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WO2014183177A1 - Procédé de réduction de minerai de fer dans un réacteur avec torches à plasma en régime transitoire - Google Patents

Procédé de réduction de minerai de fer dans un réacteur avec torches à plasma en régime transitoire Download PDF

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Publication number
WO2014183177A1
WO2014183177A1 PCT/BR2013/000461 BR2013000461W WO2014183177A1 WO 2014183177 A1 WO2014183177 A1 WO 2014183177A1 BR 2013000461 W BR2013000461 W BR 2013000461W WO 2014183177 A1 WO2014183177 A1 WO 2014183177A1
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WIPO (PCT)
Prior art keywords
plasma
reactor
iron ore
torches
transient
Prior art date
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Ceased
Application number
PCT/BR2013/000461
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English (en)
Portuguese (pt)
Inventor
Alberto Carlos PEREIRA FILHO
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Individual
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Individual
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Filing date
Publication date
Priority claimed from BR102013011912-1A external-priority patent/BR102013011912B1/pt
Application filed by Individual filed Critical Individual
Publication of WO2014183177A1 publication Critical patent/WO2014183177A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B4/00—Electrothermal treatment of ores or metallurgical products for obtaining metals or alloys
    • C22B4/04—Heavy metals
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B11/00—Making pig-iron other than in blast furnaces
    • C21B11/10—Making pig-iron other than in blast furnaces in electric furnaces
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B13/00—Making spongy iron or liquid steel, by direct processes
    • C21B13/12—Making spongy iron or liquid steel, by direct processes in electric furnaces
    • C21B13/125—By using plasma
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces
    • F27B3/02—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces of single-chamber fixed-hearth type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces
    • F27B3/10—Details, accessories or equipment, e.g. dust-collectors, specially adapted for hearth-type furnaces
    • F27B3/20—Arrangements of heating devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D17/00—Arrangements for using waste heat; Arrangements for using, or disposing of, waste gases
    • F27D17/10—Arrangements for using waste heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D99/00—Subject matter not provided for in other groups of this subclass
    • F27D99/0001—Heating elements or systems
    • F27D99/0033—Heating elements or systems using burners
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21B—MANUFACTURE OF IRON OR STEEL
    • C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
    • C21B2100/60—Process control or energy utilisation in the manufacture of iron or steel
    • C21B2100/62—Energy conversion other than by heat exchange, e.g. by use of exhaust gas in energy production
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/10—Reduction of greenhouse gas [GHG] emissions
    • Y02P10/143—Reduction of greenhouse gas [GHG] emissions of methane [CH4]

