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EP0139310B1 - Process for obtaining molten carbon-containing iron from spongy iron - Google Patents

Process for obtaining molten carbon-containing iron from spongy iron Download PDF

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Publication number
EP0139310B1
EP0139310B1 EP84201106A EP84201106A EP0139310B1 EP 0139310 B1 EP0139310 B1 EP 0139310B1 EP 84201106 A EP84201106 A EP 84201106A EP 84201106 A EP84201106 A EP 84201106A EP 0139310 B1 EP0139310 B1 EP 0139310B1
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EP
European Patent Office
Prior art keywords
iron
carbon
electrical energy
sponge iron
arc furnace
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
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EP84201106A
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German (de)
French (fr)
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EP0139310A1 (en
Inventor
Lothar Formanek
Martin Hirsch
Wolfram Dr. Schnabel
Harry Dr. Serbent
Klaus Dietrich Fritzsche
Heribert Koenig
Gero Dr. Rath
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Vodafone GmbH
GEA Group AG
Original Assignee
Metallgesellschaft AG
Mannesmann AG
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Publication of EP0139310A1 publication Critical patent/EP0139310A1/en
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/14—Multi-stage processes processes carried out in different vessels or furnaces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D17/00—Arrangements for using waste heat; Arrangements for using, or disposing of, waste gases
    • F27D17/10—Arrangements for using waste heat
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S75/00—Specialized metallurgical processes, compositions for use therein, consolidated metal powder compositions, and loose metal particulate mixtures
    • Y10S75/958—Specialized metallurgical processes, compositions for use therein, consolidated metal powder compositions, and loose metal particulate mixtures with concurrent production of iron and other desired nonmetallic product, e.g. energy, fertilizer

