron ingots saturated with carbon. In the procedure called "IRSID", described by Berthet and others at the international conference on Science and Technology of iron and steel, Tol > -yo, September 1970, pages 60 et seq., metal is continuously charged, such as an iron ingot, in a reactor in which oxygen is blown on the upper part on a metal bath, causing formation of an emulsion. of slag / metal / gas where metal refining occurs very fast. The refined steel is then moved to a decanter vessel for slag / metal separation and emptying. The carbon content of the metal fed is from 4 to 5% and there is no carbon level gradient from the ext -emo input to the output of the reactor. This procedure is also described in French Patent No. 2,244,822. Patent of E.U.fi. No. 5,139,568 to Geiger describes a reactor vessel that receives solid material feed. The ore feed enters a molten metal bath consisting of a lower dense alloy or metal layer and a higher light slag layer (column). 6, lines 35-37). Oxygen is injected into the molten metal to submerged nozzles and reacts with carbon from the iron carbide to generate carbon onoxide. The carbon monoxide enters a vapor space per encuna of the molten bath (column 6, lines 51-55), where it reacts with oxygen that is injected into the vapor space. The heat of combustion of carbon monoxide in the vapor space is estimated to provide approximately 100% of the heat energy necessary for the continuation of the reaction in the reactor (column 8, lines 11-22). In the structure taught in the '68 Geger Patent, the amount of oxygen injected into the molten metal through the lower part of the reactor varies along the length of the reactor (column 9, lines 63-68). ). In this way, a gradient of carbon content is formed along the length of the reactor and a low carbon alloy is formed for removal at the removal end. Without forming a carbon content gradient, a sufficiently low carbon-carbon alloy is not formed at the reactor removal end. In addition, in the reactor described in the '568 Geiger patent, the reaction product of carbon monoxide passes into the vapor space and oxygen is injected into the vapor space for combustion with carbon monoxide. The '568 patent teaches that the combustion of monoxi or carbon occurs with the oxygen injected into the vapor space. The oxygen in the molten bath is a "highly unlikely" source of oxygen for the combustion of carbon monoxide. They must react significant amounts of carbon monoxide and oxygen in the vapor space to form enough heat to make the process sustainable or self-heating. Therefore, all or substantially all of the monoxide or carbon reaction product must enter the vapor space and be burned therein to generate sufficient heat to subsequently activate the reaction and allow a self-heating or self-heating process. Although the general heat balance of the Geiger reaction can be substantially corrected for its purpose, the problem with the individual container and the accompanying need for a carbon concentration gradient is that the heat balance does not reflect where it exists. in the process, energy deficiencies and excesses of energy, and how to control and recover the release of energy from the combustion of carbon monoxide to carbon dioxide - which is necessary to achieve - the provision of energy in the location within the reactor where it is needed The '568 Patent of Geiger recognizes that, to operate such an individual reactor continuously to achieve the desired carbon content, a carbon concentration gradient must be maintained from the iron carbide feed end to the reactor discharge end. The patent teaches that, in order for the process to be thermally autogenous, oxygen must be introduced into the steam space of the reactor to burn the CO generated in the molten metal bath, producing heat and CO2. It is contemplated that the heat generated is transferred substantially to the molten metal bath and this is a necessary condition to maintain a thermally autogenous process. However, that description shows serious deficiencies. At the ferrous carbide feed end of the reactor, the predominant chemical reactions are endothermic, therefore external heat is required for these reactions to proceed. In the same region, the volume of gas evolution is high, resulting in a high rate of turbulent diffusion in the metal bath, leading to a well-mixed reaction region. In the remaining portion of the reactor, the predominant chemical reaction is exothermic (decarburization) and is accompanied by the generation of carbon monoxide by supplying a fuel rich in energy when burned to carbon dioxide. Due to the elongated geometry of the Ge ger reactor, a significant amount of carbon monoxide is released into the vapor space at locations that are not in the vicinity of the energy-deficient region where iron carbide is fed into the reactor. Therefore, most of the energy released by combustion of carbon monoxide at locations distant from the ferrous carbide feed region does not reach that region since it is under the observed factor of radiation heat transfer between that region and the remaining reactor surfaces. (The observed heat transfer-radiation factor is used in the heat transfer technique to characterize the effectiveness of heat transfer of radiation between surfaces and between gases and surfaces). Therefore, and from the point of view of the use of most of the carbon monoxide energy in the iron-deficient iron carbide feeding region, in the method described by Geiger- no, it is possible to achieve self-efficacy. thermal Another problem with the Teiger Patent is with respect to the efficiency of combustion energy utilization of carbon monomer originating directly from the carbon monoxide generated directly within the iron carbide feed region of the reactor. Therefore, in the Geiger procedure, all of this monoxide or car-bond is burned in the reactor vapor space; the heat of combustion released tends to be transferred equally well to both the surface of the bath and the refractory dome walls of the reactor forming the vapor space. In this way, the refractory walls of the reactor dome will be very hot, which, in practice, could require provisions for water cooling. However, since the walls of the dome contain more surface area than the surface of the molten bath, significant heat losses would occur towards the walls of the reactor dome. In this way, the amount of energy that the bath reaches from the combustion of directly generated carbon monoxide will only be a fraction of the total energy generated. This additional factor also illustrates the point at which the procedure fails as described in the Geiger Patent to be autogenous. Sohn et al., In Proceedi ngs of t he Savard / Lee International Syrnposiurn on Bat Srneltmg, Mmerals, Meta ls 8 5 Materi al the S ociety, 1992, pages 377-412, provide information concerning reactor-reactor relationships. Continuous bottom blowing refinement to minimize remixing. _?) BRIEF DESCRIPTION OF THE INVENTION The present invention provides an improvement in the process of manufacturing steel from iron carbide in a steelmaking furnace, such as the process taught in the earlier and identified Stephens patents. In contrast to the single-stage reactor vessels taught in the Stephens, Kalling, Oueneau and Geiger patents, the present invention provides a two-stage process for the conversion of 0 iron carbide into an iron-carbon alloy. The method of the invention uses two separate reactors but is re-coupled. In the first step of one embodiment of the present invention, heated iron carbide is fed, the liquid may contain some residual iron oxide, and slag-forming materials in a molten bath in the first reactor.

The cast iron carbide and loose creates a lower layer of molten metal in the molten bath. A separate layer of foamed slag is formed above the molten metal in the bath. Foamy scum is characterized by a relatively thick layer of gaseous liquid, or foam. Oxygen is injected into the molten metal bath, preferably through several nozzles at the bottom of the reactor. In contrast to the described carbon content gradient, which is formed along the length of the individual reactor of Geiger Patent '568, the injected gases, together with the carbon onoxide gas reaction product, provide a high stirring energy to achieve a well-mixed, gradient-free molten bath in the reactor of the first stage of the present invention. The well-mixed reaction is also facilitated by the geometry of the container (for example, width versus height of the metal bath). The stirring action necessary to generate a foamy slag eliminates the need for formation of a carbon gradient in the molten bath. In the first reactor, at least one stream of oxygen is directed towards the foamed slag in order to burn carbon monoxide which has been generated in the bath of molten metal and which has passed inwards and generated the foamed slag. Preferably, at least 70%, preferably at least 90%, and most preferably as close as possible to 100%, of the carbon monoxide generated in the molten mixture is burned in the foamed slag. By burning the carbon monoxide in the foamed slag, most of the heat generated by the reaction is retained in the foamed slag and transferred directly back to the molten metal bath, difference from the reactor of the '568 Geiger Patent, the reaction of the first stage does not include injection of oxygen into the vapor space of the area and seeks to prevent the passage of carbon onoxide into the vapor space for combustion there. However, in an alternative embodiment of the invention, oxygen may be blown into the upper part on the liquid metal bath in the reactor of the first stage and aid in the decarburization of that liquid metal. The iron-carbon alloy produced in the reactor * of the first stage, which may have a carbon content of about 0.5-2%, is then used as a molten feed for the reactor of the second stage. Oxygen is injected into the molten metal bath through submerged nozzles at the bottom of the second stage reactor. The reaction in the second stage reactor is exothermic, and the reaction product of the second stage reactor, a mixture of carbon onoxide and carbon dioxide, is collected, cooled, treated and then returned to the reactor. the first stage where it is preferably injected towards the foamed slag layer, and the carbon monoxide is burned there with injected oxygen, similar to the combustion of carbon inonium evolved in the metal bath of the first reactor, for a good transference of heat from the slag to the molten metal bath. (In an embodiment of the invention, oxygen can also be injected into the steam space of the second stage reactor to burn a portion of the carbon onoxide to provide some additional heat that may be required to maintain a suitable bath temperature). In this way, the system of two reactors - and ensures to be essentially autogenous. The reactor outlet of the second stage is an iron-carbon alloy (steel) with a carbon content of about 0.01-0.5%, for example.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an isometric view of a steel fabrication plant in accordance with the invention. Figure 2 is a temperature-composition diagram for the iron-carbon system, showing the scale of iron-carbon alloys in the liquid region, corresponding to the temperature and composition of the iron-carbon intermediate alloys. of the invention. Figure 3 is a velocity profile in a portion of the reactor of the second stage, showing high velocities in the metal bath in the region of the nozzles below the surface. Figure 4 is a plan view of a first stage r-eactor according to the invention. Figure 5 is a side elevational view of the reactor of the first stage turned along the fifi line of Figure 4. Figure 6 is an elevational end view of the reactor of the first stage taken on line BB of Figure 4. Figure 7fi is a cross-sectional view, in elevation, of the reactor of the second stage of the reaction. Figure 7B is a cross-sectional plan view of the reactor of the second stage, and Figure 8 is a graph relating residence time of the metal in the reactor of the second stage with the number of oxygen nozzles in that reactor.

