RU2521175C2 - Iron production from water suspension of particles of iron compounds ore and device to this end - Google Patents

Abstract

FIELD: metallurgy.

SUBSTANCE: invention relates to nonferrous metallurgy, particularly to production of metallic iron. This method comprises formation of initial stock composed of water suspension containing iron compounds produced by introduction of iron ore particles into preset water volume. Said initial stock is displaced through serial processing zones. Here, metal is reduced with the help of carbon contained in gases fed to said zones. Variable rotary magnetic fields generated in said zones allow deposition of metal particles, their accumulation and discharge of finished metal. Note here that this process is conducted at continuous processing of said stock. Used water suspension features dispersity of iron ore particles of 0.001-1.0 mm and their content of 40-70%. Said variable rotary magnetic fields feature intensity in processing zones of 1*10⁶-1*10⁷ A/m and frequency of 40-70 Hz, in amount of 2 to 6, finished iron yielding as iron granules sized to 4-10 mm.

EFFECT: decreased electric power consumption, some 8-15 times, non-polluting process.

6 cl, 2 dwg, 3 ex

Description

The proposed method relates to those areas of metallurgical production in which metallic iron is obtained from the ore raw material compounds containing it, as well as to the design of devices by which such technologies are implemented.

Known methods for producing iron from melts consisting of its compounds using so-called electric furnaces. When performing the latter, the loaded raw material mass containing iron pellets is subjected to heating, which is carried out using the electrode system introduced into the internal cavity of the housing into which it is filled.

The effect of the electric arc system that occurs when the above-mentioned system is turned on puts iron pieces in the raw state and thereby ensures that the final product is obtained at the final stages of this process (see the Internet article "Electrometallurgy. Furnace design. Steel production in electric furnaces" (elektrometallurgiya-ustroystva-pechey)).

However, the implementation of such a well-known method of processing the feedstock into metal is associated with the need to use significant material and financial waste during the execution of this process.

Those. the implementation of melting with the help of a powerful electric arc created in the processing zone will require the attraction of high power sources of electric power for its implementation. The equipment itself, in which all the above operations take place, will be distinguished by a high degree of its structural complexity (refractory lining, the presence in it of electrodes for the distribution of electrical energy serving the electrodes, as well as the same units for controlling their movement, heat-resistant steel, thick-walled metal casing, etc. etc.).

In addition to all this, the performance indicators of this kind of known technologies remain quite low (smelting takes 2-3 hours), and high-quality metal is obtained through the use of a number of additional techniques, such as “oxidation”, “deoxidation” using the resulting molten metal of various kinds of additives - lime, feldspar, aluminum, etc., as well as the use of reception, ensuring the accumulation in the thickness of the latter of the specified technology gas volumes (argon , Oxygen). All of the above significantly narrows the scope of possible industrial use of such known technologies.

The situation becomes somewhat better if the so-called “induction furnaces” are used to obtain iron from the ore compound containing it.

Those. in one of the known methods, hereinafter taken as a prototype, the so-called carbothermic reduction is used to increase the obtained economic indicators of the process of this kind of metal melting. The latter flows in the zone occupied by the mass of the raw materials used in the liquid state, and its implementation is ensured by loading further into the furnace cavity the ore briquettes used to obtain the melt, which include carbon-containing components — lump coal (see patent RU 2080391 “Method direct production of iron "С21В 13/00, publication date 05/28/1997 - hereinafter the prototype). The essence of the above known process for producing iron is as follows.

It uses briquettes formed by extrusion consisting of iron ore and carbon-containing compounds (for example, iron ore and coal) as a feedstock.

Such carbon-containing components, which serve as the basis for the formation of a subsequent, directly in the melt, reducing atmosphere, are also used as a binder, which provides the connection of the constituent briquettes of elements into a single whole.

When prepared in this way, composite two-component briquettes during the implementation of the known prototype method are loaded into the internal cavity of the induction furnace, where they are heated using eddy currents created in the furnace by the inductor.

When performing the latter, the particles of iron ore contained in the briquette are restored until they acquire the state of the metal with the carbon in it. As a result of all this, a melt is formed containing both of these elements (i.e., Fe and C).

The resulting liquid metal bath is also heated intensively due to the heat evolution flowing in the melt volume due to the action of eddy currents generated in the thickness of its layers and carried out using an electromagnetic field artificially created in them.

The CO gas resulting from the reduction of metallic iron is burned in the volume of the crucible by means of oxygen supplied there, which is directed there through channels specially provided for in the roof of the furnace. The metal obtained at the end of the processing process is released from its internal cavity through the tap holes intended for this operation.

However, this well-known technical solution, the prototype, has the same drawbacks that occur when using other previously considered analogs similar to it.

In the case of its application, the melting process is carried out at sufficiently high temperatures - from 1620 ° C and takes a long period of time (3.5-4 hours).

Remains significant and consumed in the course of the melting process and the necessary energy costs for its implementation.

As follows from the text of the description of this known method, for the processing of 250 kg of ore, a 320 kW power transformer was used.

It should also be noted that the final product obtained during the processing is presented in the form of an iron-carbon alloy, i.e. is mild steel. The latter does not have the necessary set of properties that could provide the possibility of application to meet the needs of the electrical engineering branches of engineering. Those. this steel is not classified as soft magnetic.

Based on the considered materials describing the above-mentioned well-known technical solution - the prototype, it can be noted inherent in it and only to it, as well as the essential technical features used in the method used for its implementation, as well as the device, and characterizing these objects. Those. It should be noted that when implementing this kind of technology for producing metal, the initial raw material mass is placed in the internal cavity of the tank (crucible) used for processing. The body of the latter is isolated from its external environment with the help of its constituent and forming the latter structural elements (side walls; upper cover, the function of which is performed by the “arch” of the furnace). The conversion of the very mass of the feedstock to the final product is carried out by acting on the components included in it of a physical field specially generated for this purpose (in this case, the temperature role used for heating and melting pieces of ore containing metal compounds). This transformation takes place directly in the recovery zone of the latter.

The component necessary for its implementation - carbon - is present in the cavity of the crucible used, since it is laid in it together with the pellets used to obtain the final product and containing the compounds of the metal obtained. The above material provides the formation directly in the processing zone necessary to obtain a metal containing carbon reducing gas atmosphere.

Regarding the device used in carrying out the known prototype method, it should be noted that the following elements are used as part of its design.

First of all, it must be pointed out that there is a container (crucible) in the cavity of which the applied raw material mass and carbon-containing components are placed.

In the same device, in addition, work elements are also used that provide the generation of the physical field necessary for the conversion of the feedstock into the final product (in this case, in the known device, the inductor acts as the latter, forming an eddy current, with the help of which heating is provided pieces of raw materials to the temperature required for their melting).

In the process of generating a physical field (temperature) acting on the raw materials, the working elements of the device used to achieve the above goal are necessarily connected to an external source to supply electric power to them. The processed raw materials in the device used to perform the processing are isolated from the possible effects of the external environment with the help of its body, in the internal cavity of which it is placed just before the start of the process of metal reduction from the material containing it.

But the mere presence of these essential technical features listed above, inherent in this known method, as well as the device used in the process, is clearly not enough to significantly reduce the costs necessary for the formation of the above final product, and also guarantee the allocation it during the process of converting the raw materials used in the form of a metal having high magnetic permeability.

The aim of the invention is to reduce the costs associated with the implementation of the processing technology of the used raw material, as well as obtaining its final product in the form of a metal having high magnetic permeability.

Achieving this goal is achieved through the use of the following factors in the proposed solution.

Upon receipt of metallic iron from an aqueous suspension of particles containing its ore compounds, the used raw materials are loaded into the device used before starting this treatment, as well as unloading from the last finished metal at its end.

In the proposed method, in the process of its execution, the mechanical mixture is also formed from the feedstock and carbon, followed by the reduction of metal from it, which is carried out under the influence of a specially generated physical field to achieve this goal.

During processing during the implementation of the proposed method, the final products obtained during its implementation are precipitated in the region located in the zone of generation of the physical field, accumulating them in its lower part.

This processing itself is carried out in the internal volume of the housing used to obtain iron devices.

The device used to implement the proposed method contains a housing for accommodating the processed raw material mixture.

It also has a working element, which ensures the formation of a reducing agent acting on the ore particles and molecules — the physical field.

This element, also part of the design of the proposed device, is made in the form of a coil-solenoid. The above coil, in turn, is connected to an external source of electrical power. At the same time, the body cavity containing the raw material is isolated from the surrounding environment by the structural elements used in it, i.e. walls and end caps.

New in the proposed method is that as a mechanical mixture containing iron compound, water suspension obtained by introducing into a predetermined volume of water with subsequent distribution of iron ore particles in it is used. The dispersion of these particles is in the range of 0.001-1.0 mm, and their content in this volume is 40-70%.

In addition, when performing the proposed method, the movement of this kind of raw material in the used device is carried out with the obligatory passage of its volumes through successively placed areas in it in which the physical fields used to restore the metal are generated. Moreover, the number of the latter is in the range from two units to six.

The peculiarities of the flow of the proposed method should also include the fact that the loading of raw materials and the unloading of finished metal in the process of processing the starting material is carried out without stopping the device used during its implementation.