Definitions

  • the invention relates to a process for the production of liquid, carbon-containing iron with about 1.8 to 2.5% C by direct reduction of iron oxide-containing materials by means of solid carbon-containing reducing agents to sponge iron and melting of sponge iron in an electric reduction furnace, or for the production of liquid steel by direct reduction from materials containing iron oxide using solid carbon-containing reducing agents to sponge iron and melting of sponge iron in an electric reduction furnace.
  • arc furnaces is to be understood as directly heated arc furnaces in which the heating is carried out by electric arcs burning between the electrodes and the metallic insert or the steel bath. For this reason, a process for melting iron sponge in electric reduction furnaces was developed.
  • electroreduction furnaces is understood to mean furnaces in which electrodes are preferably immersed either in an open or half-covered slag bath or in a standing Möller column and in which the energy conversion takes place mainly through resistance heating in the slag bath.
  • the melting of sponge iron in electric reduction furnaces is e.g. B. described in «Stahl und Eisen 97 (1977), pages 7-17. These processes are primarily designed to replace the electric arc furnace, i.e. H. for the production of steel with carbon contents up to approximately 1%.
  • the sponge iron used has carbon contents of over 1%, i.e. H. it comes from a direct reduction with gaseous, CO-containing reducing agents.
  • the lower grain size of the iron sponge used is 6 mm and the metallization is about 90%.
  • An iron sponge with a higher carbon content and good metallurgical properties is used as the input material.
  • the electrical energy is taken from a network.
  • Direct reduction using solid carbon-containing reducing agents produces an iron sponge that contains considerably less carbon.
  • the carbon content is generally less than 0.5%.
  • part of the sponge iron with poorer metallurgical properties i.e. H. with less metallization and / or smaller grain size.
  • melting this sponge iron with poorer metallurgical properties causes difficulties and may require additional costs.
  • the invention has for its object to melt the sponge iron produced by direct reduction with solid carbon-containing reducing agents, and in particular the resulting portion with poorer metallurgical properties, in a simple and economical manner.
  • the sensible heat and the latent heat of the direct reduction exhaust gas released by post-combustion are used to generate steam, and the steam is used to generate electrical energy which is conducted into the electric reduction furnace.
  • the carbon-containing iron is a carbon unsaturated iron with about 1.8 to 2.5% C. Because of the reaction kinetics it cannot be saturated with carbon. A corresponding amount of carbon is added to the furnace to achieve this carbon content. Short-term fluctuations in the amount of electrical energy generated do not interfere because the electric reduction furnace with variable power consumption can be operated. In the event of long-term fluctuations, regulation can be carried out using the amount of sponge iron used.
  • the electric reduction furnace can be used when hot.
  • the iron produced can be cast, granulated or processed further in liquid form.
  • the direct reduction takes place in particular in a rotary kiln, but can also be done in other ways, e.g. B. in the circulating fluidized bed using fine-grained ores.
  • the discharge material is processed by sieving and magnetic separation. It can be carried out as a hot or cold preparation.
  • the following fractions can occur during processing: coarse sponge iron, fine-grained sponge iron, excess carbon, ash and desulfurizing agent.
  • the processing enables a precisely metered addition of the carbon required in the electric reduction furnace.
  • the separated carbon excess can be used for this, in particular one which is of good quality, i. H. the ash and sulfur content is relatively low.
  • the excess carbon can also be returned to direct reduction or used for other purposes.
  • the hot combustion gases in the combustion unit can be generated by burning coal.
  • the separated carbon excess of the direct reduction can be used as carbon.
  • carbon with poor metallurgical properties - such as a high ash and sulfur content - can be used easily and effectively in this way.
  • the combustion is preferably carried out in a circulating fluidized bed.
  • Such processes are described in DE-AS 2,539,546, US Pat. No. 4,165,717, DE-OS 2,624,302, US Pat. No. 4,111,158.
  • the generation of the electrical energy from the hot combustion gases can be carried out together with the generation of energy from the Exhaust gas of the direct reduction or separately from this.
  • the blowing into steel takes place by means of oxygen-containing gases, preferably technically pure oxygen, in a converter.
  • oxygen-containing gases preferably technically pure oxygen
  • the sponge iron with better metallurgical properties which is obtained after processing, is preferably used as the coolant.
  • the sponge iron with poorer metallurgical properties is melted down with optimal utilization of the heat content of the exhaust gas of the direct reduction, and the sponge iron with better metallurgical properties is used to produce steel.
  • the system is very flexible. Excess sponge iron with good metallurgical properties can still be used for other purposes. Part of the electrical energy generated can be used to generate oxygen.
  • a preferred embodiment consists in that the carbon-containing iron produced in the electric reduction furnace is carburized.
  • the carburization is expediently carried out in a pan with the addition of carbon.
  • the iron is overheated in the electric reduction furnace to such an extent that it reaches the carburizing stage at a temperature which is approximately 150 ° C. above the liquidus line.
  • Excess carbon from the direct reduction can be used as carbon.
  • the carburization can take place up to a C content of up to about 4%.
  • a preferred embodiment consists in that the temperature and / or the content of combustible components of the exhaust gas of the direct reduction is increased in order to increase the amount of electrical energy generated.
  • the temperature and / or the content of combustible constituents are increased via the values required for direct reduction. This can be done by using coal with a high volatile content, which is not used in direct reduction, or by using larger amounts of coal. As a result, a larger part of the sponge iron can be melted down.
  • a preferred embodiment is that the exhaust gas from the electric reduction furnace is used to generate electrical energy.
  • a preferred embodiment is that the exhaust gas from the converter is used to generate electrical energy.
  • One embodiment is that the additional amount of electrical energy generated is controlled so that the entire sponge iron is processed into steel. If e.g. B. the electrical energy generated with exhaust gas is sufficient for melting 50% of the sponge iron into liquid carbon-containing iron with about 1.8 to 2.5% C and for blowing this iron into steel another 20% of the sponge iron is required as a coolant 30% iron sponge as the remainder. Then so much additional electrical energy is generated that of the remaining 30% iron sponge, such an amount is melted into hot metal that the other remainder needs as a coolant when blown into steel. As a result, the entire sponge iron can be melted into a high-quality end product and processed.
  • a preferred embodiment is that the blowing into steel takes place with the addition of energy sources.
  • the energy sources can be introduced into the blowing unit in the solid, gaseous or liquid state, for. B. in the form of fine-grained coal in the bath.
  • the heat required is largely generated by burning carbon in the bathroom. If the carbon introduced with the feedstocks is not sufficient to cover the required amount of heat, the missing amount of heat can be directly and economically introduced by primary energy.
  • the system is made very flexible by the addition of the energy sources, since a correspondingly larger amount of sponge iron and / or scrap can be entered into the blower unit by adding the energy sources. Fluctuations in power generation can be absorbed in the same way. This control option is available both for blowing a part of the sponge iron and the entire sponge iron into steel.
  • the oxygen can also be generated by means of a steam turbine, which is connected directly to the compressor.
  • the oxygen generated can be stored and used as a buffer for operational fluctuations.
  • Gas turbines can also be used to generate electricity.
  • the invention is illustrated by a figure.
  • the feed 2 consisting of iron ore, coal and aggregates, is charged in the rotary kiln 1.
  • the reduced material 3 is placed in the preparation 4, which consists of sieving and magnetic separation. To simplify matters, only one output is shown for each product.
  • the sponge iron with poorer metallurgical properties 5 is charged into the electric reduction furnace 6.
  • the exhaust gas 7 of the rotary kiln 1 is fed into the electrical power generation 8, which consists of afterburning, steam generation and power generation. Electrical energy 9 is conducted into the electric reduction furnace 6.
  • the carbon-containing iron 10 produced is carburized in the carburization 11, which consists of a pan.
  • the carburized iron 12 is charged into the converter 13 and blown into steel 15 with the addition of sponge iron with good metallurgical properties 14 as a coolant.
  • the exhaust gas 16 of the electric reduction furnace 6 and the exhaust gas 17 of the converter 13 are also conducted into the electrical power generation 8.
  • the excess carbon-containing material with good metallurgical properties 18a, 18b, 18c separated in the treatment 4 is partly charged into the electric reduction furnace 6, partly into the carburization 11 and partly into the rotary kiln 1. Ash and desulfurizing agent are removed from treatment 4 as outlets 19.
  • the excess carbon-containing material with poor metallurgical properties 20 is passed into the combustion 21, which consists of a circulating fluidized bed and into which further carbon-containing material 22 is passed.
  • the hot combustion gases 23 are conducted into the electrical energy generation 8.
  • Electrical energy 24 is conducted into the oxygen generation 25.
  • the oxygen 26 is inserted into the converter 13. Missing electrical energy can be drawn from a network 27. Instead of the excess carbon-containing material 18a, 18b, 18c, other carbon can also be used. If the carbon-containing iron 10 or the carburized iron 12 is not blown into steel, it is cast or granulated over 10 a or
  • energy sources can be introduced via line, z. B. fine-grained coal can be blown into the bath.
  • the advantages of the invention are that the iron sponge obtained in the direct reduction with solid, carbon-containing reducing agents, which contains a relatively low carbon content, can be melted down with optimum use of the heat content of the exhaust gases.
  • the portion of the sponge iron that has poorer metallurgical properties can be processed into an intermediate product that can be used without restriction.
  • An integrated process without external energy or with cheaply produced external energy is possible.
  • the process can be operated very variably.
  • the entire sponge iron can be processed into a valuable raw material with a significantly smaller volume and problem-free properties with regard to transport and storage.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Iron (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Blast Furnaces (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Vertical, Hearth, Or Arc Furnaces (AREA)

Description

Die Erfindung betrifft ein Verfahren zur Erzeugung von flüssigem, kohlenstoffhaltigem Eisen mit etwa 1,8 bis 2,5 % C durch Direktreduktion von eisenoxidhaltigen Materialien mittels fester kohlenstoffhaltiger Reduktionsmittel zu Eisenschwamm und Einschmelzen von Eisenschwamm in einem Elektroreduktionsofen, oder zur Herstellung von flüssigem Stahl durch Direktreduktion von eisenoxidhaltigen Materialien mittels fester kohlenstoffhaltiger Reduktionsmittel zu Eisenschwamm und Einschmelzen von Eisenschwamm in einem Elektroreduktionsofen.The invention relates to a process for the production of liquid, carbon-containing iron with about 1.8 to 2.5% C by direct reduction of iron oxide-containing materials by means of solid carbon-containing reducing agents to sponge iron and melting of sponge iron in an electric reduction furnace, or for the production of liquid steel by direct reduction from materials containing iron oxide using solid carbon-containing reducing agents to sponge iron and melting of sponge iron in an electric reduction furnace.