DESCRIPTION OF THE PREFERRED MODALITIES In Figure 1, the number 1 generally denotes a refractory-lined, elongated first reactor having a feed end 2 and an output end 3. An iron carbide filler is fed, which has a composition of, for example, 91% by weight. % of Fß3C, 5% of Fe3?, 3% of S1O2 and 1% of Fe, through line 4 from a preheater 6 in dons s heated to a preheating temperature, for example, of 550 ° C, and it is carried by a stream of nitrogen or CO2 directly to a mixture of molten metal 9 contained in the first reactor wherein the melting and dissolution of the iron carbide contribute significantly to a well-mixed reaction in that reactor. Slag-forming materials, such as lime, are fed through suitable equipment, such as at 7 and, optionally, steel waste is fed at 8. The molten metal bath 9 is maintained in reactor 1 and is overloaded with a layer of foamed slag 11. A burner 12 is mounted near the feed end of the reactor and is fed with oxygen through line 13 and fuel, such as a hydrocarbon fuel, for example natural gas, through the line 14. Burner 12 can be used to supply extra heat as required, and to heat or melt waste or to heat reactor 1 at startup (or liquid metal can be introduced from an external source, such as a bucket or electric arc furnace, for start-up purposes) decarburization oxygen is fed through the head 16 to a plurality of nozzles 17 which are covered with a gas that is decomposed endothermally as a hydrocarbon gas (for example, example methane), or with another cooling gae such as carbon dioxide, argon, nitrogen or steam. The oxygen nozzles for decarburization can be installed under or on top of the metal bath line, or a combination of both. All or a portion of the decarburization oxygen can be supplied to one or more shuttles (not shown) above the bath creating a high velocity jet that strikes the metal bath. Subsequently, combustion oxygen is fed through one or more lines 18 so that the oxygen shuttles in the walls of the reactor burn the carbon monoxide evolved to carbon dioxide above the molten iron-carbon bath in the foamed slag. The rear combustion shuttles may be of various designs, such as continuous wall shuttles as shown, or movable shuttles may be introduced through the mouth of the reactor vessel. A burner 19 is provided in an end wall of reactor 1 and is fed with oxygen through the line , 21, and carbon onoxide through line 22 (with a small percentage of carbon dioxide). As necessary, supplemental fuel gas can be supplied to burner 19 through line 20. Waste gas, which consists mainly of CO 2 with a little water vapor and CO (depending on the degree of subsequent combustion) is removed through from turn 23 to a temperature of for example about 1700 ° C. Any excess of 00 that is not burned in the foamed slag is externally up to 0% CO, and the waste gas is cooled, for example, to a temperature of 1100 ° C, in the combustion chamber via heat intercarbidity 24 to which cooling water is introduced through line 10 and removed through line 15. The partially cold gas phases through line 6 pass to preheater 6 and from there through line 27 to a house shaft bags 28. Then the clean, CO2-rich waste gas passes from the bags house through line 29 to a fan 31 and stack 32 (or can be picked up for another use or for sale). The solids of the bag house are returned through line 33 to the iron carbide feed line for remoting in the first reactor. The slag is removed, for example, continuously from a slag hole 34 which, as shown, may be at the metal exit end of the first reactor. The slag-free carbon-iron product of the first reactor is fed to an extrusion feed of a second elongated, refractory-lined reactor, generally denoted by the number 36. Alternatively, the iron-carbon alloy with a carbon content intermediate can be removed from the reactor of the first stage, like 45, and collected in a suitable container (not shown). When the iron-carbon product of the first reactor is fed to the second reactor, oxygen is fed from the header 37 to a plurality of submerged nozzles covered in gas 38 and the waste gas, which comprises mainly CO, for example 80% or more CO , it is collected at a temperature of for example about 1630 ° C, and it is sent through line 39 to an indirect heat exchanger 41 into which cooling water is introduced through line 25 and it is added to the heat exchanger. withdraws through line 30. To be pre-heated, oxygen is introduced into inter-exchanger 41 through line 35, from which it passes, through line 21, to burner 19 in the first reactor 1. The carbon monoxide, cooled to a temperature of about 300 ° C and a pressure of about 1.4 kg / crt 2, passes through line 22 to burner 19. The smoke evolved in the second reactor 36 is mainly droplets fine iron that passes with the gas to the first reactor. Larger particle size c may be removed if present, for example with the use of a hot cyclone (not shown). If it is required to maintain a bath temperature in the reactor 36, oxygen may also be introduced through shuttles (not shown) to burn a portion of the carbon monoxide, thereby providing heat to the bath. The final steel product leaves reactor 36 as in 42, for example at a temperature of approximately 1670 ° C, and is collected in bucket 43. Provisions are made before the operation to preheat the interior of the second stage reactor with Oxygen fuel burners, co o at 40, and pair vent the combustion gases to the atmosphere, as required. In the present invention, the process of converting solid iron carbide into liquid steel has been analyzed from a point of view of heat balance in stages and it has been determined that the process must be separated into two separate stages including separate reactor reactors but closely coupled, as shown in Figure 1 and as described above. In the reactor of the first stage the material of iron carbide, preferably preheated, is introduced into a liquid-carbon iron bath together with oxygen and sufficient flux necessary to form a foamy slag with the gangue materials, mainly silica with some alumina, which enter with the iron carbide. Preferably, the iron carbide shaft material is injected continuously, although it may be periodically injected so that the level of the molten metal bath inside the reactor reactor rises and falls concomitantly. The carbide material typically has an analysis within the scales given in Table 1 and is finely divided, with particle size typically in the range of 0.01 to 2 nm.

TABLE 1 COMPOSITION OF IRON CARBIDE MATERIAL Constituent Percentage by weight of material Fe3C 80-94 Fe (metallic) 0-2.0 S1O2 1-6 PII2O3 0.1-2.0 The simultaneous injection of oxygen allows the oxylation of the carbide carbon from iron to monoxi or carbon in the molten metal bath, submerging heat . The carbon content of the bath is maintained at a continuous state level equalizing iron-carbide and oxygen carbide fluxes. The output of the first reactor is a stream, preferably continuous, of liquid alloy of iron-carbon with a composition of between 0.5 and 2% by weight of carbon, especially approximately 1 to 2% of carbon, and at a temperature typically of 1490 °. C, but always above the liquid of the iron-carbon phase diagram, as shown in area fl of Figure 2. This current is the entrance to the reactor-of the second stage. In the second stage reactor, the carbon content of the liquid metal is decreased to the desired level of carbon in the product to be made of steel, for example from 0.01% to 0.05% carbon. This is achieved by injecting oxygen into, and preferably under the surface of, the metal and exothermically producing a CO-CO2 gas mixture. With this the steel can be drained at a temperature of approximately 1670 ° C. The longitudinal or longitudinal remixing of the metal shaft bath in the second stage reactor has been minimized, and carbon axis gradient has been provided in the reaction of the second stage by various resources. First, the length of the container becomes much larger than the other two dimensions to induce sealed flow. Secondly, the oxygen required for removal of carbon from the molten metal mixture is supplied, mainly through lower nozzles, spaced apart, for example equally along the length of the reactor. The gas? Nyecta < Jo induces a vertical flow in the molten mixture above which it also acts as an impediment to longitudinal re-milking. Third, relationships have been established between the depth of the bath, the width of the bath, and the separation between the nozzles to further reduce the flow of remixing to a minimum. Fourth, the reactor production of the second stage has e} It should be high enough that the metal bath has sufficient force from the rear flow towards the outlet of the furnace to reduce any tendency of the flow to return and move backward. The procedure < The reaction of the second stage has to be designed for approximately 50 to 150 or 200 tons per hour of liquid steel production. For lower production tonnage, operational problems related to premixing, higher heat losses, etc. may be encountered. Another potential problem in the reactor axis the second stage is the phenomenon of "continuous blowing" of gas, where the depth of the molten mixture would be insufficient to avoid that part of the gas injected crossed the molten mixture without reacting in the atmosphere of gas above the metal bath. 7 The invention provides a sufficient melt mixing depth to solve this problem. Fl CO of the second stage reactor leaves the vessel at the same temperature as the steel, for example about 1670 ° C, and is collected and cleaned before being introduced as fuel in the first stage reactor, together with oxygen, to be burned to CO2 in the foamed slag in the reactor vessel of the first stage. The majority of the reducing CO produced in the second stage reactor is generated upstream of the furnace. Therefore, the shaft bore preferably is located near the end of the metal outlet of the reactor to provide a reductive atmosphere over the entire bath. The combustion of this CO from stage 2 in the reactor of stage 1, and the provision made by the present invention to carry out this combustion within a foaming scum, make the energy balance in the first stage (and the system of two reactors) essentially autogenous, without additional necessary fuel, for example if the carbide material is heated to 550 ° C before its injection, which can be done using the sensible heat in the axle-axle gas of stage 1. If the carbide is not highly converted, and has for example 15% magnetite, this will make the reaction in stage 1 not completely autogenous. In such a case, or where a smaller portion of cold steel slag is added to the reactor of the first stage, part of the additional energy input might be required, for example in the form eg natural gas, oil or coal burned in the container to compensate for the loss of energy. These required additional energy axis quantities are not large enough to cause significant changes in the design of the first-stage reactor. Tables 2, 3, 4 and 5 give examples of staged heat balances, for different groups of conditions, with a subsequent combustion degree of 0.7 in the slag of stage 1"The degree of subsequent combustion refers to the fraction of total CO formed or injected into the container of stage 1 which is transformed into 00. in the slag. Tables 6-9 are generally for the same conditions as tables 2-5, but with a subsequent combustion degree of 0.9 in the slag of stage 1.