As the physical fields acting on the processed raw materials, variable rotating magnetic are used. Their tension, measured in the processing zones, is 1 × 10 ⁶ ÷ 1 × 10 ⁷ A / m, and the frequency is 40-70 Hz. At the same time, carbon acts as a metal reducing agent, which is part of the gases containing this element and present in the jets of compressed atmospheric air blown through the working zone.

It should also be pointed out that the novelty of the proposed technology also lies in the fact that the areas filled with a water suspension inside the case of the device used, in the process of processing raw materials, when placing its volumes directly in the zones of exposure to the magnetic fields formed there, perform the functions closing connecting links for generated there and created in these magnetic flux systems used for this purpose.

Further, the novelty of this method also lies in the fact that in the thickness of the raw material passing inside the housing of the device used during the processing process, compressed air jets are supplied. These jets are formed during the supply to the exhausting the last elements of the volumes of the gases entering this product coming from the external line under an overpressure of 0.1 ÷ 0.6 kgf / cm ² .

The very movement of the raw material mass in this method when processing inside the body cavity of the device used is performed under conditions of continuous and artificially created mechanical mixing of its layers, performed throughout the entire path of such a movement.

New in the design of the proposed device is that its working elements are made in the form of stacked plates of magnetically conductive material. When carrying out their installation, the latter form closed rectangular contours. Their number in the device can be from 2 to 6 pieces. In the body of each of the components of these circuits of a separate element, electrical winding coils are placed. Their placement is made in such a way that for each loop of such coil windings entering the device, there are three units. Moreover, any of these winding coils is connected to the corresponding separate phase of an external three-phase power source. In one of these elements, which is part of each of the circuits used in the device, a through groove is made. The dimensions of these grooves ensure that the housing containing the processed water suspension is placed in them. This case itself is laid in these circuits installed at the same distance from each other, and is covered from its outer surface by forming this through groove in each circuit with its magnetically conductive elements. At the same time, such a housing is provided with a screw located in its inner cavity and carrying out the transfer of the raw material located there in the direction from the front zone of the housing to its rear part. This auger has its own drive, ensuring its angular movement with a given speed. The front end of such a housing, due to the hole made therein, communicates with the cavity of the loading hopper located above it. Its rear end is connected to the hatch for unloading the finished metal in its drive, mounted directly under the latter. It should also be noted that the housing of the proposed device is mounted with a slope of its longitudinal axis of symmetry to the horizon line, while its front end is raised and the rear part is lowered, and the angle of this inclination is from 10 ° to 20 °. On the outer surface of the casing of this device are evenly spaced one from another rows of nozzles supplying compressed air. These nozzles are inclined with respect to the latter.

Additionally, it must be indicated that hollow pipes passing through its walls are fixed on the housing of the proposed device. Such pipes are installed at its front and rear ends. These nozzles are equipped with pressure reducing valves, while their cavity communicates directly with the internal volume of the housing. Using these elements, an emission into the atmosphere of gases formed there during the processing and excess volumes of compressed air supplied to the device is ensured.

The introduction of all the above features of the proposed method, as well as the above new design features in the composition of the device used during its implementation, allows you to fundamentally change the nature of the process of formation of metallic iron during processing used to obtain the original raw material.

In connection with the foregoing, the latter begins to acquire the following differences characteristic of it.

First, the latter should include the fact that the initial stage of the implementation of the proposed method differs from the known technologies in that it includes the stage of the so-called "fine grinding" of pieces of the original ore containing iron compounds.

During its implementation, any lumpy material crushing methods known in industrial production are used, for example, performed using ball mills. When applying the above device to achieve this goal, the pieces of the initial raw material mass used in the proposed method during its execution were ground using ore particles having overall dimensions from 0.001 mm to 1.0 mm.

The implementation of this “grinding” of large lumps of rock provided the possibility of further formation from the obtained small particles of iron particles consisting of iron compounds, viscous, homogeneous, not stratified into individual components over a long period of time, of an aqueous suspension. In order to create the latter, it will only be necessary to add to the volume thus obtained from solid ore particles the required amount of water (30-60% of the total mass of this material). After performing this action, the bicomponent substance thus obtained is thoroughly mixed. To carry out this operation, any equipment reassigned to accomplish this purpose can be used, for example, an ordinary paddle mechanical stirrer.

The homogeneous “mud-like” portion of the volume of the aqueous suspension 2 formed at the end of its holding, consisting of these two above substances, is then placed in the cavity of the loading hopper 1, which is part of the device used for processing this raw material. After completing the stage of such loading, all winding coils 15 included in the circuits 5 are immediately and simultaneously connected to an external power source, and, in addition, the rotation drive of the feed screw 4 comes into operation, and it is also connected by blowing nozzles 6 to the external supplying compressed air under overpressure, mains. Through the loading hole “B”, the portions of the raw material 2 located in the lower part of the hopper 1 fall down, falling into the internal cavity of the housing 3 used for processing the device. The volumes of water suspension 2 previously obtained in the manner described above are picked up by the blades of a rotating feed screw 4 and moved with the help of the latter along the internal cavity of the housing in the direction from its front end to its rear part. In the process of such “pushing”, the rotating blades of the auger 4 crush larger portions of the raw materials placed in the cavity of the housing 3 into smaller ones, periodically lifting them to a certain height above the horizon, and also dumping them from there at certain intervals to the lowest zone of the housing 3. Through any relatively small number of revolutions of the screw 4 performed around the longitudinal axis of symmetry 4, the mass of the processed material 2 filling the cavity of the housing 3 is carried out by the blades after days into the area of influence created by the very first of the installed circuits 5 of an alternating rotating magnetic field.

The formation of the latter proceeds with the following characteristic features, the presence of which determines the receipt of the required positive effect when implementing the proposed method. When conducting a review of the reasons leading to the appearance of these factors of its influence, it must be remembered that the casing 3, filled with a fluid mass of the raw material suspension processed in it, was made in through grooves “B” made for this purpose and used in the device of magnetic generators (see Fig. 1). Those. in fact, the housing 3 of the device used is laid through artificially created “slots” (ie, grooves “B”) left in them for this purpose. Moreover, such a “laying” was carried out with the formation of the same type of mounting clearances “a” at the points of passage of its outer surface through the body of any circuit 5 included in this magnetic system used for processing.

In addition, it should also be noted that the magnetic generators 5 included in it are placed at the same distance from each other.

Due to the fact that three units included in each of the magnetic circuits 5 per one generator of the coil-coil 15 are included in an external electrical circuit at the time of the processing process, then each of them begins to fulfill the function of a solenoid. At the same time, it is also necessary to indicate that each winding-coil 15 that is present in any circuit 5 is connected when it is connected to its supply current only for it corresponding to the phase of a three-phase external electric power source.

When making such a connection, any separately taken from these winding coils 15 begins to generate a magnetic alternating field around itself.

Such individual fields obtained in the installation zones of winding coils 15, passing through the volume including solenoids of this kind and constituting each individual circuit of the magnetically conductive elements 14, are summarized in them with the formation in each circuit 5 ultimately of a single common.

Since an alternating electric current is used to supply the winding coils 15, then, accordingly, such a total magnetic field created in the zone “D” of each circuit 5 at the moment of passage of the processed raw material through it will also be variable (see Fig. one).

In addition, due to the fact that each of the three phases of the 5 windings-coils 15 of the applied external power supply source used to power the generator has corresponding angular displacements of its sinusoidal pulses relative to neighboring ones, the total magnetic field created with their help and, as it were, “rotates” in the area where its effect is carried out.

The resulting magnetic flux, which is formed inside each individual circuit 5 torn apart by a mounting groove “B”, tends to unite its half formed by this artificially performed dismemberment, making a kind of “jump” through the air space separating them, and also, respectively, through the trajectories of its flight adjacent to this zone volumes of the internal cavity of the housing 3 of this device (see figure 1). Those. the trajectory of its movement inside any individual contour 5 will be a kind of “closed loop”. Thus, the corresponding zones located near the magnetic generators in the internal cavity of the housing 3 turn into peculiar steps, based on which this kind of transition between the working elements 14 in the circuits 5 used for processing becomes feasible with the least possible energy loss.

Those. the volume of the housing 3 filled with the water suspension being processed by the water is fulfilled at the moment of connecting the halves of the circuit separated by groove “B” into the whole physical fields formed in it, the role of closing connecting links for the magnetic fluxes generated and created using these systems.

All of the above and ensures the maximum possible concentration of the lines of force formed in the device of magnetic fields directly in the zones where the conversion of raw particles into the desired final product takes place.

If we mentally imagine that it is necessary to connect the curves passing through the end points in a single figure, fixing the position of the end of the resulting total vector of such a magnetic flux during the last vibrational angular spatial movements with a given frequency (40-70 Hz) for a certain pre-selected period of time , then in the above manner using the latter, and a spatial “ellipsoid” will be obtained. It should be noted that this spatial ellipsoid (see zone “D” in FIG. 1, FIG. 2) is located in the zones of the housing 3 filled with the processed raw material 2, almost overlapping all its mass in this region with its own body.

The narrowing of the front and rear ends of this ellipsoid "D" is due, first of all, to an increase in the value of magnetic resistance, which inevitably appears due to the occurrence of mounting clearances "a" formed when the housing 3 is placed in the "gap" formed by a system sequentially arranged one after another installation grooves "B". The latter, in turn, are made in the generators used for processing 5. Due to the fact that this resultant vector obtained in the above manner makes this entire set of vibrational spatial displacements directly in the volume occupied by the medium 2, then those located in particles of iron ore, as well as molecules of gases, carbon monoxide, methane supplied to the same region, a whole series of “jerks” and “shocks” created by this vector and periodically repeating (40-70 Hz) collapses. At the same time, they are applied immediately from all sides and using the entire set of directions of their possible impact.