Das Einschmelzen von Eisenschwamm in Elektrolichtbogenöfen führt zu Schwierigkeiten, insbesondere wenn der Lichtbogenofen ausschließlich mit Eisenschwamm beschickt wird. Unter dem Ausdruck « Lichtbogenöfen » sind direktbeheizte Lichtbogenöfen zu verstehen, bei denen die Beheizung durch zwischen den Elektroden und dem metallischen Einsatz bzw. dem Stahlbad brennende elektrische Lichtbögen erfolgt. Aus diesem Grunde wurde ein Verfahren zum Einschmelzen von Eisenschwamm in Elektroreduktionsöfen entwickelt. Unter dem Ausdruck Elektroreduktionsöfen sind Öfen zu verstehen, bei denen Elektroden entweder vorzugsweise in ein offenes oder halbgedecktes Schlackenbad oder in eine stehende Möller-Säule eintauchen und in denen der Energieumsatz hauptsächlich durch Widerstandserwärmung im Schlackenbad erfolgt.The melting of sponge iron in electric arc furnaces leads to difficulties, especially if the arc furnace is only loaded with sponge iron. The term “arc furnaces” is to be understood as directly heated arc furnaces in which the heating is carried out by electric arcs burning between the electrodes and the metallic insert or the steel bath. For this reason, a process for melting iron sponge in electric reduction furnaces was developed. The term electroreduction furnaces is understood to mean furnaces in which electrodes are preferably immersed either in an open or half-covered slag bath or in a standing Möller column and in which the energy conversion takes place mainly through resistance heating in the slag bath.

Das Einschmelzen von Eisenschwamm in Elektroreduktionsöfen ist z. B. beschrieben in « Stahl und Eisen 97 (1977), Seiten 7-17. Diese Verfahren sind in erster Linie als Ersatz für den Elektrolichtbogenofen konzipiert, d. h. für die Herstellung von Stahl mit Kohlenstoffgehalten bis zu etwa 1 %. Der eingesetzte Eisenschwamm hat Kohlenstoffgehalte von über 1 %, d. h. er stammt aus einer Direktreduktion mit gasförmigen, COhaltigen Reduktionsmitteln. Als untere Korngröße des eingesetzten Eisenschwamms werden 6 mm angeführt und die Metallisierung beträgt etwa 90 %. Als Einsatzgut wird also ein Eisenschwamm mit höherem Kohlenstoffgehalt und guten metallurgischen Eigenschaften verwendet. Die elektrische Energie wird aus einem Netz entnommen.The melting of sponge iron in electric reduction furnaces is e.g. B. described in «Stahl und Eisen 97 (1977), pages 7-17. These processes are primarily designed to replace the electric arc furnace, i.e. H. for the production of steel with carbon contents up to approximately 1%. The sponge iron used has carbon contents of over 1%, i.e. H. it comes from a direct reduction with gaseous, CO-containing reducing agents. The lower grain size of the iron sponge used is 6 mm and the metallization is about 90%. An iron sponge with a higher carbon content and good metallurgical properties is used as the input material. The electrical energy is taken from a network.

Bei der Direktreduktion mittels fester kohlenstoffhaltiger Reduktionsmittel fällt ein Eisenschwamm an, der beträchtlich weniger Kohlenstoff enthält. Der Kohlenstoffgehalt liegt im allgemeinen unter 0,5 %. Außerdem fällt auch ein Teil des Eisenschwamms mit schlechteren metallurgischen Eigenschaften, d. h. mit geringerer Metalli- sier.ung und/oder kleinerer Korngröße an. Insbesondere das Einschmelzen dieses Eisenschwamms mit schlechteren metallurgischen Eigenschaften bereitet Schwierigkeiten und erfordert eventuell zusätzliche Kosten.Direct reduction using solid carbon-containing reducing agents produces an iron sponge that contains considerably less carbon. The carbon content is generally less than 0.5%. In addition, part of the sponge iron with poorer metallurgical properties, i.e. H. with less metallization and / or smaller grain size. In particular, melting this sponge iron with poorer metallurgical properties causes difficulties and may require additional costs.

Aus der EP-A-0 117 928 ist es nach Art. 54(3) bekannt, Stahl durch Einschmelzen von Eisenschwamm im Lichtbogenofen zu erzeugen, wobei ein Teil des Eisenschwammes in einem Elektroreduktionsofen zu flüssigem, kohlenstoffhaltigem Eisen eingeschmolzen wird, das kohlenstoffhaltige Eisen als Bad in den Lichtbogenofen chargiert wird, der andere Eisenschwamm auf diesem Bad im Lichtbogenofen umgesetzt wird, und der Elektroreduktionsofen in Abhängigkeit von den durch den Lichtbogenofen bedingten elektrischen Lastaufnahme-Schwankungen so geregelt wird, daß eine praktisch gleichbleibende Belastung des elektrischen Netzes resultiert.From EP-A-0 117 928 it is known, according to Art. 54 (3), to produce steel by melting sponge iron in an electric arc furnace, a part of the sponge iron being melted in an electric reduction furnace into liquid, carbon-containing iron, the carbon-containing iron as Bad is charged in the arc furnace, the other sponge iron is implemented on this bath in the arc furnace, and the electroreduction furnace is controlled in dependence on the electrical load fluctuations caused by the arc furnace so that a practically constant load on the electrical network results.