CURDRQ 2? B. Co di cio is of So 1. uci n% Fe30 in carbide 5% C in Fe-C mt. 1.5% Disposal 0.0 Subsequent combustion degree c -: > 0.7 Ton steel / hr. 50% steel C axis 0.05 Temp. emptying, sC 1630.00 Ternp. waste, ° C 25 Temp. carbide, ° C 550 SOLUTION STAGE 2 P steel Kg / hr- 50000 P (In. Fe-C) Kg / hr 51248.1 I Volume flow Fe-C, m3 / hr 7.11 P ol o (Fe), 2, Kg / hr 504 80 P 00.2, Kg / hr 1388.29 P 002.2, Kg / hr 545.40 Vol. C0, 2 Nm3 / hr 1110.b3 Vol. C02.2 Nm3 / hr 277.66 Vol CO, 2, at T, rn3 / hr- 7741.89 Vol. C02,2, at T,? N3 / hr 1935.47 Total gas volume mt. ? n3 / hr 9677.36 P 02.2 Kg / hr 1189 .. < ) h ETfiPfl 1 P CaO, l Kg / hr 3426.03 P waste, 1 Kg / hr 0.00 P carbide Kg / hr 57100.09 P slag, Kg / hr 5525.86 P C0.1 Kg / hr 2351. 3 P 002.1 Kg / hr 9168.39 P powder (Fe), 2, Kg / hr 1113.75 P 02.1, want rb Kg / hr 3165.94 P 02.1, PC,, Kg / hr 186.11 5 P02 fuel ab., Kg / hr 1515. Ul PCH4, Kg / hr- 378.75 PH20, Kg / hr, output 852.19 PC02, fuel ab. 1041.57 Fxcess (Je energy E a a 2, Kcal / hr 909 10 Excess energy axis Stage 1, Kcal / hr -3172942 Supplemental fuel energy Kcal / hr 3172942 TOTAL Total 02, N 3 / ton 126.80 ia Total dust, Kg / ton 22.25 Total slag Kg / ton 110.52 Total flow, Kg / tonne b? .52 Total CH4, Nm3 / ton 10.61 Total carbide, Kg / ton 1142.00 0 Disposal total, Kg / ton 0.00 (1) The degree of subsequent combustion is the ratio of C0__ a (CO + COs ») or the relationship ej (C0a + Ha0) to (CO * - C02 + Ha + H__0) CUñPRQ 3 aa Conditions e Solution% Fe 0 in carbide 10% C in Fe-C int. fifteen Desocho,% 0.0 Degree of back combustion < 5 0.7 Tons of steel / hr "50 % of C on steel 0.05 Teinp. empty < 1o, ° C 1630.

Ternp. waste, ° C 25 Ternp. carbide, ° C 55ü SOLUTION STAGE 2 P acoro Kg / hr- 50000.00 P (Int Fe-C) Kg / hr 51248.53 Volume flow Fe-C, m3 / hr 7., 11 Ppoivo (Fe), 2, Kg / hr 504.00 PC0.2, Kg / hr- 1388.29 PC02.2, Kg / hr 545.40 Vol. C0,2 Nrn3 / hr 1110..63 Vol. C02.2 Nm3 / hr 277.66 Vol CO, 2, at T, rn3 / hr 7741.89 Vol .. C02,, at t T,? N3 / hr 1935.47 Vol. Total gas int. m3 / hr 9677.36 P02.2 Kg / hr 1189.96 STAGE 1 PCaO, l Kg / hr 3451.54 P waste, 1 Kg / hr 0.00 P carbide Kg / hr 57525.25 P slag, Kg / hr 5567.01 POO, L Kg / hr- 2233.23 PC02,1 Kg / hr 8733.92 P powder (Fe), 2, Kg / hr 1113.77 P02, l, decarb Kg / hr 2360..73 P02, l, PC ,, Kg / hr 3028.12 P02 fuel ab., Kg / hr- 3543.50 PCH4, Kg / hr 885.08 PH20, Kg / hr, s llela 1993.22 PC02, combus i ble at). 2 6.1 b Energy fxceso Stage 2, Kcal / hr 909 Excess of energy Stage 1, Kcal / hr -7421287 Supplementary fuel energy Kcal / hr 7421287 TOTAL Total 02, Nrn3 / barrel ada 141. 71 Total dust, Kg / ton 20.25 Total slag Kg / ton 111.34 Total flow, Kg / ton 69.03 CH4 total, Nrn3 / ton 24.80 Total carbide, Kg / ton 1150., 51 Total waste, Kg / ton 0.00 CURPRQ. a a Qor l, i, cíon s < E? .o,., U,?, N% Fe 04 in carbur-o 10 % C in Fe-C mt. 1.5 Disposal, Z 0.0 Degree of afterburning t > 0.7 Tonnes axis ac ro / hr. fifty % ele C in steel 0.05 Ternp. Drain, ° C 1630 .. Temp. waste, ° C 25 Temp. carbide, ° C 25 SOLUCTON STAGE 2 Pacero Kg / hr 50000.00 P (Int. Fe-C) Kg / hr 51248.53 Volume flow Fe-C, rn3 / hr 7.11 Pf > olvo (Fe), 2, Kg / hr 504..80 PCO, 2, Kg / hr 1388.29 PC02,2, Kg / hr 545..40 Vol. C0.2 N? N3 / hr 1110.63 Vol. C02.2 Nrn3 / hr 277"bb Vol C0,2, at T, m3 / hr 7741.89 Vol. C02,2, at T,? N3 / hr * 1935.47 Total gas volume int. m3 / hr 9677.36 P02,2 Kg / hr- 1189.96 STAGE 1 PCa0, l Kg / hr 3451.54 P waste, 1 Kg / hr 0.00 P carbide Kg / hr 57525.25 P slag, Kg / hr 5567.01 PC0.1 Kg / hr- 2233.23 PC02.1 Kg / hr 8733.92 P powder (Fe), 2, Kg / hr 1113.77 P02, l, ejecarb Kg / hr- 2360..73 P02,1, PC ,, Kg / hr 3028.12 P02 fuel ab., Kg / hr 5892.30 PCH4, Kg / hr 14 3, .08 PH20, Kg / hr, seal it 3314.42 PC02, fuel ab. 4050.96 Excess energy axis Stage 2, Kcal / hr 909 Excess energy Stage 1, Kcal / hr -12340464 Supplementary fuel energy Kcal / hr 12340464 TOT L Total 02, Nrn3 / ton 174.60 Total dust, Kg / ton 22.25 Total slag Kg / ton 111.34 Total flow, Kg / ton 69.03 CH4 total, Nm3 / ton 41.25 Total carbide, Kg / ton 1150.51 Total waste, Kg / ton 0.00 CURPRQ 5 A conditions, axis- solution% Fe304 in carbide 5 % C in Fe-C int. 1.5 Waste,% 10.0 Degree of back combustion < ) 0.7 Tons steel shaft / hr. 50% C in steel 0.05 Temp. emptying, ° C 1630.