All these phenomena arise due to the fact that the resulting total magnetic flux vector generated directly in the processing zone, with a frequency set in the device (40-70 Hz), makes oscillatory angular movements in these areas, changing its spatial position not only with high speed , but also its size (the latter moves inside a spatial ellipsoid elongated along the longitudinal axis). Under the influence of these artificially created in the layers of the processed raw materials and the volumes of gas bubbles arising in its mass, intensively acting on these components of this kind of “force” factors, the following processes begin to occur in the processing zones of the source material.

The reasons servicing their appearance should include, first of all, the fact that as a result of a powerful energy flux carried out by this magnetic flux, the atoms of their molecules entering as the initial structures used in the construction of these components are inevitably activated. The electrons of the latter in this case move to higher orbits relative to their nucleus. In this case, covalent molecular bonds previously existing between them are broken, and in these processing areas newly created ions appear, which are formed from the number of their constituent elements that were previously included in the initial molecular compounds.

In these very regions subjected to such magnetic “irradiation” and filled with the material to be processed, ultimately, activated molecular fragments arise, synthesized from the individual components that were previously made up and included in the recipe of the used raw material mixture, as well as from the gases that fill the bubbles through the suspension , of which the stream of compressed air supplied into it consists.

When a series of reactions subsequently proceeds in the areas of such magnetic action, all the compounds obtained during their implementation form in the thickness of the suspension used crystalline “nuclei” of a new, previously absent element, metallic iron itself.

When considering the whole complex of physical and chemical processes occurring in the processing zones, the following should also be remembered. The particles of iron ore included in the composition of the aqueous suspension used in processing cross the magnetic fields generated in the device by picking up these components of the raw material mass and then pushing them from one part of the cavity of the housing 3 to the other, carried out using the blades of a rotating screw. The impact of the above elements, in addition to crushing large portions of the feedstock into smaller volumes, forces the latter to move in the area of the maximum possible concentration of the lines of force of the magnetic field generated there, along a complex spatial path (i.e., the possible points of their location are determined by the x, y, z). Thus, under the influence of this forced and continuously carried out transfer by the screw of the layers of the used raw material 2, the layers of particles that make it up, falling into the “D” zones (see FIG. 1), repeatedly change their initial orientation, thereby opening up the most convenient access to their constituent crystal structures generated in the indicated areas of magnetic fluxes.

But the “scrolling” of the indicated raw microvolumes with a relatively high frequency of this kind relative to the own “axis of symmetry” during the intersection of the systems acting on the last magnetic fields formed in the cavity of the housing 3 of the system determines, ultimately, the optimal rate of conversion of the particles of the starting material into metal , as well as the completeness of its implementation (that is, it creates the prerequisites for eliminating the possibility of “embedding” foreign impurities in the formed during processing ke in the resulting final product is a crystal lattice).

Taking into account all the above, it can be concluded that during the operations of “magnetization” in the volume of an aqueous suspension filling the body 3, the thickness of which is “pierced” by gas bubbles created when compressed air flows to its layers, the following reactions occur.

Fe ₂ O ₃ → 2Fe ⁺³ + 3O ^-2

Fe ₃ O ₄ → Fe ₂ O ₃ + FeO

FeO ₃ → FeO + CO ₂

FeO → Fe ⁺² + O ^-2

CO ₂ → C ⁺⁴ + 2O ^-2

CH ₄ → C ⁺⁴ + 4H ⁺

FeS → Fe ⁺² + S ^-2

Fe ₂ O ₃ + C ⁺⁴ → 2Fe ⁺³ + CO ₂ + O ^-2

S ^-2 + 2H ⁺ → H ₂ S

H ₂ O → 2H ⁺ + O ^-2

2FeO + C ⁺⁴ → 2Fe ⁺² + CO ₂

H ₂ S + 4O ^-2 → H ₂ SO ₄

H ₂ SO ₄ → H ₂ O + SO ₃

Fe + ²⁺ 2e → Fe ⁰

Fe + ²⁺ 2e → Fe ⁰

And so on, direct and reverse molecular transformations with a shift in chemical equilibrium towards the formation of metallic iron in the zone of their flow and the microvolumes of the above gaseous products emitted during their implementation that are released into the surrounding device for processing the atmosphere.

Thus, their earlier consideration clearly shows that the atomic carbon C ⁺⁴ ultimately takes away from the carbon-containing molecules that make up the atmosphere of gases (СО ₂ ; СН ₄ ) during the execution of “magnetic shocks” applied to them. in an iron oxide molecule, atomic oxygen released during its decomposition, connecting with the latter. In addition to the above, reverse reactions also occur in the treatment zone with the formation of gas volumes that, under the conditions of this powerful and continuously performed energy action, have a minimum of their internal energy (Н ₂ О, H ₂ S, SO ₃ СО ₂ ). Due to the presence of the action of the entire complex of conditions indicated above, the metallic iron thus obtained is a crystal that is stable with respect to all these external artificially created factors, which do not transfer into connection with other components located next to them under the conditions of this intensively conducted energy exposure.

Other pollutants, which are also part of the impurities present in the feedstock, will be converted into new crystalline structures in the same way as metallic iron itself, and subsequently they will constitute spongy slags that appear at the end of the treatment process.

The “nuclei” made of metallic iron obtained in the above-mentioned manner in the very first zone of magnetic influence carried out in it tend to move under the action of gravity to the lower part of the body cavity 3. Moving in the layers of the last aqueous suspension 2 filling in the vertical direction from the upper point of their initial placement in the lowest, these "seeds" of newly obtained metal capture along the road small particles of ore from the raw material surrounding them on all sides and "clothe "Consisting in coating one kind (like the crosslinked natseplyaya of these" coat "component). As a rule, they never succeed in reaching the lowest region of the housing 3, since they inevitably collide with the surface of the blade of the screw rotating in the cavity of the housing 3 of the screw 4, which changes their angular position, and, while catching the latter, they, together with the unreacted force the actions of any complex of adverse conditions for this portion of the starting raw material 2 "push" the screw further. Those. fall into the area of influence of the second installed at a predetermined distance from the first magnetic circuit 5.

This promotion of the processed mass of the used raw material in the direction from the front end of the housing 3 to its rear is facilitated by installing it at an angle to the horizon. The value of this angle is 10-20 °. Sent to the formation zone by the second circuit 5 used in the device, which intensively affects the surrounding space region of the magnetic flux, this mass of raw material 2 passes through the same transformations as took place in the magnetic "irradiation" zone carried out by the very first of the applied in the device of magnetic generators 5.

The difference in the processing processes in the above areas of the housing 3 will consist only in the fact that not only the ore particles that are in the volume of the aqueous suspension, but also those that have attached a “coat” to the zone of generation of the magnetic flux created by the second circuit 5, consisting of the latter, “nuclei” of crystalline iron already obtained. As a result, under the influence of a powerful magnetic field generated by the second circuit in the mass of the raw material crossing the zone of its application, in addition to the existing ones, newly created small centers from the metal crystallizing there are added.

On the other hand, the “fur coat” that has grown on the earlier “embryos” from small particles of ore is transformed, due to the presence of the action of the above factors, into a full metal coating. Those. a small crystalline iron due to the implementation of this kind of "growth", which occurs when the coating of the outer surface consisting of ore particles "fur coat" is transferred to the newly formed metal structure based on it, significantly increases its originally obtained dimensions. Leaving the treatment zone created by the magnetic flux generated by the second generator of the device used, and the raw material mass 2 converted by the above method continues to carry out its movement through the cavity of the housing 3.

The scheme of its implementation exactly matches the one that was indicated earlier, when describing the features of the operation of transferring volumes of the same material inside such a device into the installation zone on it of the first generator 5.

Due to this, the inevitability of the supply of partially processed raw material 2 is already ensured even in the zone where the intense magnetic action is carried out using the third of the same type of magnetic circuits 5 used in the device.

The previously discussed processes of the conversion of compounds from iron to metal in the field of influence of the generated magnetic field and in the third circuit 5 will proceed in the latter in exactly the same way as in the installation zones of other generators 5 used in the device, i.e. first and second.

The peculiarity of their implementation will consist only in the fact that almost all the ore particles that make up the aqueous suspension are “attached” to new metal crystals forming in this part of the device’s body.

Such newly obtained metal germs will necessarily “put” the remaining microvolumes of this ore directly on themselves in this zone, using them as a kind of raw material coating formed from their last residues in this zone.

Thus, at one of the final stages of this kind of processing, the raw material mass obtained in the zone of influence of the third magnetic circuit and converted under the influence of the magnetic flux generated by it is transferred by the rotating screw 4 to another part of the cavity of the housing 3, further removed from its front end.

As a result of this, this kind of material ultimately enters the installation zone in the device of the fourth contour 5.

In the process of carrying out the last, “finishing” part of the processing step, in the above region, located in the zone of operation of the magnetic flux generated by the fourth contour, the last residues are removed from the volume of material that has already been “saturated” with small and large crystalline “nuclei” of iron ore particles in it. These components are converted into metal crystals and subsequently, falling under the influence of the same magnetic flux generated in the same zone, begin to perform the functions of a “building mortar”, which provides for the connection of small “nuclei” that stick together in this section of the body into larger granules .