Der Erfindung liegt die Aufgabe zugrunde, den durch Direktreduktion mit festen kohlenstoffhaltigen Reduktionsmitteln erzeugten Eisenschwamm, und insbesondere den dabei anfallenden Anteil mit schlechteren metallurgischen Eigenschaften, in möglichst einfacher und wirtschaftlicher Weise einzuschmelzen.The invention has for its object to melt the sponge iron produced by direct reduction with solid carbon-containing reducing agents, and in particular the resulting portion with poorer metallurgical properties, in a simple and economical manner.

Die Lösung dieser Aufgabe erfolgt bei der Herstellung von kohlenstoffhaltigen Eisen erfindungsgemäß dadurch, daß

  • a) das Austragsmaterial der Direktreduktion in einer Magnetscheidung in Eisenschwamm mit höherer Metallisierung und/oder größerer Korngröße und Eisenschwamm mit geringerer Metallisierung und/oder kleinerer Korngröße und überschüssigen Kohlenstoff enthaltendes unmagnetisches Material getrennt wird,
  • b) das Abgas der Direktreduktion nachverbrannt und zur Erzeugung von elektrischer Energie benutzt wird,
  • c) heiße Verbrennungsgase in einem Verbrennungsaggregat erzeugt und zur Erzeugung von zusätzlicher elektrischer Energie benutzt werden,
  • d) mindestens ein Teil des kohlenstoffhaltigen unmagnetischen Materials gemäß (a) in das Verbrennungsaggregat gemäß (c) chargiert werden,
  • e) der Eisenschwamm gemäß (a) gänzlich in einem Elektroreduktionsofen eingeschmolzen wird,
  • f) die Summe der gemäß (b) und (c) erzeugten Mengen an elektrischer Energie mindestens der Menge an elektrischer Energie entspricht, die zum Einschmelzen des Eisenschwammes in flüssiges kohlenstoffhaltiges Eisen gemäß (e) notwendig ist und diese notwendige Menge an elektrischer Energie in den Elektroreduktionsofen geleitet wird.
This object is achieved in the production of carbon-containing iron according to the invention in that
  • a) the discharge material of the direct reduction is separated in a magnetic separation into sponge iron with higher metallization and / or larger grain size and sponge iron with lower metallization and / or smaller grain size and non-magnetic material containing excess carbon,
  • b) the exhaust gas from the direct reduction is afterburned and used to generate electrical energy,
  • c) hot combustion gases are generated in a combustion unit and used to generate additional electrical energy,
  • d) at least part of the carbon-containing non-magnetic material according to (a) is charged into the combustion unit according to (c),
  • e) the sponge iron is melted entirely in an electric reduction furnace according to (a),
  • f) the sum of the amounts of electrical energy generated in accordance with (b) and (c) corresponds at least to the amount of electrical energy which is necessary for melting the sponge iron into liquid carbon-containing iron in accordance with (e) and this necessary amount of electrical energy in the Electric reduction furnace is conducted.

Die fühlbare Wärme und die durch Nachverbrennung freigesetzte latente Wärme des Abgases der Direktreduktion werden zur Erzeugung von Dampf verwendet, und mit dem Dampf wird elektrische Energie erzeugt, die in den Elektroreduktionsofen geleitet wird. Das kohlenstoffhaltige Eisen ist ein an Kohlenstoff ungesättigtes Eisen mit etwa 1,8 bis 2,5 % C. Aus Gründen der Reaktionskinetik kann es nicht mit Kohlenstoff gesättigt werden. Zur Erzielung dieses Kohlenstoffgehaltes wird eine entsprechende Menge Kohlenstoff in den Ofen zugesetzt. Kurzzeitige Schwankungen in der Menge der erzeugten elektrischen Energie stören nicht, da der Elektroreduktionsofen mit variabler Leistungsaufnahme betrieben werden kann. Bei längerzeitigen Schwankungen kann eine Regelung durch die Menge des eingesetzten Eisenschwamms erfolgen.The sensible heat and the latent heat of the direct reduction exhaust gas released by post-combustion are used to generate steam, and the steam is used to generate electrical energy which is conducted into the electric reduction furnace. The carbon-containing iron is a carbon unsaturated iron with about 1.8 to 2.5% C. Because of the reaction kinetics it cannot be saturated with carbon. A corresponding amount of carbon is added to the furnace to achieve this carbon content. Short-term fluctuations in the amount of electrical energy generated do not interfere because the electric reduction furnace with variable power consumption can be operated. In the event of long-term fluctuations, regulation can be carried out using the amount of sponge iron used.

Der Einsatz in den Elektroreduktionsofen kann in heißem Zustand erfolgen. Das erzeugte Eisen kann vergossen, granuliert oder flüssig weiterverarbeitet werden. Die Direktreduktion erfolgt insbesondere im Drehrohrofen, kann aber auch auf andere Weise erfolgen, z. B. in der zirkulierenden Wirbelschicht unter Einsatz feinkörniger Erze.The electric reduction furnace can be used when hot. The iron produced can be cast, granulated or processed further in liquid form. The direct reduction takes place in particular in a rotary kiln, but can also be done in other ways, e.g. B. in the circulating fluidized bed using fine-grained ores.