Ternp. waste, ° C 25 Ternp. carbide, ° C 550 SOLUTION ETfiPfi 2 Pacer-o Kg / hr 50000.00 PITT Fe-C) Kg / hr 51248.53 Volume flow Fe-C, rn3 / hr 7.11 Ppoivo (Fe), 2, Kg / hr 504.80 PC0.2, Kg / hr- 1388.29 PC02.2, Kg / hr 545.40 Vol. C0.2 Nm3 / hr 1110.63 Vol. C02,2 Nrn3 / hr 277.66 Vol C0,2, at T, m3 / hr 7741.89 Vol. C02,2, at T,? N3 / hr 1935.47 Vol. Total gas int. p »3 / hr 9677.36 P02.2 Kg / hr 1189.96 ETfiPfi 1 PCa0, l Kg / hr 3080.37 P waste, 1 Kg / hr 5133.00 P carbide Kg / hr 51338.95 P slag, Kg / hr 4968.33 PC0.1 Kg / hr 2104.62 PC02.1 Kg / hr 8262.34 P powder (Fe), 2, Kg / hr 1001.37 P02, l, decarb Kg / hr- 2742.65 P02, l, PC ,, Kg / hr 2856.64 P02 fuel ab., Kg / hr- 2336. bñ PCH4, Kg / hr 584.16 PH20, Kg / hr, warm 1314.37 PC02, fuel ab. 1606.45 Excess of energy Stage 2, Kcal / hr 909 Excess of energy Stage l, Kcal / hr -4893745 Supplementary fuel energy Kcal / hr 4893745 TOTPIL Total 02, Nrn3 / tonel ada 127. 76 Oral powder, Kg / ton 18.21 Total slag Kg / ton 99.37 Total flow, Kg / ton 61.61 Total CH4, Nrn3 / t one lada 16.36 Total carbide, Kg / ton 1026., 70 Total waste, Kg / ton 102.66 CURPRQ 6 B B. Solution Conditions% Fe304 in carbide 5 % 0 in Fe-C mt. 1.5 Waste,% 0.0 Degree of back combustion < "1-) 0.9 Tons of steel / hr" 50 % C axis in steel 0.05 I p. emptying, ° C ih30., Temp. waste, ° C 25 Temp. carbide, ° C 550 SOLUTION ETAPfi 2 Pacero Kg / hr 50000.00 PÍInt. Fe-C) Kg / hr 51248.53 Volume flow Fe-C, rn3 / hr 7.11 Powder (Fe), 2, Kg / hr 504.80 PC0.2, Kg / hr 1388., 29 PC02,2, Kg / hr 545.40 Vol. CO, 2 Npl3 / hr 1110.63 Vol. C02,2 Nrn3 / hr 277.66 Vol CO, 2, at T,? N3 / hr 7741.89 Vol. C02,2, at T,? N3 / hr- 1935.47 Total volume «gas int. ? n3 / hr 9677.36 P02.2 Kg / hr 1189.96 ETfiPft 1 PCaO, l Kg / hr 3426.03 P waste, 1 Kg / hr 0.00 P carbide Kg / hr 57100.09 P slag, Kg / hr 5525.86 PC0.1 Kg / hr 783.91 PC02.1 Kg / hr 11632311 P powder (Fe), 2, Kg / hr 1113.75 PO2, 1, decar-b Kg / hr 31b5"94 P02,1, PC ,, Kg / hr 4082.01 P02 fuel ab., Kg / hr 0.00 PCH4, Kg / hr 0.00 PH20, Kg / hr, output 0.00 PC02, fuel ab. 0.00 Excess of energy Stage 2, Kcai / hr 909 Excess of energy Stage 1, Kcal / hr -113345 Supplementary fuel energy Kcal / hr 0 TOTAL Total 02, N? N3 / ton 118.13 Total powder, Kg / ton 20.25 Total slag Kg / ton 110.52 Total flow, Kg / ton 68.52 Total CH4, Nm3 / ton 0.00 Total carbide, Kg / ton 1142.00 Total waste, Kg / ton 0.00 TABLE 7 B B. Condition < je luci n% Fe 04 in car-bu ro 10 % C in Fe-C mt. 1.5 Disposal,% 0.0 Degree of rear combustion c 5 0.9 Tons eie ace o / hr. fifty % C axis in steel 0.05 Ternp. Vaciaejo, ° C 1630. Te p. waste, ° C 25 reinp. carbide, ° C 550 SOLUTION ETAPfi 2 Pacero Kg / hr 50000.00 P (Tnt. Fe-C) Kg / hr 51248.53 Volume flow Fo-C, rn3 / hr 7.11 Powder (Fe), 2, Kg / hr 504.80 PC0; 2, Kg / hr 1388.29 PC02.2, Kg / hr 545.40 Vol. CO, 2 Nrn3 / hr 1110.63 Vol. C02.2 Nin3 / hr 277.66 Vol CO, 2, at T, rn3 / hr 7741.89 Vol. C02,2, at T, m3 / hr 1935.47 Total gas volume int. m3 / hr 9677.36 P02 ,? Kg / hr 1189..96 ETftPfi 1 PCa0, l Kg / hr 3451.54 P age, 1 Kg / hr 0.00 P carbide Kg / hr 57525.25 P slag, Kg / hr 5567.01 CURPRQ 7 (CQNTINURCIQN? Weight C0.1 Kg / hr 744.41 Weight 002.1 Kg / hr 11073.49 Weight powder (Fe), Kg / hr 1113.77 Weight 02.1, axlescarb. Kg / hr 2360.73 Weight 02, l, PC, Kg / hr 3878.88 Weight 02, fuel suin. Kg / hr 2053.44 Weight CFI4 Kg / hr 513.36 Weight H20, Kg / hr, outside 1155.06 3 b Weight C02, fuel ourn. Kg / hr 1411.74 Fnergia in excoso stage 2, Kcal / hr- 909 Energy in excess stage 1, "-4300583 Ener-g i a cornbustib1 e sup1 e- 5 mental, Kcal / hr 4300583 TOTAL Total of 02, Nrn3 / ton 132.76 Total dust, Kg / ton 20. 5 Total slag, Kg / ton 111.34 Total flow, Kg / ton 69.03 Total CH4, Nrn3 / ton 14.37 Total carbide, Kg / ton 1150.51 Total of rnat. Shafts, Kg / ton 0.00 Ib TABLE 8 n B Conditions 20 of solution% Fe304 in carbide 10% C in Fe-C int. 1.5 Waste rnatepal% 0 Postcornbustion grade 0.9 5 Tons. steel / hr 50 Percentage of C in steel 0.05 Ternp. of **, C 1630 Ternp. of mat. from cese cho 25 Temp. of carbide, C 25 SOLUTION ETfiPfi 2 Weight steel Kg / hr 50000.00 Weight (Fe-C int.) Kg / hr 51248.53 Flow volume Fe-C, rn3 / hr 7.11 Weight powder (Fe), 2, Kg / hr 504.00 Weight CO, 2, Kg / hr 1388.29 Weight C02,2 Kg / hr 545.40 Vol. C0,2 Nm3 / hr 1110.63 Vol. C02.2 N? N3 / hr 277.66 Vol. CO, 2, at T,? N3 / hr 7741.89 Vol. C02,2, at T, m3 / hr 1935.47 Total gas volume mt. , m3 / hr 9677.36 Weight 02.2, Kg / hr- 1189.96 STAGE 1 Weight CaO, l Kg / hr- 3451.54 Mat weight scrap! Kg / hr 0.00 Carbide weight, Kg / hr 57525.25 Slag weight, Kg / hr 5567.01 Weight C0.1 Kg / hr 744.41 Weight C02, l Kg / hr 11073.49 Weight powder (Fe), Kg / hr 1113.77 Weight 02.1, decarb. Kg / hr 2360.73 Weight 02.1, PC, Kg / hr 3878.88 Weight 02, fuel south. Kg / hr 4402.24 Weight CH4, Kg / hr 1100.56 Weight H20, Kg / hr, outside 2476.26 Weight C02, fuel south. Kg / hr 3026.54 Excessive energy in stage 2, Kcal / hr 909 in excess stage 1, "-9219759 Supplemental fuel energy, Kcai / hr 9219759 TOTAL Total of 02, Nrn3 / ton 165.65 Total dust axis, Kg / ton 20.25 Total slag, Kg / ton 111.34 Total flow, Kg / ton 69.03 Total CH4, Nm3 / ton 30.82 Total carbide, Kg / ton 1150.51 Total inat. waste, Kg / ton 0.00 TABLE 9 fi 13 Solution conditions% Fe304 in carbide 10 % C in Fe-C mt. 1.5 % rna t n a 1 de de se c ho 10.0 Degree of post coinbust ion 0.9 Tons steel / hr 50 Percent of C in steel 0.05 Ternp. of **, C 1630 Ternp. of inat. of waste 25 Ternp. of carbide, C 500 SOLUTION ETfiPfi 2 Weight steel Kg / hr 50000.00 Weight (Fe-C int.) Kg / hr 51248.53 Volume flow Fe-C, m3 / hr 7.11 Dust weight (Fe), 2, Kg / hr 504.80 Weight 00.2, Ky / hr 1388.29 Weight C02.2 Kg / hr- 545.40 Vol. CO, 2 Nm3 / hr 1110.63 Vol. C02,2 Nrn3 / hr 277.66 Vol. C0,2, at T, m3 / hr 7741. Ü9 Vol. C02,2, to T, rn3 / hr 1935.47 Total gas volume int., M3 / hr 9677.36 Weight 02.2, Kg / hr 1189.96 ETRPfi 1 Weight CaO.l Kg / hr 3100.93 Weight inat. cjesecho, l Kg / hr 5168.00 Carbide weight, Kg / hr 51681.64 Slag weight, Kg / hr 5001.49 Weight CO, l Kg / hr 665.49 Weight 002.1 Kg / hr 9957.37 Weight powder (Fe), Kg / hr 1000.63 Weight 02.1, decarb. Kg / hr 201b. b Weight 02.1, PC, Kg / hr 3473.01 Weight 02, fuel its. Kg / hr 2832.59 Weight CH4, Kg / hr 708.15 Weight H20, Kg / hr, outside 1593.33 Weight C02, fuel surn. Kg / hr 1947.41 Excess energy stage 2, Kcal / hr 909 Excess energy stage l, "-5932397 Supplemental fuel energy, Kcal / hr 5932397 TOTfiL Total of 02, N? N3 / ton 133.17 Total dust, Kg / ton 18.19 Total slag, Kg / ton 10,034 Total flow, Kg / ton 62.02 Total CH4, Nm3 / ton 19.83 Total carbide shaft, Kg / ton 1033.63 Total inat. scrap, Kg / ton 103.36 The heat losses used in the calculations in Tables 2-9 are based on the experience with recipients of similar size with retracting liners. The preheating of the carbide material is carried out using the completely combusted gases discharged from the first stage reactor, in an indirectly heated heat exchanger 6, for example, one consisting of parallel grooves alternately carrying heating gas. and carbide in found streams. The bulk carbide is preheated by flowing vertically through the slots, with hot gases flowing through adjacent slots. The thermal conductivity of the bulk carbide is such that 2000 g / inin can be preheated in such a heat exchanger - with approximate dimensions of 1.5 x 2 x 5 meters. The main problem of stage 1 in the use of the combustion heat of CO generated both in stage i and in stage 2, is the speed of transfer of energy in the gas phase to the metal bath. From the results in the basic oxygen furnace (an erect and incunable general cylindrical converter), it is clear that only about 11% of the potential chemical energy e-jue comes from the complete combustion of CO to C02 is typically recovered in the bath of In such furnaces, due to the upward flow of waste gases, the heat-sinking effect of the water-cooled cover, and the intimate contact of the gases with the slag-metal emulsion, which, for the Most of the procedure, it is high in carbon (greater than 0.2% O) and therefore, through the blowing cycle it does not allow any C0__ to survive in the vicinity of the metal-slag emulsion.This makes an oxygen furnace Basic is a difficult, if not impossible, to carry out an autogenous process from a wide feed axis carbide iron shaft.In the electric arc furnace, the post-combustion of the CO that emerges from the metal bath can of taking place but, since the transverse area of the bath is very wide, it is difficult to penetrate towards the center or the opposite sides with the oxygen necessary to burn the CO generated in the bath, and the overall use of the potential chemical energy that comes from the oxidation of CO to C0? It is difficult. The large bathroom area makes it difficult to provide a deep foaming scum in which to carry out the post-cornbustion. Likewise, the walls and roof of the electric furnace are cooled with water, which quickly absorbs the energy from the furnace. In this way, neither the basic oxygen converter nor the electric oven is optimal in relation to heat transfer efficiency. The fact that higher heat efficiencies are obtainable in other types of furnaces is exemplified by the ejatos obtained from the iron ore smelting reduction processes, such as DTO and HIsmelt. These smelting procedures include the need to generate energy from the post-combustion of the CO fired from the reduction of the ore and the gasification of the coal in the smelter, as well as the transfer of the combustion heat to the metal and slag bath. To supply the energy required for the heating of the feed material and the endothermic reaction of the reduction of iron ore to metal iron. These data have provided a measurement of the capacity of the heat transfer in a slag / bath system eg metal /. A heat flux of 2 Gcal / hr / ms. (2 x 10c »cal / hr / rn__) or greater was obtained in the GOD system, as calculated from the ciatos reported in an article by T.? Baraki et al., [Rum &; steelrnal-ers, Vol.17, No. 12, December 1990. The transfer of combustion energy from the gas phase in the free-board region over the slag and metal can also be achieved, but not as intense as the transfer of slag to metal. Table 10 compares the energy flows that can be expected for the transfer of the gas phase to that between metal and slag.