Based on the foregoing, it can be assumed that in the installation area of this particular fourth fourth magnetic generator 5, the processes of synthesis of large pieces of metal from smaller ones are intensively taking place. The implementation of the latter is ensured, first of all, through the use of the effect of the so-called “bonding” of small crystalline formations located there, which, due to its presence, are connected to each other and form more massive “aggregates”.

Those. at this time period for the processing of raw materials, the most noticeable factor at this stage of its implementation will be the formation of large pieces of metal from any small-sized fines located in the zone of such a process.

Since the processing of raw materials is carried out without the use of any intermediate stops associated with its execution, the "enlarged" granules of metal 10 obtained in the above region of the housing 3 are transferred by the screw 4 to the plane of the output opening "G" (see figure 1).

The granules 10 moved by its blades onto the open surface of this section of the cavity of the housing 3 of the granule 10 slide into this opening without any barriers and eventually end up in the cavity of the storage hopper 9 used to collect them (see Fig. 1). The processing of raw materials at the end of this fourth stage can be considered already completed.

After opening its shutter 13, the material accumulated in the hopper 9 is withdrawn to any technological container convenient for its subsequent transportation.

The decrease in the volume of raw material 2 as a continuous process of its processing takes place in the cavity of the housing 3 is constantly compensated by supplying new portions of the last of the volume of the loading hopper 2 connected by the input opening “B”, which directly communicates with the latter. Since the raw material 2 used is a viscous plastic mass, as its volume decreases in the cavity of the front end of the housing 3, new portions of the latter easily pass from the hopper 1 to the vacant place there, without experiencing any additional difficulties (i.e. . Their submission is carried out "by gravity").

Gases generated during the recovery of metal from its raw material compounds, as well as excess air volumes accumulated in the cavity of the housing 3, are automatically removed from the cavity of the housing 3 by means of the hollow nozzles 7 mounted on its front and rear ends, equipped with pressure reducing valves 8. These gas gases can be removed from there the components are produced by ejecting them into the external atmosphere surrounding the device at the moment of operation of the nozzle 7 r that is configured for a given overpressure and which is part of the design an induced valve 8.

The operation of the device used in the implementation of the proposed method can be carried out around the clock with the execution of its stops only in order to carry out the necessary repairs.

In addition to the granules obtained by processing metallic iron 10, slag waste, which is in the form of large-sized pieces with a spongy structure, also gets into the storage hopper 9 and which is formed during processing from the various raw materials used in various raw materials.

Due to the fact that iron granules and slag of this kind falling into the cavity of the hopper 9 with them have sharply different sizes from each other (the dimensions of the iron granules are in the range from 4 to 10 mm, and the overall dimensions of the waste are from 25 to 50 mm), then the subsequent separation of these final products when unloading them from the hopper can be carried out without special difficulties using a system that includes ordinary calibrated sieves.

As the feedstock for the implementation of the proposed method, any ore rocks can be used, the composition of which includes iron compounds as one of their constituent components.

Their processing can be carried out without involving any additional operations for their preliminary preparation or enrichment.

If the raw material is “poor” in the content of iron compounds in it, then, correspondingly, the indicators characterizing the percentage ratio of the metal yield from the volumes of the starting material used to obtain it will fall. However, taking into account the high degree of purity of the final product produced using the proposed method, the use of the latter, even in this case, will be referred to processes, the implementation of which can be considered quite economically justified.

The processing of the aqueous suspension, carried out in accordance with the proposed technology, is carried out at an intensity of alternating rotating magnetic fields, measured directly in the zone of its execution, amounting to 1 × 10 ⁶ ÷ 1 × 10 ⁷ A / m.

The oscillation frequency of these magnetic fields is in the range of 40-70 Hz. When performing the proposed method for producing iron from feedstock, a four-loop magnetic system mounted on the device’s body was used.

As shown by experimental verification, such a system may include in its composition the above components in an amount of from two to six units. The choice of just such a scheme for installing magnetic generators on the case used to process the device is determined primarily by the presence of the following considerations.

When using only one contour in the device, and not two, the conditions are created for “growing” into the metal granules formed in the processing zones a large number of atoms of foreign elements, which are necessarily present in the composition of the raw material used for processing.

With an increase in the number of such elements over six units, no additional positive effect is achieved in the process of processing the aqueous suspension. At the same time, the use of an excessive number of such constituent elements in the magnetic system used in the device leads to its complication and increases the operating costs necessary for processing raw materials.

Based on the foregoing, upon receipt of metallic iron, the processing of the raw material used was carried out using a system consisting of generators evenly spaced along the device body using their optimal amount - i.e. four circuits were used in the system.

The total length of the housing used to implement the proposed technology of the device was 1.5 meters. Its overall dimensions, i.e. the width and height of the enclosure included in the design of the device corresponded to a value of 0.2m × 0.2m (in cross section, the case is a square).

The range of possible changes in the angles of inclination of this body to the horizon is in the range of 10-20 °.

In this particular case, when performing experiments, the data of which are given below, this angle of inclination was 15 °.

To simplify the design of the magnetic circuit, the installation on the device case of this kind of its constituent elements was carried out at an angle of 90 ° to the plane of the outer surface of the latter. Those. these contours during their installation, respectively, also had an inclination angle with respect to the vertical equal to the same 15 °. Using the above installation option, the through groove uniformly spanning the device’s body, made in each of the generators used in this system, was a regular rectangular parallelepiped (rather than a complex figure formed when the spatial volume of the body of the working element intersects the secant plane).

Before starting the process of producing metallic iron, 200-240 kg of the initial raw material (or 340-350 kg of the mixture formed on its basis) was loaded into the loading hopper included in the composition of the proposed device.

The latter was a two-component aqueous suspension obtained by mixing small particles of iron ore in a given volume of water.

The iron ore used in this suspension was extracted from its closest deposit, in which it was developed to meet the needs of the existing metallurgical industry using it as raw material. Before starting the preparation of the aqueous suspension, an operation was carried out to break its large pieces into smaller ones using a conventional ball mill.

The resulting particles of the feedstock had overall dimensions in the range from 0.001 mm to 1 mm. The processing time of the above volume of raw materials using this kind of four-circuit system and using the previously given range of values of the intensity of the alternating magnetic field was 15-21 minutes (0.25-0.35 hours).

The yield of metallic iron, calculated on the use of 200-240 kg in the aqueous suspension of the above iron ore, reached 44.4 - 53.8 kg (i.e. 22.2 ÷ 22.44% of its total applied volume).

These indicators come close enough to the theoretically possible limit that determines the amount of metal produced from the feedstock with the percentage of iron compounds in the ore used in the implementation of the processing process indicated below.

The degree of purity obtained in the implementation of the proposed method of the metal corresponds to a value of 99.99992%

If it is necessary to maintain the obtained purity value of the metal manufactured by the proposed method, in the process of its accumulation and further transportation, an inert gas medium can be used to isolate the final product thus formed from adverse external influences. This medium may include argon gas, which is quite common in industrial production sectors.

It should also be noted that the metal granules 10 obtained by this treatment have an almost perfect crystal lattice with only a small number of geometrically correct dislocation outlines distorting it.

This metal itself, relative to the magnetic properties formed in it, must be classified as “soft magnetic”.

In the process of magnetization reversal, the last hysteresis loop in it practically degenerates in the sign of _ Those. the vertical component of this loop does not have any noticeable thickness. The average value of the magnetic permeability obtained by the proposed method of iron is in the range of 16.9-17.1 Gn / m

Received by processing the raw materials of the proposed method, the metal granules have overall dimensions of 4 to 10 mm.

Along with such metal granules, the composition of the final product obtained during the implementation of the proposed method also includes lumpy spongy waste generated from various impurities (Ca, Si, S, Mg) that are part of the feedstock. They have overall dimensions from 25 to 50 mm, their amount relative to the initial mass used to form the aqueous suspension of the rock reaches 56-67%.

The remaining products of processing are represented by the volumes of gases received there formed in the cavity of the device body and thrown out from there into the external atmosphere.

Occupied by the device used in the case of processing the specified raw materials using the proposed technology, the production area is 2.5-3.0 m ² .

The amount of metal produced with its use corresponds to 1.2 tons, provided that work is carried out in a three-shift mode.

The amount of consumed electric energy to obtain the above volumes of the latter is in the range of 2.5-2.8 thousand kWh.

Classical methods for producing iron from feedstock require its use in an amount not less than 8-10 thousand kWh. Among other things, the iron obtained by known methods must be passed through operations on its "refining".

The presence of the above circumstance determines that in order to obtain the specified final product, it will also be necessary to attract an additional amount of the same electrical energy used in the implementation of this kind of “post-treatment” of metal. As a result of all of the above, its amount used for processing will obviously exceed the already specified limits.

The proposed method for producing metal is performed at room temperature (17 ° -27 ° C), and the processing of raw materials is performed under the influence of excess pressure, the value of which is only slightly higher than atmospheric (by 0.1 ÷ 0.6 kgf / cm ² ).

The rotation speed of the pushing raw material from the beginning of the device body to its end of the screw is relatively small and is 6-10 rpm.

Technological modes used in the implementation of the proposed method for producing metal are assigned based on the following considerations.

The intensity of the alternating rotating magnetic field used to produce the metal, measured directly in the zones of influence on the processed raw materials by the magnetic fluxes generated in the device, as already mentioned, is 1 * 10 ⁶ ÷ 1 * 10 ⁷ A / m.