Die Aufbereitung des Austragsmaterials erfolgt durch Siebung und Magnetscheidung. Sie kann als heiße oder kalte Aufbereitung durchgeführt werden. Folgende Fraktionen können bei der Aufbereitung anfallen : grober Eisenschwamm, feinkörniger Eisenschwamm, Überschußkohlenstoff, Asche und Entschwefelungsmittel. Durch die Aufbereitung ist eine genau dosierte Zugabe des im Elektroreduktionsofen erforderlichen Kohlenstoffs möglich. Dazu kann der abgetrennte Kohlenstoffüberschuß verwendet werden, insbesondere solcher, der gute Qualität hat, d. h. dessen Gehalt an Asche und Schwefel relativ niedrig ist. Der Kohlenstoffüberschuß kann auch in die Direktreduktion zurückgeführt oder anderen Zwecken zugeführt werden. Die heißen Verbrennungsgase in dem Verbrennungsaggregat können durch Verbrennung von Kohlen erzeugt werden. Als Kohlenstoff kann der abgetrennte Kohlenstoffüberschuß der Direktreduktion verwendet werden. Insbesondere der Kohlenstoff mit schlechten metallurgischen Eigenschaften - wie hoher Asche- und Schwefelgehalt - kann auf diese Weise problemlos und nutzbringend verwendet werden. Weiterhin können billige Kohlen, aber auch Gas oder 01 verwendet werden. Die Verbrennung erfolgt vorzugsweise in einer zirkulierenden Wirbelschicht. Solche Verfahren sind beschrieben in der DE-AS 2 539 546, US-PS 4 165 717, DE-OS 2 624 302, US-PS 4 111 158. Die Erzeugung der elektrischen Energie aus den heißen Verbrennungsgasen kann gemeinsam mit der Energieerzeugung aus dem Abgas der Direktreduktion oder getrennt von dieser erfolgen.The discharge material is processed by sieving and magnetic separation. It can be carried out as a hot or cold preparation. The following fractions can occur during processing: coarse sponge iron, fine-grained sponge iron, excess carbon, ash and desulfurizing agent. The processing enables a precisely metered addition of the carbon required in the electric reduction furnace. The separated carbon excess can be used for this, in particular one which is of good quality, i. H. the ash and sulfur content is relatively low. The excess carbon can also be returned to direct reduction or used for other purposes. The hot combustion gases in the combustion unit can be generated by burning coal. The separated carbon excess of the direct reduction can be used as carbon. In particular, carbon with poor metallurgical properties - such as a high ash and sulfur content - can be used easily and effectively in this way. In addition, cheap coal, but also gas or oil can be used. The combustion is preferably carried out in a circulating fluidized bed. Such processes are described in DE-AS 2,539,546, US Pat. No. 4,165,717, DE-OS 2,624,302, US Pat. No. 4,111,158. The generation of the electrical energy from the hot combustion gases can be carried out together with the generation of energy from the Exhaust gas of the direct reduction or separately from this.

Die Lösung der oben genannten Aufgabe erfolgt bei der Herstellung von Stahl erfindungsgemäß dadurch, daß

  • a) das Austragsmaterial der Direktreduktion in einer Magnetscheidung in Eisenschwamm mit höherer Metallisierung und/oder größerer Korngröße und Eisenschwamm mit geringerer Metallisierung und/oder kleinerer Korngröße und überschüssigen Kohlenstoff enthaltendes unmagnetisches Material getrennt wird,
  • b) das Abgas der Direktreduktion nachverbrannt und zur Erzeugung von elektrischer Energie benutzt wird,
  • c) heiße Verbrennungsgase in einem Verbrennungsaggregat erzeugt und zur Erzeugung von zusätzlicher elektrischer Energie benutzt werden,
  • d) mindestens ein Teil des kohlenstoffhaltigen unmagnetischen Materials gemäß (a) in das Verbrennungsaggregat gemäß (c) chargiert werden,
  • e) ein Teil des Eisenschwammes gemäß (a) in einem Elektroreduktionsofen zu kohlenstoffhaltigen Eisen mit etwa 1,8 bis 2,5 % C eingeschmolzen wird und der andere Teil des Eisenschwammes mit höherer Metallisierung und/oder größerer Korngröße als Kühlmittel beim Verblasen des kohlenstoffhaltigen Eisens mit etwa 1,8 bis 2,5 % C zu Stahl zugesetzt wird,
  • f) die Summe der gemäß (b) und (c) erzeugten Mengen an elektrischer Energie mindestens der Menge an elektrischer Energie entspricht, die zum Einschmelzen des Eisenschwammes in flüssiges kohlenstoffhaltiges Eisen gemäß (e) notwendig ist und diese notwendige Menge an elektrischer Energie in den Elektroreduktionsofen geleitet wird.
The above object is achieved in the manufacture of steel according to the invention in that
  • a) the discharge material of the direct reduction is separated in a magnetic separation into sponge iron with higher metallization and / or larger grain size and sponge iron with lower metallization and / or smaller grain size and non-magnetic material containing excess carbon,
  • b) the exhaust gas from the direct reduction is afterburned and used to generate electrical energy,
  • c) hot combustion gases are generated in a combustion unit and used to generate additional electrical energy,
  • d) at least part of the carbon-containing non-magnetic material according to (a) is charged into the combustion unit according to (c),
  • e) a part of the sponge iron is melted in an electric reduction furnace to carbon-containing iron with about 1.8 to 2.5% C and the other part of the sponge iron with higher metallization and / or larger grain size as a coolant when blowing the carbon-containing iron with about 1.8 to 2.5% C is added to steel,
  • f) the sum of the amounts of electrical energy generated in accordance with (b) and (c) corresponds at least to the amount of electrical energy which is necessary for melting the sponge iron into liquid carbon-containing iron in accordance with (e) and this necessary amount of electrical energy in the Electric reduction furnace is conducted.