CURPRQ 1Q Heat transfer requirements SRUPRS kacl / hr Energy required in bath 9943494 Fner-gia available in slag without supplemental energy -8634903 with supplemental energy -9675074? > Required energy ejel gas s n supplemental energy 1308591 with supplemental energy 286420 0 Calc or obtainable flow rate, cal / hr / m¡_; from slag to bath (smelting procedure data 2000000 from slag gas (calculated) 150154 Area required for heat transfer, ___ from slag to slag 4.97 from gas to slag, p / or power supply 8.71 It can be seen from quot 10 that the heat flux 0 from gas to slag is much smaller than the slag to bath, and that relying on the transfer of heat from gas to slag would require a very large container and, therefore, , it is necessary, in order to obtain a container of reasonable size, to optimize the energy vibration of the post-combustion reaction directly in the slag axis phase. As mentioned above, there is no need to maintain any chemical concentration gradient on the metal bath in the reactor of stage 1. Due to the great evolution of the CO gas in the bath and the melting and dissolution of the iron carbide, The energy of agitation and intensity is very great and the bathroom and the bathroom are well mixed on all occasions. Table 11 shows typical mixing energy intensity values calculated for the reactor of stage 1.

TABLE 11 Energy intensity typical mixed shaft for the reactor of the ana 1 CO fired from the reduction of FeaOA ^ Nm3 / rnin 18.41 CO fired from 0 »injected, Nma /? N? N 89.63 Emission of total CO, Nm3 / rnin 108.4 Mixture energy, watts / ton 35542 Mixing time, sec, based on Naka Ishi and others. (> 12 Mixed time, secs, based on Kato and others. < __ > 22 CO blow speed, Nma / ton-rn? N 3.9 (1) Ironrnaking & teel ina lo ng, vol. 3 (1975), page 193 (2) Kato, Y., Nakanishi, K., Leap, K., Nozaki, T., Suzíki, K. and Erní, T., Tets? - to-Hagane, ££., (1980) 11, S881 The reactor of stage 1 is preferably operated in a continuous form, with continuous feed of iron carbide, oxygen and fuel, continuously bleeding metal and slag. (However, it can be operated in an intermediate manner, with a minimum initial liquid load at which the iron carbide material is added continuously, constantly increasing the amount of metal in the container until it is bled. This operation requires a container in a certain deeper way). The reactor of stage 1 can be thought of as having three zones: gas, slag and metal bath. In the fixed state, each zone has an energy balance that must be satisfied. In the case of the metal bath, the solid carbide is injected directly into the bath and the oxygen is injected through the submerged nozzles, despite the fact that the carbon coming from the iron carbide is continuously oxidized to CO by the Oxygen, releasing heat from the metal phase, there is still not enough heat released as a couple to provide the sensible heat and heat of the solution to melt and dissolve the carbide. In this way, the heat must be transferred from the slag phase to the metal phase. This heat- must come from the combustion of CO to C0_ > in the slag phase by means of throwers and post-bus burners. The burners preferably burn the CO recovered from the refining vessel of step 2, or they can use another fuel such as natural gas. The slag is preferably of a composition that easily foams and allows combustion to take place within the slag foam, thereby retaining the heat of combustion in the slag phase, from which it can be easily transferred to the slag phase. metal. Oxygen in the vapor space of the first stage reactor is limited and any CO that has not been burned in the foamy scum will normally be burned out of the reactor., e.g., in a chamber of post-conbustión / intercarnbiador axis heat 24, as previously explained. The calculations of the energy balances of the subzones have been made for various operating conditions, and the areas between the zones required to transfer the heat-necessary to satisfy the heat balances-of the inter-zone have been calculated. Based on these areas, the size of the container needed to reach a certain production speed is established. Table 10 is an example of such a cat. The concentration of carbon in the metal bath in the reactor of stage 1 is maintained at the desired concentration to bleed and transport it to the reactor axis the second stage. The reactor of the second stage is a continuous channel-type refining vessel with a series of submerged oxygen nozzles, the iron-carbon alloy preferably being constantly reduced in carbon content by flowing the metal from one nozzle to another. Alternatively, the reactor of the second stage may be a well-mixed reactor vessel, continuously injecting oxygen into the metal bath to maintain the carbon content at all times at a desired level in the steel product. Also, the reactor of the second stage can be a serni-intermittent reactor, with an input f ja of the product axis the first stage and gaseous oxygen, but without any bleeding until the column and the carbon content are equal to the size and desired composition of the steel batch. In all cases, the CO gas is collected without dilution of air for use as a fuel in stage 1. The exothermic reaction of stage 2 is self-generated, without needing any additional fuel if, for example, ( 1) The carbon content of the incoming liquid iron-carbon axis of stage 1 is approximately 1.35% axis, the inlet temperature is approximately 1520 ° C, the final content of the carbon steel axis is approximately 0.05% and the tempera The steel content is approximately 1670 ° C / o (2) The content of incoming liquid carbon alloy is about 1.0% and the temperature is about 1500sC, the steel composition is about 0.05% and the temperature of the steel is approximately 1650 ° C. Many combinations occur so that they will result in a self-flowing stage 2, within the general limits of temperature and composition as shown in area fl of Figure 2 for the incoming iron-carbide step 1. In other cases, the post-combustion oxygen can be introduced into the reactor vapor space of the second stage to burn-a portion of the CO, if additional heat is needed. The gas co in CO leaves the reactor of the second stage at the temperature of the steel, take it once it is created inside the steel axis barium and, preferably, no oxygen is added to the gas phase ,, If used a continuous fan reactor, the oxygen nozzles may be separated apart by approximately 1.0-1.5 meters and the channel through which the metal stream flows shall be such a cross-sectional area that the speed of the metal plug flow shall be at least less approximately 0.5-1 meters per minute, to avoid re-embedding. Mixing patterns in a portion of such a container are shown in Figure 3. As illustrated in that figure, a marked upward velocity is imparted to the metal immediately above each nozzle, and there is a distinct circulatory pattern around each pen metal axis that rises over the nozzle. Such patterns, with a sufficient forward flow of metal imparted by the geometry of the container, ineffectively minimize the re-migration in the reactor-and establish a gradient of carbon concentration in the bath. Is the reactor of the second stage completely enclosed so that the CO emitted from the bath can be collected without exposure to air? other sources of oxygen, like the first stage reactor, the reactor of the second stage also has a refractory lining to minimize heat loss. If the reactor of the second et al is operated in a continuous manner, means for intermittently opening and closing the bleeding vessel must be provided. In such a case, there is no need to maintain a carbon concentration gradient from one end to the other, and the container can be operated as a well mixed reactor. Using data as described and exemplified above, a system was designed, based on the conditions indicated in Table 2, to produce 50,000 kg / hour of steel from the carbide iron axis. Shown in Figures 4, 5 and 6 is such an exemplary first stage reactor which, together with a corresponding second stage reactor, is capable of producing steel at such a rate and containing about 0.05% C at a temperature of about 1630 ° C. . As shown in Fig. 4, the reactor of the first stage is generally rectangular in plan view and has a rounded bottom 44 as shown in Fig. 6. The reactor of the first stage can be tiltable, for example, as shown in figure 6, it can be on rollers 46 and can be mclinable by eclio of a driving shaft 47, through a gearbox 48, by means of shaft a motor 49 (Fig. 5). A tilting action of the reactor facilitates the service and maintenance of the subsurface nozzles 17, the re-furnace of the furnace, e .. The reactor with refractory lining 1 of Figure 4 has an interior width in the line of slag approximately 2 meters and an interior length of approximately 5 meters. The distance from the lowest point of the bottom to the metal shaft axis surface is approximately 0.7 meter axis in the operation in fixed state; the distance from the bottom point of the bottom towards the top-of < ? The slag is approximately 2.5 meters (the depth of the slag foam is preferably not more than 2.0 meters above the metal bath under the operation in a fixed state), and shafts from the lower point of the bottom to the inside of the roof are approximately 4.0 meters. A fixed-state feed of 1000 kg / rnin of iron carbide (table 1) is maintained continuously, through a single launcher 51, which can be a simple steel tube. With such high carbide injection speeds, it is difficult or impossible to operate the first stage in the sealing flow to the reactor. In fact, as noted above, the injection of the iron carbide feed directly into the metal batch contributes significantly to the well-mixed reaction in the reactor of the first stage. As also mentioned above, this is another disadvantage for the Geiger Patent No. 5,139,568. I? 1 launcher 51 is retractable and is submerged in the metal bath eg, at least 30 crn under the slag when in operation. The dense flow phase of iron carbide is maintained with a typical ratio of 37.3 kg of iron carbide to 0.373 kg of carrier gas. The carrier gas is preferably carbon dioxide or nitrogen. The weight of the metal in the bathroom in the fixed state is 32 tons. The burner 19, capable of burning up to 1200 Nm3 / hr of CO of the reaction of the second stage with oxygen, is positioned in the end wall of the reactor closest to the reactor axis stage two approximately 2.3 meters above the bottom point of the bottom, and pointing down to an angle of approximately between 30 degrees . The burner 19 is also provided with a natural gas supply line 20 so that natural gas can replace CO at a maximum total energy input rate of approximately 5 x 10 * Kcal / hr. The natural gas burner / ox igen? 12 is installed, in a similar way, at the opposite end of the 00 burner It is capable of energy velocities of 0 to 5 x 1 ü & Kcal / hr.

Four to eight nozzles covered with gas 17 are located at the bottom of the furnace, allowing continuous injection of approximately 40.8-45 Nm'Vmin of oxygen, evenly divided between the nozzles, together with approximately 6.8-8.0 Nm3 / of natural gas or 10.2-11.2 Nrn3 /? N? N ele COs. or a », as a reflector of the nozzle, evenly divided in the nozzles. From four to eight post-combustion 18 launchers, they allow the injection of approximately 35 Nm-Vmm of oxygen, which can be evenly divided along the launchers, are located on the side walls of the reactor l, for example , approximately 1 meter above the barium of rnetal, that is to say within the foamy slag layer. These launchers are angled down at an angle, for example about 25-30 degrees, towards the metal bath and extended into the slag phase. The oxygen thus injected serves to post-combustion to the CO fired from the reactor in the first stage, to CO »within the slag is umo a. The metal is then bled from a bleeding port 52 and the level of the metal bath is maintained at about 0.7 meters during the operation in a fixed state. The gases of the furnace, mainly CO 2, are thus removed from the vapors, the first reactor is removed through a sliding seal 53 (Figures 4 and 5), avoid the significant air intake and connecting to the conduction duct 23.