The use of less than the above values of this parameter - 4 * 10 ⁶ A / m does not provide the formation of conditions guaranteeing the release of metal from its compounds that are part of the initial raw material mass. Using higher values of the same parameter than 1 * 10 ⁷ A / m does not allow achieving any additional positive effect. At the same time, an increase in the magnitude of the magnetic fields used in the device above the specified limits - 1 * 10 ⁷ A / m will require additional costs used to generate the latest electrical energy.

The same factors determine the selection of the frequency range of oscillations, within which the generation of alternating magnetic fields.

That is, when applying frequency values less than 40 Hz, the process of separating metallic iron from its compounds is difficult when implementing the proposed technology.

The resulting magnetic flux vectors obtained during the generation of such variable magnetic fields in this case act on the processed ore particles with an insufficient degree of intensity.

Those. such resulting vectors in the volumes of the aqueous suspension surrounding them, including ore particles, move too “sluggishly”.

On the contrary, when the frequency value is higher than 70 Hz, the above vectors move in the zones of their influence so rapidly that the ore particles falling on the path of their spatial transfer do not have time to interact with them. Again, in this case, the creation of optimal conditions for obtaining the necessary final product during processing is not guaranteed.

The purpose of the time intervals used to obtain the metal (0.25-0.35 hours) is based on the following. When the values of the time interval used in the processing of raw materials are less than 0.25 hours (15 minutes), the structural transformations necessary for the formation of this final product do not have time to completely finish in the particles themselves used for processing the raw material mass.

When applying the same time interval if its value is more than 0.35 hours, it is not ensured that any additional positive effect is achieved. At the same time, the use of longer than necessary time intervals leads to an inevitable increase in the total costs associated with the implementation of this kind of process of processing the feedstock into the above final product.

Based on the same considerations, the amount of overpressure in the volumes supplied through the external line to the compressed air nozzles distributing it was also assigned. The latter arrive at these elements, having an overpressure of 0.1 ÷ 0.6 kgf / cm ² .

When the values in the volumes of compressed air supplied to these nozzles of excess pressure are less than 0.1 kgf / cm ² , indicators characterizing the productivity of the process for producing metallic iron fall. When the values of this parameter are greater than 0.6 kgf / cm ² , it is not possible to provide additional intensification of its implementation.

At the same time, when using values of the excess pressure in the volumes of compressed air supplied to such elements of the device that are larger than this value indicated above, the costs necessary to obtain and supply applied electric energy to these areas increase.

The percentage of ore particles in the composition of the aqueous suspension used in the processing process, having a value of 40 -70%, is assigned based on the presence of the following factors.

When the concentration of this kind of component in the latter is less than 40%, the raw material used turns into “poor”, which negatively affects the efficiency of the processing of raw materials, since the yield of the required final product is significantly reduced.

With an increase in its content above a value of 70%, the processed raw material mass sharply decreases the indicators determining the degree of its plasticity. This ultimately makes it very difficult to carry out the process of moving it from the loading hopper into the cavity of the device body, as well as the subsequent transfer of volumes of such material that make up the mass of raw materials on the inner surface of the latter.

The presence of the above circumstance also negatively affects the results provided by the implementation of the proposed technology for the production of metallic iron.

The sizes of ore particles used to obtain an aqueous suspension, the dimensions of which are in the range of 0.001-1.0 mm, are determined on the basis of the need to form with their use a stable "mud-like" raw material mass.

The latter should not be stratified into separate components for the time period necessary for the complete completion of the process.

The choice of values of the angles of inclination of 10-20 ° of the longitudinal axis of the device’s body to the horizon line was made taking into account the possibility of the following circumstances affecting the processing of raw materials.

When the values of the angle of inclination of less than 10 °, the rate of passage of a viscous water suspension from the beginning of the device to its very end is substantially slowed down. This can adversely affect the quality characteristics obtained with the application of the proposed method of the final product.

On the contrary, with an increase in the indicated angle to a value exceeding 20 °, the process of moving can accelerate so much that the necessary structural transformations do not have time to undergo in the processed raw material mass. This circumstance, as in the variant discussed above, can also adversely affect the results characterizing the efficiency of the process.

The speed range (6 - 10 rpm), within which the screw is rotated, is assigned taking into account the following considerations. When rotating it with an angular speed of less than 6 rpm, the movement of the raw material inside the device’s body slows down so much that the yield of the required final product under the influence of this factor will be significantly reduced. When the values of the angular speed of rotation of the screw exceeding the value of 10 rpm, the processed material containing ore particles can pass through the regions of its reduction to metal formed in the device’s body and cross them in an unreasonably short period of time.

The presence of this circumstance will serve in this case as an obvious obstacle to the occurrence of structural transformations necessary for obtaining the final product in the latter.

In connection with all this, the adopted range of screw rotation speed in the housing is set in the range of 6-10 rpm.

To carry out the process of producing metallic iron, carried out using the proposed method, a rock containing ore was used, which included iron compounds. The volumes necessary for the implementation of the series of experiments described below were withdrawn from the closest quarry, in which the ore lying in it was extracted to meet the corresponding needs of the existing metallurgical production. The ore used as the main component to obtain the starting raw material contained the following compounds:

Magnetic iron ore Fe ₃ O ₄ - 14.2%

Spar iron Fe ₂ O ₃ - 8.3%

Iron pyrite FeS - 12.1%

Minerals containing calcium Ca, Mg, Si, S, H ₂ O - the rest is up to 100%

To conduct all of the experiments below to obtain metallic iron using the proposed method, the same type of raw material was used, formed using the rock compound containing it, having the same composition indicated above.

Before the preparation of the aqueous suspension loaded into the processing device, pieces of the iron ore used in it were crushed using a ball mill to obtain rock particles from them, the dispersion of which corresponded to a value of 0.001 - 1.0 mm. The impurities that make up the feedstock — compounds of Ca, Mg, Si, S — at the final stages of processing turned into large-sized spongy wastes of a dark gray color.

In the case of preliminary enrichment of the initial ore, the obtained percentage of metallic iron output from the volume of the used rock will accordingly increase in relation to the previously indicated. However, the implementation of this operation is associated with significant additional financial and labor costs, and this technique was not applied in the series of examples below. For the production of metal, only the so-called ″ poor ″ and ″ ore ″ not purified from impurities was used. But from it, as already noted above, the indicators of iron production reached quite significant values. Grinding into small particles containing iron compounds, the initial rock was then poured with the required volume of tap water and mixed in it until a homogeneous viscous aqueous suspension was obtained from these two components.

After obtaining the latter, the volume of suspension formed by this operation was loaded directly into the hopper of the device used to obtain the metal. Further, the process of implementing the proposed method is illustrated using a number of examples below.

Example 1. In a feed hopper with a capacity of the last 350 l was placed an aqueous suspension, the content of which particles of iron ore with a dispersion of 0.001-1.0 mm was 245 kg or 70%. The remaining mass of the load was water - 105 l or 30%.

After the loading operation was completed, they simultaneously turned on: a rotation drive supplying feed of screw 4 at a speed of 6 rpm, electrical windings of coil 15 in all four generators 5 mounted on the housing 3 of the device, and compressed air was supplied through all nozzles 6. Its entry to the latter from the external highway was carried out under an overpressure of 0.6 kgf / cm ² . The housing 3 of the device used tilted to the horizon. The magnitude of this angle of inclination was 15 °. The tension generated in all four circuits 5, evenly spaced along the housing 3 of the proposed device of magnetic fields, measured directly in the working areas ″ D ″ using a Hall sensor and a measuring bridge, was 1 * 10 ⁶ A / m. Their oscillation frequency corresponded to a value of 70 Hz. The processing time in this example was 0.35 hours (21 minutes). The water suspension 2 of iron ore particles passing through the housing 3 of the proposed device, under the influence of magnetic fluxes formed in the circuits 5, was turned into a set of metal granules of iron, and into lumpy waste having the structure of a “sponge” consisting of the constituent feedstock impurity compounds.

Thus, at the end of the process of processing the aqueous suspension, metallic iron was obtained, the amount of which amounted to 53.8 kg - 21.96% of the used mass of the rock, as well as lump waste, the mass of which was equal to 131.2 kg. The overall dimensions of the pieces of which the slag consisted were in the range from 20 mm to 40 mm, and the pieces themselves had a dark gray, almost black color shade.

The rest of the processed ore was represented by 7 volumes of gases (СО ₂ ; Н ₂ О; H ₂ S; SO ₃ ) released through the outlet pipes, which were sent directly to the atmosphere surrounding the device.

The metal granules obtained by processing had overall dimensions from 4 to 6 mm. The degree of purity of the metal obtained by such treatment with respect to the iron content in it was 99.99993%. The bulk density of the obtained metal was equal to 8.02 g / cm ³ .

The magnetic permeability value formed at the end of the metal processing corresponds to 17.1 Gn / m.

The specific electric resistance of the metal ρ was 81.12 N * Ohm * m.

Example 2. The processing of feedstock was carried out in accordance with the same scheme as was indicated in example 1.

The amount of material containing iron ore used to prepare the aqueous suspension was 140 kg or 40% of its mass, the rest water - 210 l kg or 60% of the total volume of the aqueous suspension.

The air supply to the processed raw materials was carried out under its excess pressure equal to 0.1 kgf / cm ² .