Das Verblasen zu Stahl erfolgt mittels sauerstoffhaltiger Gase, vorzugsweise technisch reinem Sauerstoff, in einem Konverter. Vorzugsweise wird als Kühlmittel der Eisenschwamm mit besseren metallurgischen Eigenschaften eingesetzt, der nach der Aufbereitung anfällt. Auf diese Weise wird der Eisenschwamm mit schlechteren metallurgischen Eigenschaften unter optimaler Ausnutzung des Wärmeinhaltes des Abgases der Direktreduktion eingeschmolzen und der Eisenschwamm mit besseren metallurgischen Eigenschaften zur Erzeugung von Stahl verwendet. Das System ist sehr flexibel. Überschüssiger Eisenschwamm mit guten metallurgischen Eigenschaften kann weiterhin für andere Zwecke verwendet werden. Ein Teil der erzeugten elektrischen Energie kann zur Erzeugung von Sauerstoff verwendet werden.The blowing into steel takes place by means of oxygen-containing gases, preferably technically pure oxygen, in a converter. The sponge iron with better metallurgical properties, which is obtained after processing, is preferably used as the coolant. In this way, the sponge iron with poorer metallurgical properties is melted down with optimal utilization of the heat content of the exhaust gas of the direct reduction, and the sponge iron with better metallurgical properties is used to produce steel. The system is very flexible. Excess sponge iron with good metallurgical properties can still be used for other purposes. Part of the electrical energy generated can be used to generate oxygen.

Eine vorzugsweise Ausgestaltung besteht darin, daß das im Elektroreduktionsofen erzeugte kohlenstoffhaltige Eisen aufgekohlt wird. Die Aufkohlung erfolgt zweckmäßigerweise in einer Pfanne unter Zugabe von Kohlenstoff. Dazu wird das Eisen im Elektroreduktionsofen soweit überhitzt, daß es mit einer Temperatur in die Aufkohlungsstufe gelangt, die etwa 150 °C über der Liquiduslinie liegt. Als Kohlenstoff kann abgetrennter Überschußkohlenstoff aus der Direktreduktion verwendet werden. Die Aufkohlung kann auf einen C-Gehalt bis zu etwa 4% erfolgen.A preferred embodiment consists in that the carbon-containing iron produced in the electric reduction furnace is carburized. The carburization is expediently carried out in a pan with the addition of carbon. For this purpose, the iron is overheated in the electric reduction furnace to such an extent that it reaches the carburizing stage at a temperature which is approximately 150 ° C. above the liquidus line. Excess carbon from the direct reduction can be used as carbon. The carburization can take place up to a C content of up to about 4%.

Eine vorzugsweise Ausgestaltung besteht darin, daß die Temperatur und/oder der Gehalt an brennbaren Bestandteilen des Abgases der Direktreduktion zur Steigerung der erzeugten Menge an elektrischer Energie erhöht wird. Die Erhöhung der Temperatur und/oder des Gehaltes an brennbaren Bestandteilen erfolgt über die für die Direktreduktion erforderlichen Werte. Dies kann durch Einsatz von Kohle mit hohem Gehalt an flüchtigen Bestandteilen erfolgen, die nicht in der Direktreduktion ausgenutzt werden, oder durch den Einsatz von größeren Mengen an Kohle. Dadurch kann ein größerer Teil des Eisenschwamms eingeschmolzen werden.A preferred embodiment consists in that the temperature and / or the content of combustible components of the exhaust gas of the direct reduction is increased in order to increase the amount of electrical energy generated. The temperature and / or the content of combustible constituents are increased via the values required for direct reduction. This can be done by using coal with a high volatile content, which is not used in direct reduction, or by using larger amounts of coal. As a result, a larger part of the sponge iron can be melted down.

Eine vorzugsweise Ausgestaltung besteht darin, daß das Abgas des Elektroreduktionsofens zur Erzeugung elektrischer Energie verwendet wird.A preferred embodiment is that the exhaust gas from the electric reduction furnace is used to generate electrical energy.

Eine vorzugsweise Ausgestaltung besteht darin, daß das Abgas des Konverters zur Erzeugung elektrischer Energie verwendet wird.A preferred embodiment is that the exhaust gas from the converter is used to generate electrical energy.

Eine Ausgestaltung besteht darin, daß die zusätzlich erzeugte Menge an elektrischer Energie so geregelt wird, daß der gesamte Eisenschwamm zu Stahl verarbeitet wird. Wenn z. B. die mit Abgas erzeugte elektrische Energie für das Einschmelzen von 50 % des Eisenschwamms zu flüssigem kohlenstoffhaltigem Eisen mit etwa 1,8 bis 2,5 % C ausreicht und zum Verblasen dieses Eisens zu Stahl weitere 20 % des Eisenschwamms als Kühlmittel benötigt werden, verbleiben 30 % Eisenschwamm als Rest. Dann wird soviel zusätzliche elektrische Energie erzeugt, daß von den restlichen 30 % Eisenschwamm eine solche Menge zu hot metal eingeschmolzen wird, die beim Verblasen zu Stahl den anderen Rest als Kühlmittel benötigt. Dadurch kann der gesamte Eisenschwamm in ein hochwertiges Endprodukt eingeschmolzen und verarbeitet werden.One embodiment is that the additional amount of electrical energy generated is controlled so that the entire sponge iron is processed into steel. If e.g. B. the electrical energy generated with exhaust gas is sufficient for melting 50% of the sponge iron into liquid carbon-containing iron with about 1.8 to 2.5% C and for blowing this iron into steel another 20% of the sponge iron is required as a coolant 30% iron sponge as the remainder. Then so much additional electrical energy is generated that of the remaining 30% iron sponge, such an amount is melted into hot metal that the other remainder needs as a coolant when blown into steel. As a result, the entire sponge iron can be melted into a high-quality end product and processed.