The design of the r-ector is such that bleeding, injection of "gas and removal of waste gas is achieved without a substantial intake of air and thus reducing the investment in the management of the axeshaft gas and the formation of NOx. To facilitate refractory repair, a replaceable top half of the reactor can be provided. The intermediate iron alloy (with a typical composition of 1.0-1.5% C and a temperature of 1490-1540 ° C) is transferred from the first stage reactor to the second stage reactor without slag and with the least loss of possible temperature. For this purpose, the molten metal of the first stage is transferred, for example, through a bifurcated tiltable sustaining container running through or this intermediate (not shown). Alternatively, the molten metal or a portion thereof can be removed and solidified either in the form of ingots or granules. A heat balance for the reactoi of the first stage is given in table 12 below for the conditions described in table 6. TABLE 12 Heat balance - first stage Heat in river KcaJL / hr C or out? Cai / hr Scrap Nat. 0 FeaC in carbide -4221205.88 00 * 5603686.36 FßaO * in carbide -316767.64 CO 369827.96 iOa in carbide -220231.96 Fe-C int. 15782894.27 C0 - Stage 2 less heat axis axis - 1 5621. 36 esco r a 2 1 384 1 9. 65 (as 2CaOS? O_) Stage 2 CO minus heat loss -62453.86 powder 436281.24 reaction: 5 4Fe3C + Fe30 «= 15Fe * 4C0 1714063.08 Fe (rnetal ico) in carbide -19539. 8 Reaction: 10 CO r 1/2 02 = C02 -17119880.14 reaction: C (gr) = C in solution 370561.01 Heat of slag formation 786938.43 per heat a 3283233.27 Reaction: "Q Reaction: 'Fe _-, C = 3Fe« • CO - 3702 70. 60 cal or axis dust formation -899057.91 required fuel energy of its fuel, Kcal / hr 0.00 TOTALS - 29698966.85 29698966.85 The reactor of the second stage with refractory lining 36 is for the purposes of (1) removing carbon from the carbon-iron alloy of stage one by injecting oxygen into the molten metal stream through the lower nozzles covered with gas 38, (2) ) collecting the carbon onoxide gas formed by the reaction of carbon and oxygen for use as a fuel in the first 5 stage and (3) bleed a fixed stream of steel in a pouring trough 43 pair-to temperature setting and of composition for its subsequent casting. A more detailed view of a r-eactor of the second exemplary stage is shown in Figures 7a and 7b, in which the length of the container is much greater than the other two diameters, and the injection of bottom oxygenation is a through six nozzles 38 defining 6 treatment zones, separated, for example, 1.06 meters apart along the central line of the bottom of the channel. The flow of oxygen, at N? N / m? N, to the various nozzle zones can be varied, preferably to provide substantially equal stirring energy within the molten metal in each nozzle zone, for example, with oxygen flows as follow: zone 1, 4.04; zone 2, 2.18; zone 3, 1.39, zone 4, 1.74; zone 5, 1.39, and zone 6, 2.12. As a protective gas, 0.15-0.23 Nrn3 / mn natural gas or 0.38-0.58 Nrn3 / rn? N of CQ__, N__ or Ar flow towards each nozzle. Carbon dioxide is a preferred nozzle coolant in the second stage reactor to avoid the possible accumulation of non-combined hydrogen and a resultant explosion hazard, as can occur with the use of methane refrigerant (in contrast to the reactor). of the first stage where the oxygen blown in the foamed slag was combined with hydrogen to form water). Such number and separation of the oxygen nozzles in the reactor of the second stage is optimal for this example between obtaining the desired level of decarburization and keeping the residence time of the molten metal in the short furnace to avoid the problems of refixing and of blowing. Figure 8 refers to the residence time of the melt or the number of nozzles in the reactor of the second stage, where the carbon content of the intermediate iron-carbon alloy introduced in the reactor (the second stage is 1.5% and the carbon content of the final carbon-carbon alloy is 0.01-0.5 weight percent As shown, the minimum residence time for this final carbon content is obtained with approximately six nozzles. As shown above, the oxygen flow to each nozzle can be separately controlled as needed to maintain a desired carbon gradient from the inlet to the outlet end of the reactor.In any case, the total oxygen injected into the steel bath is in These amounts are essentially stoichiometric in order to reduce the carbon content of the bath to the desired level.The provision is also made for the injection of iron, v.gr., approximately 0-1.5. N ^ / inin, in the last two nozzles. The reactor of the second exemplary stage, as illustrated in Figures 7A and 7B, may have a slight tilt in the downstream direction (eg, about i%) to assist the flow of metal, and has a refractory channel of first section 60, adjacent to the feed end of the reactor, as wide and deep as a second section channel 61, adjacent to the outlet end of the reactor. For example, the interior dimensions of the channel of the first section 60 and zones 1 and 2, which define the dimensions of the liquid metal bath in that section, can be approximately 1.02 meters wide by 0.61 meters deep and have a Approximately 2.77 meters long. The second section 61 and the zones 3-6 can have a channel width of approximately 0.61 meters, a bath depth of 0.41 meters and a length of approximately 4.11 meters. Such a container provides for the regulation of a flow with inuo of molten iron-carbon alloy in the sealing flow along the length of the reactor. The speed of the sealing flow in the second narrowest section bl is approximately 0.5-0.6 meters / minute, and the total metal flow is approximately 51,000 kg / hr. Such a reactor design also reduces the splashing of the liquid metal bath (resonant waves on the surface of the liquid metal). The metal enters the reactor of the second stage at a temperature of between 1450 and 1550 ° C, preferably about 1520 ° C and at a temperature of about 1630 ° C to 1670 ° C. A heat balance in stages relies on stage 2 of the previous example and, based on table 6, is shown in table 13 below.

CURPRQ 13 Heat balance-second stage Heat in roads Kcal / hr Heat < 1e salt? 1a Kcal / hr Fe-C intermediate -15782894 Steel 16875560 using Kcal / kg reaction: c (gr-) + 0__ C0__ -1165818 Powder 170375 reaction: c (g? -) + 1/2 02 - C -1 09754 Co 624526 Dissolution of C -286808 CO? »156203 Per''da of heat- 718611 TOTAL 18545275 18545275 As in the case of the reactor of the first stage, the reactor of the second stage 36 is designed to prevent air access, so as not to burn the CO emanated from the reaction. Therefore, both the entrance and the exit of the molten metal is through bleeding holes or submerged siphons, as well as on the reactor of the first stage. The gases leaving the reactor of the second stage 36 at the temperature of the molten metal, e.g., about 1630 ° C, are cooled in the water cooler 41 to bring them to a condition where they can be provided to the burner. 00 19 of stage 1, e.g., a pressure of approximately 1,406 kg / cm58 rnanomet rich. As noted above, the vapor from the second stage reaction is essentially pure iron, which in finely divided form (eg, approximately 1 miter) is pyrophoric, so care must be taken to avoid air or Other sources of oxygen contact this material, since, in the presence of oxygen, it will burn at temperatures up to approximately 100 ° C. The input power of the second stage procedure is pure enough that very few, if any, fluid agents are necessary. The small amount of slag formed in the second reaction is periodically bled, e.g., from the feed end of the reactor channel of the second stage. The flow of metal can be stopped for short periods of time to accommodate the change from one collection vessel to another, or when there is a delay in feeding material from stage i. In the previous example, the collection bucket 43 is capable of holding up to 60,000 1-g of steel and of maintaining the temperature of the steel at about 1600sC. For such a purpose, the tub 43 may be equipped with a cover (not shown) through which a burner is inserted. The emergency emptying of the second stage reactor can be carried out by the use of a bled cast bi-channel metal channel (not shown). The provision is made to investigate the waste gases from both the reactors of the first and second stage for the continuous analysis of CO and CO2. " Flow measurements and controls are provided in all oxygen and natural gas lines, and dynamic feedback is provided from gas analyzers to flow controllers through a programmed logic controller (PLC). The two-step reaction is critical for an effective operation of the carbide to steel process of the invention. As described in the above specific example, the reactor of the first stage is a well-mixed reactor, there being no need, and in fact an impossibility, to maintain a cornpositional gradient along the length of the reactor and leading to Simplified heat axis balances and control of the procedure. Although the reaction of the second stage can be operated as a well mixed reaction, it is preferred that the sealing or laminar flow be maintained, with a carbon gradient from the inlet to the outlet end of the reactor. It is essential that at least a large portion of the CO that was fired from this reaction of the second stage be collected for burning in the first stage reactor, preferably in the foamed slag layer for efficient heat transfer from the second stage. scoria to the molten metal layer in the reactor axis the first stage. In this way, a maximum energy value is e? r < The 00 that was fired from the reaction of the second stage, and the reaction of the first stage also proceeds essentially automatically. The balance of the corresponding total material for the previous example of the inventive process, again based on table 6, is as follows: TABLE 1 Global material balance Current Can, Kq / Hr Iron carbide feed 57100 Flow 3426 Steel 50000 Slag 5525 Powder 1114 0H decarburized, stage 2 1190 OH decarbon, stage 1 3166 Post-co b., Stage l 4082 Exit gas, stage 1 12416 For commercial and practical production a single unit consisting of a first and second reactor is capable of producing 25-200 especially 50-150 metric tons per hour. For higher production speeds, several such units can be arranged in parallel. The charge to the reactor of the first stage may consist of up to 50% of components other than the iron carbide material, such as shaft-shaped material, iron in ingots and pre-reduced minerals. In such cases, some supplemental energy, eg, through the burning of natural gas, petroleum or coal, is generally required if the non-carbide portion of the load is substantial.