The screw rotation drive provided a speed of its angular displacement equal to 10 rpm. The angle of inclination of the device’s body to the horizon line remained the same as that indicated in example 1 - 15 °. The intensity of the magnetic fields generated in all four circuits of 5 magnetic fields in the “D” zones was 1 * 10 ⁷ A \ m, at a frequency of 40 Hz.

The processing time was 15 minutes (0.25 hours). The mass of iron granules obtained after the end of the processing process had a weight of 31.41 kg (22.44% of the total ore mass used). The volume of slags formed as a result of processing was 89.6 kg.

The remaining mass of the raw materials used to obtain the metal was spent on the formation of the volume of gases released from the device into the outside atmosphere. The degree of purity obtained by processing the metal corresponded to a value of 99.99991%.

The obtained granules of metallic iron had overall dimensions of 8 to 10 mm.

The bulk density of the obtained metal was 7.92 g / cm ³ .

Its specific volume electric resistance was equal to the value ρ 81.2 N * Ohm * m. The magnetic permeability of the obtained metal was in the range of 16.96 Gn / m.

Example 3. The processing obtained from clay particles of an aqueous suspension was carried out in accordance with the scheme specified in examples 1, 2.

The amount of iron ore contained in the aqueous suspension used was 200 kg, or 57.14% of its total mass. The rest of its volume was water - 150 liters, or 42.86%. The supply of compressed air to the processed raw materials was carried out under an excess pressure of 0.4 kgf / cm ² . The screw was rotated at a speed of 8 rpm. The angle of inclination of the device to the horizon line was the same as in examples 1, 2 - 15 °. The intensity of all the magnetic fields created in the ″ D ″ areas, which were located in the zones of action of all four generators used in the device, was 6 * 10 ⁶ A \ m, and the frequency of the latter was 50 Hz. The time period after which the entire volume of the feedstock was processed into the desired final product was 18 minutes (0.3 hours). The resulting metal mass had a weight of 44.67 kg, or 22.33% of the total amount of ore used to produce it.

The weight of the waste volume formed together with the metal was 107.3 kg. The remaining volume of the raw material used to produce the metal was converted into gases, which were removed from the cavity of the device used to produce iron directly into the surrounding atmosphere. The overall dimensions of the iron granules obtained at the end of the process were in the range of 6-8 mm. The degree of purity formed by processing the granules of metallic iron, relative to its content in the latter, corresponded to a value of 99.99992%.

The specific volume electrical resistivity ρ of the metal obtained using the proposed method corresponded to a value of 81.08 N * Ohm * m, the bulk density was 7.99 g / cm ³ .

The value of magnetic permeability in the metal obtained by processing corresponded to a value of 17.7 Gn / m.

The overall dimensions of large-sized spongy lumpy waste formed at the end of the processing of raw materials amounted to 25-50 mm.

From all the examples presented above, it is clearly seen that the production of metallic iron, which is distinguished by a high degree of purity, as well as possessing the corresponding indices of its magnetic permeability, can be carried out using widely used and widely used ore products for the metallurgical industry.

When performing the proposed method, the latter are not enriched or cleaned of impurities contained in them, represented by other elements common in nature. The presence of the above circumstances suggests that the application of the proposed method can be quite effective if used to meet the needs of existing industrial production.

Further, in the materials presented below, structural principles are set forth in accordance with which the device used to implement this method is implemented. The presence of the latter, ultimately, ensures that the necessary positive effect is obtained in the process of its application.

Used to implement the proposed method, the device is depicted in figure 1, figure 2.

Figure 1 - section of the device casing and the layout of the processing providing the processing of raw materials of magnetic circuits.

Figure 2 is a cross-section along aa of the device body, made in that part of it, on which the magnetic generator used in the multi-loop system is installed.

Figure 1, figure 2 in turn shows:

Position 1 - loading hopper, with the mass of processed feedstock 2 placed in its volume.

Position 2 - processed source material, consisting of pre-ground pieces of iron ore and water.

Position 3 - the housing of the device, in the internal cavity of which the processing of the feedstock 2 proceeds.

Position 4 - spiral screw auger, the blades of which carry out the movement of processed raw materials from the front end of the housing 3 to its rear.

Position 5 - mounted on the case 3 with gaps ″ a ″ on the raw material 3, magnetic circuits processing raw materials having an angle of inclination to the outer surface of the case equal to 90 °.

Position 6 - nozzles passing through the walls of the housing 3, supplying compressed air jets to the mass of the processed raw material, and placed on the housing 3 in rows spaced from each other at equal distances.

Position 7 - hollow pipes mounted on the front and rear parts of the housing 3, the lower end of which extends into the internal volume of the housing 3, and the upper provides a communication cavity of the latter with the outside atmosphere.

Position 8 - separating the lower end of the pipe 7 from the upper pressure reducing valve, which allows the flow of gas volumes coming from the cavity of the housing 3, if the pressure in it exceeds the value set by its setting.

Position 9 - the storage hopper, which is the discharge obtained by processing in the cavity of the housing 3 of its final products.

Position 10 - metal iron granules accumulated in the volume of the storage hopper and slag waste dumped there.

Position 11 - racks for fixing the housing 3 of the device at a given angle to the horizon line on its very base.

Position 12 - the same rack, providing fixation in a predetermined position used in the device magnetic circuits 5.

Position 13 is a shutter, by means of which the lower part of the hopper 9 is opened, in the case when the latter is completely filled.

Position 14 - magnetically conductive elements of circuit 5, with the help of which optimal conditions are created for the passage of the total magnetic flux generated in their volume.

Position 15 - electrical winding coils that perform the function of solenoids, and providing when they are included in the electric circuit, the formation of alternating magnetic fields.

Position 16 - made on the front and rear ends of the screw 4 of the axis, with which it is provided with its continuous rotation in the cavity of the housing 3.

The letters ″ a ″ are the installation air gaps formed during installation of the housing 3 in the through groove "B ″ of the magnetic circuit.

The letter ″ B ″ - made in one of the components of the magnetic circuit of the elements 14 through the groove, in the cavity of which is placed the housing 3 of the device used.

The letter ″ B ″ - formed in the housing 3 at the site adjacent to the lower end of the hopper 1, is the inlet opening through which raw material is supplied into its internal cavity.

The letter ″ G ″ is a similar exit opening in the housing 3, through which the final products obtained therefrom are removed.

The letter ″ D ″ - spatial ellipsoids formed in the process of vibrational angular displacement generated by magnetic circuits 5 resulting vectors of total magnetic fluxes.

The letters ″ φ ″ are the angles of inclination of the longitudinal axis of symmetry of the housing 3 to the horizon level - 10-20 °, as well as the end planes of the generators 5 mounted on the housing 3 relative to the vertical line - 10-20 °.

You should also pay attention to the fact that indicated in figure 1; figure 2 a device for implementing the proposed method has the following features of its design, namely:

The casing 3 is fixed at a given angle to the horizon line to the base surface using a system of racks 11 (see Fig. 1). Similarly, the placement of the generators 5 used in the device and also mounted with an inclination to the outer surface of the housing 3 is carried out similarly, i.e. using their supporting racks 12.

The rotation of the screw screw 4 is carried out on the axes 16 passing through the end walls of the housing 3 and fixed therein in the respective bearings (not shown in the drawing). One of these axes 16 has a kinematic connection with an external drive for rotating the screw 4 (not shown in the drawing). The flowing air jets to the raw material mass 2 of the nozzle 6 (see FIG. 1) are placed uniformly along the body of the housing 3, forming alternating rows. At the same time, they are, as it were, located along the perimeter obtained during the section of the same building of 3 squares, if we mentally draw a secant plane through it, located at a spatial angle to its longitudinal axis, the value of which is 90 ° (i.e., along the three component sides of the perimeter the square thus obtained, with the exception of its lower base).

Nozzles 6 are also fixed at equal distances from each other and have, relative to the surface to which they are attached, both tangential and radial tilt angles of 30-45 ° (these angles are not shown in the drawing). The use of just such a arrangement of nozzles 6 on the outer surface of the housing 3 (i.e., at two angles of inclination) allows not only to supply the necessary gas for the process of metal reduction from its connected portions, but also to additionally carry out the moment of getting compressed air jets formed in them into the body cavity, intensive mixing of the last microvolumes of the processed raw materials located in the impact zone 2.

In order to simplify the design of the proposed device, its housing 3 in its cross section has the shape of a square, in the center of which a spiral screw auger 4 rotating in it is mounted.

Accordingly, the through groove "B", performed for placement in the generators 5 of the housing 3, has a simple rectangular shape, which is provided due to the presence of tilt angles φ of their end planes relative to the vertical. It should also be indicated that figure 1 shows the magnetic circuits fixed on the housing 3 — the first of four attachable, mounted near its very front part, and the last - the fourth, most closely offset to its rear end.

The second and third of the circuits 5 in the drawing of figure 1 are not shown, since they fell into the zone of the conditional gap, made about half of the entire length of the housing 3, to simplify the reading of the drawing.

All four generators 5 are placed along the housing 3 at the same distance from each other and from its front and rear ends.

The installation of all magnetic circuits 5 on the outer surface of the housing 3 of the proposed device is carried out using the through rectangular grooves “B” made in them, through which the body of the latter passes. In the process of mounting these magnetic generators 5 on the casing 3, the air gaps “a” marked in FIG. 1 and FIG. 2 are created, the presence of which provides the possibility of their placement in these zones, evenly spaced along the entire length of the casing 3.