Eine vorzugsweise Ausgestaltung besteht darin, daß das Verblasen zu Stahl unter Zusatz von Energieträgern erfolgt. Die Energieträger können im festen, gasförmigen oder flüssigem Zustand in das Verblaseaggregat eingebracht werden, z. B. in Form von feinkörniger Kohle in das Bad eingeblasen werden. Beim Verblasen wird die erforderliche Wärme weitgehend durch Verbrennung von Kohlenstoff im Bad erzeugt. Wenn der mit den Einsatzstoffen eingebrachte Kohlenstoff nicht zur Deckung der erforderlichen Wärmemenge ausreicht, kann auf diese Weise die fehlende Wärmemenge direkt durch Primärenergie in wirtschaftlicher Weise eingebracht werden. Durch die Zugabe der Energieträger wird das System sehr flexibel gemacht, da durch die Zugabe der Energieträger in das Verblaseaggregat eine entsprechend größere Menge an Eisenschwamm und/oder Schrott eingegeben werden kann. In der gleichen Weise können Schwankungen in der Stromerzeugung aufgefangen werden. Diese Regelmöglichkeit besteht sowohl bei der Verblasung eines Teiles des Eisenschwammes als auch des gesamten Eisenschwamms zu Stahl.A preferred embodiment is that the blowing into steel takes place with the addition of energy sources. The energy sources can be introduced into the blowing unit in the solid, gaseous or liquid state, for. B. in the form of fine-grained coal in the bath. When blowing, the heat required is largely generated by burning carbon in the bathroom. If the carbon introduced with the feedstocks is not sufficient to cover the required amount of heat, the missing amount of heat can be directly and economically introduced by primary energy. The system is made very flexible by the addition of the energy sources, since a correspondingly larger amount of sponge iron and / or scrap can be entered into the blower unit by adding the energy sources. Fluctuations in power generation can be absorbed in the same way. This control option is available both for blowing a part of the sponge iron and the entire sponge iron into steel.

Der Sauerstoff kann auch mittels einer Dampfturbine erzeugt werden, die direkt an den Kompressor angeschlossen ist. Der erzeugte Sauerstoff kann gespeichert werden und als Puffer für Betriebsschwankungen genutzt werden. Für die Stromerzeugung ist auch der Einsatz von Gasturbinen möglich.The oxygen can also be generated by means of a steam turbine, which is connected directly to the compressor. The oxygen generated can be stored and used as a buffer for operational fluctuations. Gas turbines can also be used to generate electricity.

Die Erfindung wird anhand einer Figur näher erläutert.The invention is illustrated by a figure.

In den Drehrohrofen 1.wird die Beschickung 2, bestehend aus Eisenerz, Kohle und Zuschlägen, chargiert. Das reduzierte Material 3 wird in die Aufbereitung 4 gegeben, die aus Siebung und Magnetscheidung besteht. Zur Vereinfachung ist für jedes Produkt jeweils nur ein Ausgang dargestellt. Der Eisenschwamm mit schlechteren metallurgischen Eigenschaften 5 wird in den Elektroreduktionsofen 6 chargiert. Das Abgas 7 des Drehrohrofens 1 wird in die elektrische Energieerzeugung 8 geleitet, die aus Nachverbrennung, Dampferzeugung und Stromerzeugung besteht. Elektrische Energie 9 wird in den Elektroreduktionsofen 6 geleitet. Das erzeugte kohlenstoffhaltige Eisen 10 wird in der Aufkohlung 11, die aus einer Pfanne besteht, aufgekohlt. Das aufgekohlte Eisen 12 wird in den Konverter 13 chargiert und unter Zusatz von Eisenschwamm mit guten metallurgischen Eigenschaften 14 als Kühlmittel zu Stahl 15 verblasen. Das Abgas 16 des Elektroreduktionsofens 6 und das Abgas 17 des Konverters 13 werden ebenfalls in die elektrische Energieerzeugung 8 geleitet. Das in der Aufbereitung 4 abgetrennte überschüssige kohlenstoffhaltige Material mit guten metallurgischen Eigenschaften 18a, 18b, 18c wird zum Teil in den Elektroreduktionsofen 6, zum Teil in die Aufkohlung 11 und zum Teil in den Drehrohrofen 1 chargiert. Asche und Entschwefelungsmittel werden als Abgänge 19 aus der Aufbereitung 4 abgeführt. Das überschüssige kohlenstoffhaltige Material mit schlechten metallurgischen Eigenschaften 20 wird in die Verbrennung 21 geleitet, die aus einer zirkulierenden Wirbelschicht besteht und in die weiteres kohlenstoffhaltiges Material 22 geleitet wird. Die heißen Verbrennungsgase 23 werden in die elektrische Energierzeugung 8 geleitet. Elektrische Energie 24 wird in die Sauerstofferzeugung 25 geleitet. Der Sauerstoff 26 wird in den Konverter 13 eingesetzt. Aus einem Netz 27 kann fehlende elektrische Energie entnommen werden. Anstelle des überschüssigen kohlenstoffhaltigen Materials 18a, 18b, 18c kann auch anderer Kohlenstoff eingesetzt werden. Wenn das kohlenstoffhaltige Eisen 10 oder das aufgekohlte Eisen 12 nicht zu Stahl verblasen wird, wird es über 10 a bzw. 12 a vergossen oder granuliert.The feed 2, consisting of iron ore, coal and aggregates, is charged in the rotary kiln 1. The reduced material 3 is placed in the preparation 4, which consists of sieving and magnetic separation. To simplify matters, only one output is shown for each product. The sponge iron with poorer metallurgical properties 5 is charged into the electric reduction furnace 6. The exhaust gas 7 of the rotary kiln 1 is fed into the electrical power generation 8, which consists of afterburning, steam generation and power generation. Electrical energy 9 is conducted into the electric reduction furnace 6. The carbon-containing iron 10 produced is carburized in the carburization 11, which consists of a pan. The carburized iron 12 is charged into the converter 13 and blown into steel 15 with the addition of sponge iron with good metallurgical properties 14 as a coolant. The exhaust gas 16 of the electric reduction furnace 6 and the exhaust gas 17 of the converter 13 are also conducted into the electrical power generation 8. The excess carbon-containing material with good metallurgical properties 18a, 18b, 18c separated in the treatment 4 is partly charged into the electric reduction furnace 6, partly into the carburization 11 and partly into the rotary kiln 1. Ash and desulfurizing agent are removed from treatment 4 as outlets 19. The excess carbon-containing material with poor metallurgical properties 20 is passed into the combustion 21, which consists of a circulating fluidized bed and into which further carbon-containing material 22 is passed. The hot combustion gases 23 are conducted into the electrical energy generation 8. Electrical energy 24 is conducted into the oxygen generation 25. The oxygen 26 is inserted into the converter 13. Missing electrical energy can be drawn from a network 27. Instead of the excess carbon-containing material 18a, 18b, 18c, other carbon can also be used. If the carbon-containing iron 10 or the carburized iron 12 is not blown into steel, it is cast or granulated over 10 a or 12 a.