Separating the procedure in two different stages, eliminating the need to maintain a concentration gradient in the first stage during continuous operation and in a fixed state, the operation of the procedure and the design elel? -ec? reactor component is simplified too. It's much easier to operate a well-mixed procedure. Such separation of the steps of the procedure also results in the fact that the energy in the gases released in the second stage of refining, it is not necessary to do autogenea id reaction of the second stage and can be used completely to provide the necessary energy for hacor autogenea the first stage of fade. This recovery of 00 from stage 2 to be fully used in step 1, solves the problem of the prior art of the proper use of process gases in the appropriate place. Also, by separating the process into two stages, the refining otapci can be continuous, continuous or intermittent, depending on the needs of a particular steel plant to accommodate emptying tray kilns or continuous casting operations. Being completely closed, the inventive system eliminates contaminant aliñente aliñente, the dust of stage 1 can be captured and returned to the procedure and gas s rich in 00. ^ can be cooled and collected for another use or its sale.

As a continuous procedure, the capital costs per tonne of annual capacity can be reduced. As an essential autogenous procedure, operating costs may be lower than in other steel fabrication procedures. The procedure can use prepared shaft material with a minimum auxiliary fuel shaft required, without significantly increasing costs.

Claims (70)

1. NOVELTY PE Lfl INVENTION CLAIMS 1. - A process for converting iron carbide to steel which comprises melting and dissolving iron carbide contained in a filler material in a liquid iron-carbon bath contained in a first reactor, blowing oxygen into the liquid bath of oil. ro-carbon and produce in the first reactor a carbon-iron alloy of carbon content The content between the carbon content of the filler material and the desired carbon content of steel, and the refining of the intermediate liquid between the iron-carbon-steel alloy of the desired final carbon content in a second reactor.
2. 2. A procedure according to the rei indication 1, also characterized by the fact that the iron bath in the first reactor is well mixed and the liquid metal bar in the second reactor flows in an essential flow obt urate. 3.- A method according to claim 1 or 2 further characterized in that the process is carried out in inua form. 4. A process according to claim 1, further characterized in that the reaction of the liquid bath of the same in the second reactor is facilitated by the injection of oxygen under the surface of the liquid metal bath in the second reactor and It is carried out in the form of oxygen. 5. A process according to claim 2, further characterized in that the reaction of the liquid metal bath in the second reactor is facilitated by the injection of oxygen under the surface of the liquid metal bath in the second reactor and carried out in an augenous way. 6. A conformity procedure with claim 4, further characterized in that the monoxide or carbon-bond generated in the second reactor is collected, kept free of air and other sources of oxygen and burned with oxygen in the first reactor. . 7. A process according to claim 5, further characterized in that the carbon-onoxide generated in the second reactor is collected, kept free of air and other sources of oxygen and burned with oxygen in the first reactor. 8.-. A method according to claim 6, further characterized in that it comprises developing a foamed slag layer that overlaps the core bath in the first reactor, and burning the carbon axis monoxide in the second reactor-in the foamed slag layer. 9.-. A method according to claim 7, further characterized in that it comprises developing a foamed slag layer that overlaps the metal bath in the first r-eactor, and burning the carbon monoxide in the second reactor in the foamed slag layer. 10. A process according to claim 8, further characterized in that the filler material is essentially preheated iron carbide at least about 55 () ° C, carbon axis onoxide generated in the first reactor is burned in the Foamy scum and the reaction on the first reactor is essentially autogenous. 11. A process of consistency with claim 8, further characterized by "] that the load-bearing material contains up to about 50% by weight of iron-based waste material and the remainder of the load is essentially iron carbide. 12. A process according to claim 9, further characterized in that the ear material is essentially iron carbide preheated to at least approximately 550 ° C, carbon monoxide generated in the first reactor is burned in the slag layer foamy and the reaction in the first reactor is essentially autogenous. 13. A method according to claim 10, further characterized in that the method is carried out in a continuous manner., 14., - A method according to claim 12, further characterized in that the procedure is carried out in accordance with continue. 15. A process according to claim 2, further characterized in that the oxygen is injected into the metal baths in a first elongate reactor and a second elongated reactor in separate sites along a length of each one of the respective reactors, and the intermediate iron-carbon alloy produced in the reactor is cleaned of slag before its introduction to the reactor. 16.- (in procedure <according to claim 15, further characterized in that the post-combustion under the surface of a foamed slag contained in the carbon onoxide of the first reactor produced by the injection of oxygen is caused by the surface of the metal bath in that reactor. 17. A method for conforming to claim 16, further characterized in that it comprises preheating iron carbide in the filler material with the use of the heat of the evolved gas generated in the reactor. '18.- A process for the formation of a carbon-iron alloy from a filler material containing iron-carbide and a gangue comprising silica and alumina, comprising the steps: melting and dissolving carbide-iron content in the filler material in a liquid coal-iron bath, - add a lime-containing flux to combine with the gangue to form an oxygen scavenger in the iron-carbon fiber liquid bath and generate a reaction product. of car-bono onoxide; With the use of the carbon monoxide gener-aclo in the iron-carbon bath, form a layer of foamy slag that overlaps an upper surface of the iron-carbon bath and which contains carbon dioxide in the carbon monoxide, and burns the carbon monoxide. carbon monoxide in the foamed slag layer. 19. - A method in accordance with claim 18, further characterized in that the foamed slag layer is of uniform thickness uniformly across the surface of the f-erro-arbon bath, 20. - A process for converting iron-to-steel carbide having a carbon content of about 0.01% to about 0.5% carbon, which comprises providing a first elongated reactor and a second elongated reactor, providing a liquid iron-carbonate bath In the first reactor, injecting carbide of iron into particles ba or the "upercifie of the liquid bath of the metal in the first reactor, shake the liquid bath of metal in the first reactor" to a condition well mix it by injecting oxygen into the bath in the bath through a plurality of separate sites along the length and width of the first reactor and expelling carbon oxides from the metal bath by the reaction of carbon and oxygen, continue the injection of iron carbide and oxygen in the first reactor to provide a steady-state reaction condition with the metal bath containing an intermediate carbon level of about 0.5% to about 2%, transferring an intermediate liquid alloy of iron -carbon to the second reactor, injecting oxygen into the metal bath in the second reactor-through a plurality of separate sites along the length of the second reactor-in a manner that provides essentially flow-type of bobbin with a carbon gradient along the reactor length of the carbon content of the intermediate iron-carbon alloy at the liquid metal inlet end to the carbon content of the desired final steel in an ex-liquid metal exit exodium. Second reactor, refining in autogenous form the liquid alloy of fiero-carb n intermediate to the desired final iron-carbon axis content, collecting the gaseous carbon dioxide produced in the second reactor and burn it with oxygen in the first reactor. 21. A process according to claim 20, further characterized in that it comprises preheating the iron shaft carbide fed to the first reactor at a temperature of at least about 550 ° 0, developing a layer of friable slag that overlaps the water bath. metal in the first reactor, and wherein in carbon or carbon dioxide the second reactor and the carbon onoxide generated in the first reactor is burned in the foamed slag layer to provide an essentially autogenous reaction in the first reactor. 22. A process according to claim 21, further characterized in that the iron carbide charged to the first reactor is preheated with the use of gases produced by burning carbon monoxide in the first reactor. 23. A procedure according to one of the claims 20, 21 and 22 further characterized in that the process is carried out continuously. 24. A procedure for con ulad with an axis claims 20, 21 and 22 further characterized in that it comprises collecting dust removed from the reaction carried out in the first reactor and return the powder to the first-reactoi., 25. - An authentic process for the manufacture of steel which requires to provide an elongated final refining reactor having a length greater than the width, introducing a liquid alloy of iron at one end of the final refining reactor. With a substantially slag-free rbon having a carbon content of about 0.5% by weight to about 2.0%, the final refining reactor is divided into a series of separate sub-zones along the length of the refining reactor. Finally, oxygen is injected into separate positions in the liquid metal in the final refining reactor, thus generating carbon monoxide and imparting to the metal lying in each subzone a vertical movement and a circular motion. Atory around the injected oxygen by minimizing the mixed retro and establishing a carbon gradient between subzones as the liquid metal flows downstream from one zone to the next.Thus, the carbon content in the last zone is around 0.01% to about 0.5%. 26.- A process of conf or mucia with reiviication 25, also characterized because at least a significant portion of the carbon monoxide generator in the final refining reactor is collected and burned with oxygen in a reactor of suction and decarburization producing the liquid metal feed for the refining reactor i n 1. 27.- A procedure for compliance with the re? v? ndication 26, carried out continuously and the liquid metal flows in a flu < Type essentially shutter through the reactor shaft final refining. 28. A method according to claim 26, further characterized in that the process in the refining reactor is carried out in a regular manner. 29. A co-operation procedure with claim 26, further characterized in that the process in the fusion and decarburization reactor is carried out in an intermittent manner, the liquid metal produced in the fusion reactor. and decarburization is collected and transferred to the final refining reactor where the process is carried out continuously. 30. A method according to claim 27, further characterized in that the velocity of the sealing flow of the liquid metal is at least 0.5 millimeters per minute. 31.- A conforming procedure with 1 to claim 30, further characterized in that the length of the metal flow-through channel in the final regenation reactor is at least about 10 times the width of the flow channel of metal. 32. An axis procedure according to claim 31, further characterized in that there are at least six zones in the final refining reactor. 33. A process according to claim 26, carried out continuously and wherein the flow of liquid metal is essentially shut-off type flux through the final refining reactor. 34. A method according to claim 33, further characterized in that the sealing flow rate of the liquid metal is at least about 0.5 meters per minute, the length of a metal flow channel in the final refining reactor is of at least about 10 times the width of the metal flow channel and at least 6 or 6 subzones in the final refining reactor. 35.- A process according to claim 26, further characterized in that the reaction in the final refining reactor is a well-mixed reaction. 36.- A method according to claim 26, further characterized in that it comprises forming a layer of slag on a layer of liquid metal in the fusion and decarburization reactor, injecting oxygen into the layer of liquid alloy of iron-coal that generates carbon monoxide or the reaction of carbon and oxygen, foaming the slag with the use of carbon monoxide generated and embedding in the foamed slag layer the carbon monoxide generated in the fusion and decarburization reactor and in the final refining reactor. 