The work of the proposed device in the process of producing iron from the raw materials used for this proceeds as follows.

After loading the raw material 2 into the cavity of the loading hopper 1, the rotary drive of the helical spiral screw 4 located in the cavity of the housing 3 is turned on. Simultaneously with the start of the turning of its curved blades included in this assembly, all the electrical windings of the coil 15 located in magnetically conductive elements 14 used in the composition of the device of four magnetic circuits 5. At the same time, a pre-prepared plastic raw material mass of 2 hours Res feed opening 'B' is supplied from the hopper 1 into the internal cavity of the body 3.

Its volumes at the very first stage of the processing process fall into its front part lying in the uppermost zone of the device. It should be noted that the level of vertical placement of the structural elements of the housing 3 relative to the horizon is regulated by the appropriate selection of the length of the struts 11 used to fix its base (see figure 1). Portions of raw material entering the above region of the housing 3 are picked up by the curved blades of the rotating screw 4, mixed, and their total mass is divided with the participation of the latter into separate microvolumes that previously comprised it. Obtained in the above manner, small portions of the aqueous suspension 2, continuing to perform the process of such translational movement, fall into the zone of generation of a powerful magnetic flux "D", which is created using the very first of the four used generators 5 (see figure 1). Microvolumes of raw material 2 sent to this part of the cavity of the housing 3 inevitably intersect the force lines located there and concentrated over a relatively small area, the alternating rotating magnetic field formed in this region. You should also pay attention to the fact that towards the flows created with the help of screw 4, which include microvolumes of the raw material used, jets of compressed air are sent, which are formed in nozzles 6 fixed on the outer surface of the casing 6. The latter are connected to the compressed air supply overpressure (0.1-0.6 kgf \ cm ² ) of the external supply line (not shown in the drawing) at the same moment in time when the rest of the system device (power supply circuit of the magnetic circuits 5, the drive rotation of the feed screw 4).

Due to the presence of radial and tangential angles of inclination of the nozzles 6 with respect to the outer surface of the housing 3 (not shown in the drawing), the compressed air jets formed by them, meeting with the same neighboring ones, form a kind of “swirl” at the intersection. Since the points of such a “crossing” of the compressed air flows generated in the cavity 3, as a rule, fall into the zones of passage of the microvolumes of raw materials 2 transported in it, meeting with their constituent layers, the “vortices” that arise there provide their additional and intensive mixing.

In addition, they also carry out their main function - they add carbon fragments to the molecular fragments activated by a powerful magnetic flux, which are part of the aqueous suspension used, to restore carbon to the metal. The latter, as noted earlier, is part of the carbon-containing gases present in ordinary atmospheric air.

Like the other raw components, the molecules of these gases, falling into the “D” zone, are activated using the powerful magnetic flux generated in this region and are destroyed in it with the formation of carbon reducing agents in the above volume. The arrival of these ions to the maximum possible concentration of the field lines generated in this part of the cavity of the body 3 of the magnetic field activated with the participation of the last fragments of raw materials and provides optimal conditions for the process of reduction of metallic iron from compounds containing this element. Thus, leaving the region of the internal cavity of the housing 3, located in the installation zone of the first generator 5, the mass of raw material pushed by the screw 4 is “enriched” with small crystalline nuclei of the metal obtained there. The latter are evenly distributed in its volume due to the ongoing process of intensive mixing of portions of raw material as rotating auger blades and jets of compressed air supplied to the housing 3.

After passing through the installation zone of the first circuit 5, the volumes of the water suspension 2 filling the cavity of the body 3 of the body 2, under the influence of the same blades rotating around the own longitudinal axis of the screw 4, are pushed further, already into the zone of generation of the magnetic flux created by the second circuit 5. The latter is separated from the first circuit 5 at a preselected and the same distance for arranging the magnetic loops used in the device (the second loop is not shown in the drawing, since it falls into the zone of conditionally executed times tearing the device into two approximately equal halves). The movement of the processed raw materials in the direction from the front end of the housing 3 to its rear is facilitated by the angle of inclination of its longitudinal axis to the horizon (for the device shown in Fig. 1, the angle φ is 15 °). When passing portions of the processed raw material through the same area “D” of the second magnetic circuit 5, located at a predetermined distance from the installation site of the very first, the magnetic flux generated there acts on the incoming and constituent last components. As a result of this, the same phenomena will also be observed in this zone that occurred during the conversion of such compounds into the required final product and in the installation zone in the device of the very first but counting the same circuit.

The processes occurring in both cases do not have any significant differences. The only thing that should be noted is that the mass of raw material 2 that left the zone of the second magnetic circuit 5 will be enriched to a large degree by new metal crystals additionally formed in this region. At the same time, the latter, previously formed in the installation area of the very first generator, will increase their initial dimensions due to the addition of small crystals of this metal newly formed in the zone of influence of the second-circuit flow to the outer layers of the crystal lattice that constitute them. An increase in the size of the previously obtained “nuclei” will also occur due to the reduction of small particles of iron ore that are previously adhered to metal and are converted into metal. That is, at the same time, the process of converting the “fur coat” covering them into a metal crystal lattice, which grows on the latter using the external components of these “embryos” layers as a material base used for this, proceeds as the specified stage of processing continues. This kind of "enriched" by the metal obtained in the indicated areas of the raw material mass 2 moves further along the plane of the casing 3 installed with the slope used for processing the device. “Pushing” it in the direction from its front to the back, as already noted, continues to be carried out by curved blades of a screw screw 4 continuously rotating on the axes 16. Following this predetermined design of the device used, the trajectory “laid” in the cavity of the housing 3, microvolumes already saturated with metal at the previous stages of processing the raw material, ultimately approach the area of intensively performed exposure to magnetic flux, which is formed in the same zone “D” on the installation site on building 3 is already the third generator 5.

In the above region, all the same processes will be observed as in the cases analyzed earlier, when considering phenomena occurring in similar parts of the cavity of the housing 3, in the zones of influence generated by the first and second circuits 5 of magnetic fields. Again, the slight differences that are revealed after the processed portions pass through the raw material mass and this third area located in the mounting zone of the third contour 5 should include the presence of the following circumstances.

In the volumes of the processed material that passed the installation zone of the third magnetic generator, the particles that are part of the iron ore feedstock are practically no longer contained. Individual particles of the latter are captured by enlarged granules of metal obtained there grown in the zone of influence of the third circuit. The remaining small “grains” of iron compounds remaining after passing through this above site are completely used up to form a kind of coating (“fur coat”) consisting of them on the outer surface of the latter.

Clad metal pellets ultimately leave this area. The accumulation formed there is transferred by the feeding screw 4 to other regions of the cavity of the housing 3 located at a distance from it, moving farther and farther towards the rear end of the latter (the third circuit 5, like the second, falls into the zone of conditional rupture of the device casing and in the drawing not shown), successively passing along this path along its entire surface. This cluster of metal granules obtained earlier, in the end, is in the “D” zone, being affected by the magnetic flux generated by the last of the number of generators used in the device, i.e. the fourth magnetic circuit 5. It should also be noted that in the process of passing through the above region, also located directly on the path of movement of the raw material used, the whole complex almost completely ends in the aggregates of the initial product processed in the device that were obtained at the previous stages of processing necessary structural transformations.

The metal granules entering as separate components of the above clusters at this point in time acquire a degree of purity, determined by the percentage of iron in them, which allows attributing this product to the group “having reached the required condition”. Upon completion of the set of necessary transformations of the feedstock, performed in the zone of influence of the aforementioned magnetic flux obtained using the fourth magnetic generator, the small particles of ore adhering to the surface of the granules passing through it and forming the original non-metallic coating are transformed into new layers enveloping them, consisting of the same iron.

Due to the presence of all the above circumstances, the process of enlargement of crystalline “nuclei” located in this region proceeds, which additionally increase their originally obtained overall dimensions.

In addition, the same effect will take place when small crystalline “nuclei” of iron are “sticking” together in the same zone, and when these are interconnected, rather large pieces of metal are formed.

Thus, at this final stage of processing, the entire initial raw material mass is completely processed, and the granules of metal 10 obtained in the installation area of the last fourth magnetic circuit 5 are transported from it by the screw 4 continuing to rotate around its own longitudinal axis, freeing this zone from its the presence and ending up in the rear end of the housing 3 of the device used. Having reached this indicated part of it, which occupies a horizontal level lower than the one used to place the upper end of the housing 3, the granules 10, as well as the spongy slags formed together with them, run into the exit opening located directly on the path of their movement " G "(see figure 1). Because of this, all of the above products are dropped into the last and, ultimately, fall to the bottom of the storage hopper 9. As the cavity is filled with the above end products of processing, the shutter 13 is opened, which ensures their removal with the discharge of the latter into the one used for this technological container (not shown in the drawing). If it is necessary to preserve the degree of purity of the metal obtained by treatment, both the accumulation of its granules and their subsequent transportation can be carried out under a layer of a protective atmosphere consisting of an inert gas - argon (not shown in the drawing).

The decrease in the volume of the initial raw material 2 as it is consumed is compensated by the supply of new portions of the latter from the cavity of the loading hopper 1, communicating with the volume of the housing 3 through the input opening "B" (see figure 1). Their arrival in the indicated part of the device body from the cavity of the hopper 1, i.e. in its front end, carried by gravity.