In den Konverter 13 können über Leitung 28 Energieträger eingebracht werden, z. B. feinkörnige Kohle in das Bad eingeblasen werden.In the converter 13 28 energy sources can be introduced via line, z. B. fine-grained coal can be blown into the bath.

Die Vorteile der Erfindung bestehen darin, daß der bei der Direktreduktion mit festen, kohlenstoffhaltigen Reduktionsmitteln anfallende Eisenschwamm, der einen relativ geringen Gehalt an Kohlenstoff enthält, unter optimaler Ausnutzung des Wärmeinhaltes der Abgase eingeschmolzen werden kann. Insbesondere kann der Anteil des Eisenschwammes, der schlechtere metallurgische Eigenschaften aufweist, in ein unbeschränkt verwendbares Vorprodukt verarbeitet werden. Es ist ein integrierter Prozeß ohne Fremdenergie oder mit billig erzeugter Fremdenergie möglich. Das Verfahren kann sehr variabel betrieben werden. Der gesamte Eisenschwamm kann in ein wertvolles Vormaterial mit wesentlich geringerem Volumen und problemlosen Eigenschaften im Hinblick auf Transport und Lagerung verarbeitet werden.The advantages of the invention are that the iron sponge obtained in the direct reduction with solid, carbon-containing reducing agents, which contains a relatively low carbon content, can be melted down with optimum use of the heat content of the exhaust gases. In particular, the portion of the sponge iron that has poorer metallurgical properties can be processed into an intermediate product that can be used without restriction. An integrated process without external energy or with cheaply produced external energy is possible. The process can be operated very variably. The entire sponge iron can be processed into a valuable raw material with a significantly smaller volume and problem-free properties with regard to transport and storage.

Claims (8)

1. Process for producing molten carbon-containing iron with approximately 1.8 to 2.5 % C by direct reduction of iron oxide-containing materials by means of solid carbon-containing reduction means into sponge iron and melting down sponge iron in a submerged arc furnace,
a) the product material of the direct reduction process being separated by magnetic separation into sponge iron with higher metallisation and/or larger grain size and sponge iron with lower metallisation and/or smaller grain size and nonmagnetic material containing excess carbon,
b) the waste gas from the direct reduction being subsequently burnt and used to generate electrical energy,
c) hot combustion gases being produced in a combustion aggregate and used for generating additional electrical energy,
d) at least a part of the carbon-containing non- metallic material in (a) being charged into the combustion aggregate in (c),
e) the sponge iron in (a) being completely melted down in a submerged arc furnace,
f) the total of the amounts of electrical energy generated in (b) and (c) corresponding to at least the amount of electrical energy which is necessary for melting down the sponge iron into molten carbon-containing iron in (e) and this necessary amount of electrical energy being supplied to the submerged arc furnace.
2. Process for producing molten steel by direct reduction of iron oxide-containing materials by means of solid carbon-containing reduction means into sponge iron and melting down sponge iron in a submerged arc furnace,
a) the product material of the direct reduction process being separated by magnetic separation into sponge iron with higher metallisation and/or larger grain size and sponge iron with lower metallisation and/or smaller grain size and nonmagnetic material containing excess carbon,
b) the waste gas from the direct reduction being subsequently burnt and used to generate electrical energy,
c) hot combustion gases being produced in a combustion aggregate and used for generating additional electrical energy,
d) at least a part of the carbon-containing non- metallic material in (a) being charged into the combustion aggregate in (c),
e) one part of the sponge iron in (a) being melted down in a submerged arc furnace to carbon-containing iron with approximately 1.8 to 2.5 % C and the other part of the sponge iron with higher metallisation and/or larger grain size being added as a cooling medium in blowing the carbon-containing iron with approximately 1.8 to 2.5 % C into steel,
f) the total of the amounts of electrical energy generated in (b) and (c) corresponding to at least the amount of electrical energy which is necessary for melting down the sponge iron into molten carbon-containing iron in (e) and this necessary amount of electrical energy being supplied to the submerged arc furnace.
3. Process according to Claim 1 or 2, characterised in that the carbon-containing iron produced in the submerged arc furnace is carburised.
4. Process according to one of Claims 1 to 3, characterised in that the temperature and/or the content of combustible constituents of the waste gas of the direct reduction is increased to increase the amount of electrical energy produced.
5. Process according to one of Claims 1 to 4, characterised in that the waste gas of the submerged arc furnace is used to generate electrical energy.
6. Process according to one of Claims 2 to 5, characterised in that the waste gas from the converter is used to generate electrical energy.
7. Process according to Claim 3, characterised in that the amount of electrical energy additionally produced is controlled so that all the sponge iron is processed into steel.
8. Process according to one of Claims 3 to 7, characterised in that the blowing into steel occurs with the addition of energy carriers.
EP84201106A 1983-08-25 1984-07-28 Process for obtaining molten carbon-containing iron from spongy iron Expired EP0139310B1 (en)

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