37.- A method for manufacturing steel that comprises providing a final refining reactor, enclosed, elongated, introducing at the entrance end of the reactor-a liquid intermediate iron-carbon alloy substantially free of slag eg has a content of carbon higher than the final carbon content, injecting oxygen into the liquid carbon-iron alloy, thus decarbonising the alloy and forming carbon monoxide, excluding substan- tially other sources of oxygen from entering the reactor, of final refining, and collecting the carbon onoxide generated in the final refining reactor. 38.- A method in accordance with the claim 37, further characterized in that the liquid alloy iron-carbon shaft is continuously moved through the reactor-of final refining in the filling flux with a carbon content which decreases from the end of the reactor inlet to an outlet end of the reactor. liquid reactor 39.- A method according to one of claims 37 and 38, further characterized in that it comprises providing an enclosed, elongated fusion and decarburization reactor, which provides an iron-carbon alloy bath in the fusion and decarburization reactor, providing a layer of foamed slag that overlaps the bath of liquid alloy iron-carbon, introducing pre-heated particulate iron carbide in the bath of liquid alloy of iron-carbon, injecting oxygen into the bath with the liquid alloy of iron-carbon decarburizing the bath and forming carbon monoxide, introducing additional carbon monoxide from the final refining reactor into the fusion and decarburization reactor, burning all the carbon dioxide oxide in the foamed slag with oxygen injected into the foamy slag, continue - the reaction in the fusion and decarburization reactor in a well mixed and essentially in autogenous form until the The carbon content of the liquid iron-carbon alloy in the melting and decarburizing reactor reaches a desired level to introduce the liquid alloy of iron-carbon in the final refining reactor, remove the slag from the liquid alloy of iron-carbon in the fusion and decarburization reactor and introduce the liquid alloy of iron-carbon without slag in the final refining reactor. 40.- A reactor for the production of a coal-iron alloy from iron carbide, said reactor -including a coal-iron bath formed from an iron carbide feedstock, means for injecting- iron carbide and slag formers in the bathroom < the iron-carbon, and a launching member for injecting oxygen into the iron-carbon axis bath, said iron-carbon bath comprising: a liquid portion, iron alloy axis -carbon formed from the carbide reaction of iron with oxygen to create a reaction product of carbon monoxide, and a portion of slag that overlaps the liquid portion of iron-carbon alloy formed by the reaction of slag forms and frothing the resulting liquid slag or said carbon monoxide. 41. An apparatus for the essentially autogenous production of steel from a substantially slag-free liquid metal feedstock consisting essentially of about 0.5 to about 2% by weight of carbon, the remainder being iron, comprising a final refining reactor having a length much greater than the width, means for injecting oxygen into the liquid metal bath contained in the final refining reactor, means for excluding oxygen from the refining reactor other than injected under the surface of the liquid metal bath, and means for collecting gaseous carbon monoxide discharged from the liquid metal bath. 42. An apparatus according to claim 41, further characterized in that the length of the metal flow channel in the final refining shaft reactor is at least about 10 times the width of the metal flow channel and there is at least six equally spaced nozzles to oxygenate. 43. An apparatus according to claim 41, characterized in that it comprises an elongated reactor 5 for melting and decarburizing to produce liquid coal-iron alloy or feedstock material for the final refining reactor, said reactor for fusion and decarburization including burner means to burn carbon onoxide generated in the reactor. 10 44.- An apparatus in accordance with the claim 43, further characterized in that the burner means of carbon monoxide are directed downward at an angle from the horizontal to burn carbon monoxide in a foamed slag layer overlaying a liquid metal bath 5 content in the fusion and decarburization reactor .. 45.- A device in accordance with the claim 44, I was also oterized because it comprises injecting oxygen into a lithium metal drum or contained in the fusion reactor and the charring at separate sites along the length 0 of the ism. 46.- An apparatus in accordance with the claim 45, further characterized in that it comprises a plurality of post-combustion oxygen launcher adapted to inject oxygen under the surface of the foamed slag layer and!: Burn in the same mono carbon dioxide fired from the metal bath. liquid. 47. - An apparatus in accordance with the claim 46, further characterized in that it comprises means for injecting iron-carbide into particles as feed material under the surface ele! liquid metal bath contained in the reactor fusion and decarburization. 48.- An apparatus in accordance with the claim 47, further characterized in that it further comprises at least one oxygen-fuel burner mounted on a reactor wall-fusion axis and decarbon on to add additional caloric energy to the reactor. 49.- An installation for the production of steel from iron carbide comprising: a first fusion and decarburization reactor coated with refractory material; means for providing a liquid iron-carbon bath and a foamed slag layer in the first reactor; means for injecting particulate iron carbide as a first reaction material; means for injecting oxygen to barium of liquid iron-coal at a plurality of sites in the first reactor; means for injecting post-combustion oxygen by upstreaming the surface of the liquid bath from the liquid carbon at a plurality of sites in the first reactor; means for injecting and burning carbon monoxide with oxygen above the iron-carbon liquid bath in the first reactor; edios to collect carbon-dioxide-rich gas produced by burning the gaseous carbon monoxide in the first reactor and using the sensible heat in said gas to preheat the iron-carbide feedstock; means to collect dust emitted from the iron-carbon liquid bath in the first reactor and return the powder to the reactor; a second elongated refining reactor coated with refractory material adapted to receive liquid ferrous-carbon alloy produced in the first reactor; means for injecting oxygen into the liquid alloy of iron-carbon in separate positions along the length of the second reactor; means for collecting and cooling v.arbon gas onoxide generated in the second reactor and transferring it to the first reactor to be burned with oxygen therein, and means for collecting a final liquid steel product produced on the second reactor. 50. An installation according to claim 49, further characterized in that the means for injecting post-combustion oxygen into the first r-ector are adapted to inject the post-combustion oxygen ba or the surface of the foamed slag. in the first reactor and the means for burning carbon monoxide transferred to the first reactor from the second reactor are adapted to burn the carbon onoxide below the surface of the foamed slag. 51. An installation according to claim 49, further characterized in that the means for burning carbon monoxide from the second reactor in the first reactor is an oxygen quencher -00 mounted on a wall of the first reactor and is directed downwardly. at an angle of the horizontal. 52. An installation in accordance with the re-indication 49, further characterized by the fact that one outlet end of the second reactor is lower than the end of the shaft, which is itself enclosed. 53. An installation according to claim 49, further characterized in that it comprises at least one burner oxygen / combusible mounted on a first-stage filter and adapted to assist in the melting of iron carbide and electrical material. ele pedaceria optional. 54.- An installation according to claim 49, further characterized in that the means for injecting oxygen into the first and second reactor are nozzles covered with g. 55.- An installation according to claim 54, further characterized in that there are at least six nozzles in the first reactor and at least six nozzles in the second reactor. 56. An installation according to claim 49, further characterized in that it comprises a slag port near the exit end of the first reactor to remove slag from the same. 57. An installation in accordance with claim 56, further characterized in that it comprises one through the slag shaft in the second reactor to remove the slag therefrom. BU 58. - An installation in accordance with the re-indication 49, further characterized in that it includes means for transferring liquid carbon-iron alloy product from the first reactor to the second reactor without substantial exposure of the product of the liquid alloy of iron-carbon to a . 59. A method according to one of claims 4-9, 11, 15-19, 25, 35-37 and 39, characterized in that the procedure is carried out continuously. 60. A method according to one of claims 15, 25, 36, 37 and 39, further characterized in that the oxygen is injected into the liquid iron-carbon alloy of the upper surface thereof, or from below the surface of the ism, or a combination of the top-and bottom of the surface of the same. 61.- A method according to claim 20, further characterized in that the oxygen is injected in the metal bath respectively in the first reactor and the second reactor, from above the surface of the respective metal baths, or from below the surfaces of the same, or a combination of up and down the surfaces of the bathroom. 62. An apparatus according to claim 41, further characterized in that it includes means for injecting oxygen into the bath liquid metal shaft in the final refining shaft reactor from above the surface thereof, or from below the surface itself, or a combination of above and below the surface of it. 63.- An apparatus according to claim 45, further characterized ponμje includes means for injecting oxygen to the liquid metal shaft baths contained, respectively, in the final refining reactor and in the fusion and decarburization reactor of the surface «je the respective metal baths, or from below the surfaces of the ism, or a combination of arpba and the respective liejuido metal bath surfaces. 64.- An apparatus according to claim 49, further characterized in that the means for injecting oxygen into the liquid-iron-carbon bath respectively in the first reactor and the second reactor, comprise means for injecting oxygen from above the surface. of the respective liquid iron or steel baths, or from below the respective liquid iron or steel baths, or a combination of arr-iba and below the 1-mui iron-coal baths respectively. A process for producing an iron-carbon alloy comprising: a) providing a reactor containing a fused iron-based metal bath at a level of a height within a predetermined scale in the reactor; b) introducing carbon to the molten bath at a predetermined rate by feeding a material containing iron carbide to the bath at a rate proportional to said predetermined speed; c) introducing oxygen into the groundwater bath at a predetermined stoichiometry rate closely related to the speed at which the coal is introduced to remove carbon from the bath essentially to the same velocnlad to which the carbon is introduced thereto. 66.- The procedure of claim 6b, characterized also because the molten metal is passed to the outside of the reactor to maintain the level of the bath within the predetermined scale. 67.- The method of claim 65, further characterized in that the feed of material "containing ferrous carbide to the bath is carried out at least in part during the time the molten metal is passed through. to the outside "I read reactor. 68. The process of one of claims 66 and 67, further characterized in that the carbon content of the cast iron reactor which is passed outside of the reactor is intermediate between the carbon content of the iron carbide-containing feedstock and One contained the final desired carbon. 69.- An appliance in accordance with the claimIK. 41, further characterized in that the finial refining reactor comprises a first section adjacent to an ex-feed reactor and a second section adjacent to an outlet end of the reactor and in example the width and depth of the molten metal bath. contained in the first section of the reactor are greater than the width and depth of the liquid metal bath contained in the second section of the reactor. 70. An apparatus according to claim 69, further characterized in that the length of the liquid metal bath contained in the first section of the reactor is less than the length of the liquid metal bath contained in the second section of the reactor.