As the flow rate of the feedstock 2 placed in the feed hopper is consumed, the latter is loaded into the latter. Due to this, the process of processing raw materials into metal is performed in the proposed device without any stops and interruptions.

Since in the process of metal recovery from its compounds in the zone of its flow, volumes of gases previously absent there are formed, forming so-called gas "bubbles" in the cavity of the housing 3, and, consequently, the magnitude of the excess pressure created there increases, to eliminate the possible negative impact of these factors, a periodic release of these volatile compounds accumulated in the body cavity to the outside atmosphere is performed.

Removal of the latter, as well as excess volumes of compressed air supplied to the housing 3, is carried out by means of pipes installed on its front and rear parts that communicate directly with its cavity 7.

The opening of the latter is carried out by pressure reducing valves 8 at times when the amount of excess pressure in the cavity of the housing 3 exceeds that set by the processing technology. The adjustment of the moment of operation of the locking elements in the valves 8 is made taking into account this set value of the excess pressure (see figure 1).

In this way, the unimpeded movement of the processed raw material mass 2 along the entire cavity of the housing 3 is ensured without additional stops there because of a local increase in the excess pressure in its individual sections.

The external electric power supply units of the magnetic circuits 5 used in the device are also equipped with electronic control circuits, with the help of which the necessary changes are made to the frequency of the alternating electric current supplied to the coil windings 15, its magnitude and voltage (not shown in the drawing). Due to this, it is possible to obtain in the processing zone of magnetic fields with predetermined values of their intensity, as well as their frequency.

The smallest possible number of magnetic circuits servicing the device corresponds to two, however, in this case, it is necessary to use a low-speed drive to rotate the feed screw, which creates additional difficulties in the process of its operation and maintenance.

The maximum possible number of the latter can reach up to six units. A further increase in their number above the specified value leads to the fact that all these additional generators will work almost “idle”.

In addition, the use of magnetic circuits in such an amount that exceeds the above limit leads to the complication of the device used for processing raw materials and adversely affects its performance.

As the most optimal option in the proposed device design, a magnetic system was used that included four circuits. The presence of a positive influence of this circumstance ensured a sufficiently high efficiency in the implementation of the above technology for the processing of raw materials, due to the use of this particular version of such a design of the proposed device. Achieved in the process of use to achieve the above goals of this type of the proposed device design, the technical and economic indicators characterizing the degree of efficiency of the processing performed with its help made it possible to determine the following.

With a device length of 1.5 meters and its width, taking into account the dimensions of the systems serving it, 1.2 m, as well as with the width and height of its body 0.2 * 0.2 m and in the case of operation using a three-shift mode, it is obtained one thousand two hundred kg of metallic iron in one day. The degree of purity of the obtained metal was 99.99992%. The sizes of iron granules formed with its help were 4-10 mm. The energy consumption per ton of metal obtained is 2.0-2.5 thousand kW / h.

An iron multicomponent rock, delivered to the processing site from the nearest deposit located near the place of its implementation, was used as the initial compound of iron ore, in which the latter was developed to meet the corresponding needs of the existing metallurgical production.

To separate the final products collected in the cavity of the storage hopper, i.e. granules of metallic iron and sponge slag dumped into it, the mass of this material extracted from the hopper was passed through a system consisting of a set of ordinary calibrated sieves.

Since the above components have a significant difference in overall dimensions, after passing these products accumulated in the bunker 9 through the aforementioned calibration system, they are easily divided into fractions comprising metallic iron granules and synthesized during processing from impurities included in the feedstock slag waste.

To supply air to the dispensing nozzles 6, an external supply line is used (not shown in the drawing), compressed air under excessive pressure into which is supplied using a conventional compressor. The above compressor may be of any design.

To carry out repairs or necessary maintenance of the installation operating in the “continuous” mode, the time moment is selected when the loading hopper 2, as well as the entire volume of the cavity of the housing 3 will be freed from the raw material passing through them, i.e. the latter must be worked out to zero.

After that, all service devices of the system are disabled, i.e. all the constituent magnetic circuits 5 of the winding coil 15 are disconnected from the power source, and the rotation drive of the feed screw 4 is stopped and the external line supplying compressed air to the nozzles 6 is shut off.

At the end of all the above steps, the device can be used to carry out the necessary complex of work on it, ensuring the possibility of using it for further operation.

Re-launch it in the work as follows. First of all, the loading hopper 1 is filled with the required volume of processed raw materials 2, then, in the above order, all the systems serving the device are turned on and after that the process of processing the raw materials 2 into metal proceeds in accordance with the above execution scheme (i.e., it is used again the so-called "continuous cycle").

Given all of the above, the following conclusion can be drawn. Using the proposed method for producing metallic iron, as well as the device used for its implementation, provides a significant reduction in the cost of electric energy necessary for processing the feedstock into the final product. That is, the application of the proposed technical solutions creates the conditions for reducing its consumption by 8-15 times but in relation to the amount required when performing the process of reducing iron from its ore, carried out using an induction furnace.

In addition, in the case of processing the feedstock containing iron compounds using the proposed method, the use of substances and materials (coke) is completely eliminated, the ingress of gases generated by using them into the atmosphere (CO) can lead to environmental pollution of this production and harm human health.

It should also be noted that, in contrast to the currently known methods for this kind of metal production technology, carried out using the proposed method, ores containing any possible forms of nature can be used as suitable raw materials for use in its implementation. iron compounds, in its original "raw" form.

The process of processing raw materials, which had never before been considered suitable for industrial use, can be carried out continuously without the need for any additional technological stops.

The metal obtained from non-deficient and widespread in the natural environment of iron rock metal has a high degree of purity of 99.99992% and the same magnetic “softness” and can be used to meet the needs of the corresponding industrial production without additional operations for its final refinement.

The introduction of the proposed process (as well as the device used during its execution) into production does not require attracting significant investment and is not associated with the need to use significant labor costs, as well as the long lead times required to prepare the production.

The selection of materials and components included in the composition of the proposed device was made taking into account the possibility of using as the last similar, widespread and used in equipment designed to implement technologies similar to the proposed one.

This proposed device itself is characterized by a high degree of simplicity of its design and, as a result, has increased operational reliability.

Claims (6)

1. A method of producing metallic iron, comprising forming an initial raw material mass in the form of an aqueous suspension containing iron compound obtained by introducing iron ore particles into a predetermined volume of water, moving the initial raw material mass through successive treatment zones in which metal is reduced using carbon included in the composition of the gases contained therein, supplied to the aforementioned working areas, and through the action of variable rotating ma magnetic fields, the deposition of the obtained metal particles with their accumulation and subsequent unloading of the finished metal, and the process is carried out without stopping the processing of raw materials, characterized in that they use an aqueous suspension, the dispersion of iron ore particles in which is in the range of 0.001-1.0 mm, and their content is 40-70%, in this case alternating rotating magnetic fields are used, the intensity of which in the working processing zones is 1 * 10 ⁶ -1 * 10 ⁷ A / m, and the frequency is 40-70 Hz, in an amount from 2 to 6 while receiving the finished metal in the form Ranuli iron size 4-10 mm. 2. The method according to claim 1, characterized in that during the treatment process, compressed gas jets are supplied under an overpressure of 0.1-0.6 kgf / cm ² . 3. The method according to any one of claims 1 or 2, characterized in that the movement of the feedstock is carried out through successive processing zones under continuous mechanical stirring of the feedstock, which is carried out along the entire travel path using a screw rotating around its axis. 4. A device for producing metallic iron by the method according to any one of claims 1 to 3, comprising a hollow body intended to be placed in its cavity of the processed raw material mass, working elements that ensure the formation of an alternating rotating magnetic field reducing agent acting on the iron ore particles, which are made in the form of solenoid coils and connected to an external source of electrical power, and the cavity of the housing is isolated from its external environment, and the working elements in quantity From 2 to 6 pieces are made of plates of magnetically conductive material joined together in the form of a closed rectangular contour, and in the body of the individual parts of these circuits there are three electrical coil windings-coils in each separate circuit that perform the functions of solenoids, and each of them connected to the corresponding separate phase of the external three-phase power source, while in one of the working elements included in each of the circuits used in the device, a through groove is made, g the dimensions of which ensure the placement of the said hollow body in it, while the body is located in the above-mentioned contours sequentially installed at an equal distance from each other and is covered from its outer surface by magnetically conducting elements forming this through groove, the body being equipped with a moving located in its cavity and carrying the cavity of the raw material mass in the direction from the front of the housing to the rear of the rotary screw rotating around its axis, having its own drive, This indicates angular displacements of the screw at a given speed, while on the outer surface of the housing, at a slope with respect to the latter, rows of compressed gas supplying nozzles are uniformly spaced from one another, an opening is made in the front end of the housing that communicates with the cavity of the loading hopper located above it, and the rear end of the housing is equipped with a hatch for unloading the finished metal in the form of iron granules in a drive installed under the hatch. 5. The device according to claim 4, characterized in that the housing is mounted with a slope of its longitudinal axis of symmetry to the level of the horizon, while its front end is raised and the rear end is lowered, and the angle of inclination is 10-20 °. 6. The device according to any one of claims 4 or 5, characterized in that hollow tubes passing through its walls are mounted on the housing, mounted from its front and rear ends and equipped with pressure reducing valves, the cavity of the latter being directly connected to the internal volume of the housing.

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