Definitions

  • This patent application deals with the use of transient plasma technology torches in a compact reactor, which combined with the use of a hydrocarbon as fuel, preferably natural gas, generates a synthesis gas and thermal energy capable of making the reduction of pig iron in the same environment.
  • ferrous and non-ferrous metal ore reduction segment in particular but not limited to iron ore and may be applied in the reduction of other ores, metal oxides provided that the synthesis gas behaves well as a reducing agent. .
  • Iron metallurgy basically consists in the reduction of its oxides with the use of a reducing agent.
  • the basic principle of operation of a blast furnace is the removal of oxygen from the ore using mineral or vegetable coal or even the babassu coconut shell, which is thus reduced to iron.
  • the reduction is the result of combining the carbon present in the coke with the ore oxygen, which in an exothermic reaction generates CO.
  • hot air s 1000 ° C
  • the coke comes into combustion generating heat and reducing iron ore, resulting in pig iron and slag
  • the temperature inside a Blast furnace can reach 1500 ° C.
  • the traditional process requires some raw material preparations:
  • Coke oven - composed of a battery of coke ovens or cells where coke impurities are eliminated.
  • the resulting product is metallurgical coke which is a porous residue composed mainly of carbon having high mechanical strength and high melting point.
  • Plasma can be understood as an ionized gas at elevated temperatures compared to conventional systems such as combustion, electrical resistance and others.
  • the typical range of temperatures achieved by thermal plasmas ranges from 5,000 ° C to 10,000 ° C, although it is possible to reach higher temperatures.
  • Plasma is generated by the use of electricity and a gas as a conductive fluid with high energy efficiency in so-called "plasma torches". Once controlled, there is a high electron temperature and less energy transfer to the heavy particles (ions and neutral particles). Under such thermodynamic conditions, some plasmas, known as transient plasmas, registered in Brazil as Rotex plasma, offer great advantages in chemical processes, with low power consumption, acting as dissociation catalysts, offering good selectivity, presenting high conversion rates. .
  • US 4752329 - Midrex - a method of producing blast furnace iron in which the upper zone reduces iron oxide by reaction upon contact with a gaseous reducing agent represented by natural gas.
  • a gaseous reducing agent represented by natural gas represented by natural gas.
  • synthetic gas obtained from natural gas is used as a reducing agent.
  • synthesis gas production unit H 2 and CO
  • H 2 and CO synthesis gas production unit
  • US4439233 anticipates a method for the production of synthesis gas, in which natural gas and Water vapor passes through a steam reformer to form the reducing gas at elevated temperature.
  • a drawback of the above process is the high cost of implantation, and the iron produced, not liquefied due to the low temperature achieved, is of inferior quality, popularly known as "sponge iron".
  • the Fastmelt process uses natural gas, oil and pulverized coal as reducing agents, but does not employ plasma but a burner.
  • the reactor is of the rotary type, different from the one proposed in this claim, in addition the ore receives a carbon-enriched sintering preparation.
  • the process is made possible by the different characteristics of the reactor containing transient plasma torches whose quantity is determined by the desired production capacity, torch channels through which the plasma flows and the bowl where a plasma zone and a zone are configured. through which they pour liquid metal and slag, in an operating regime very similar to that of a blast furnace leak, but without the use of coke or charcoal, which depending on the procedural advantage can also be used.
  • part of the energy contained in the synthesis gas is used for preheating and reducing the ore load.
  • the differential in the fusion zone is the atmosphere with strong presence of the synthesis gas, which prevents reoxidation. Residual reduction of iron oxides present and dengue and ash scorification occur in the liquid state in the lower vat.
  • the natural gas or hydrocarbon is injected into the transient plasma torch with the addition of compressed air in an appropriate equivalence ratio for the formation of the synthesis gas and heat production, according to the reaction below:
  • FeO + CO Fe + C0 2 starts at 1300 ° F
  • FeO + H 2 Fe + H 2 0
  • the liquid and agitated material remains in constant interaction with the synthesis gas, increasing the residence time of the process and, consequently, the rate of conversion of iron ore to pig iron.
  • agents such as limestone, dolomite or the like are added to the ore according to their chemical need by the action of these agents.
  • Iron in the liquid state and in the bottom of the reactor is continuously poured at a rate defined by the function of its feed rate and synthesis gas consumption. Supernatant slag is expelled through a passage in the middle of the reactor.
  • the remaining gases make their way to the thermal reserve unit positioned at the upper reactor inlet.
  • the first ore reductions occur, as shown in the above equations.
  • the exhaust gases pass through a set of filters, cleaning and burning the residual fuel, to finally be thrown into the atmosphere.
  • they can be reused in energy production.
  • Compressed air generator unit for plasma torches; Natural gas or other hydrocarbon network for synthesis gas generation;
  • Thermal reserve unit for preheating and reduction of iron ore in its oxide phases.
  • Liquid or gaseous hydrocarbon in particular natural gas, but may also be used, heavy oil, diesel oil, gasoline, ethanol and even pulverized coal;
  • Synthesis gas production, ore reduction and enthalpy generation are performed in the same environment, ie in the reactor with a more favorable kinetics due to the high temperature achieved with the torches.
  • the "PROCESS FOR REDUCING IRON ORE IN TRANSIENT PLASMA TORCH REACTOR" object of this patent application consists essentially of the use of torch reactor (2) with transient plasma technology as catalytic converter in the generation of the iron ore reducing agent from natural gas or another hydrocarbon, so that the reduction, synthesis gas production and enthalpy occur in the same environment.
  • the claimed process does not require the blast furnace figure as it uses transient plasma technology, ie in an intermediate range between cold plasma and thermal plasma effected by compact torches (2) strategically located in the area. of plasma (3) from an equally compact reactor (1), thus acting as a catalytic converter in the generation of the synthesis gas via natural gas or another hydrocarbon. Catalysis is explained by the combination of the high inherent plasma temperature and the high density of high energy electrons above 2eV of cold plasma. Torches (2) are connected to an external plasma source (4), natural gas or other hydrocarbon network (not shown) and a compressed air source (not shown).
  • a mineral feeder (5) containing ore fines and or in natura iron ore with the fillers provides this material to the reactor (1), in a ratio proportional to the required pig iron flow rate and the synthesis gas, not without it must first pass a thermal reserve unit (6) using the hot gas return from the melting zone (7) located above the plasma zone (3).
  • unit (6) Preheating takes place favoring the first reductions of ore oxides, especially hematite and magnetite, due to the presence of the countercurrent hydrogen and carbon monoxide reducing gases at a temperature of 450 ° C to 850 ° C, suitable for this stage.
  • the preheated mineral charge is carried to the melting zone (7) where it is subjected to the action of plasma from the torches (2) blowing high temperature synthesis gas to the central reactor bowl in the melting zone. (7) itself.
  • the ore already in liquid form and in a state of agitation, the ore remains in contact with the synthesis gas, interacting with it and increasing the reduction period.
  • the synthesis gas makes up a vortex helical path. After performing the vortex trajectory, the gas is forced out of a central opening (8) directed to the thermal reserve unit (6), and thereafter to the filter assembly (9) where it is treated through a duct.
  • the gases When faced with a fork (10), the gases are directed to a flare chimney (11) in which the residual fuel is burned to finally be thrown into the atmosphere.
  • exhaust gases can be reused in energy production (12).
  • the highest density material ie pig iron
  • the slag remains in the supernatant and is leaked through a lateral passage (5) and from there to another crucible (16).
  • the reactor (1) is designed to operate at elevated temperatures in the range 1500 ° C to 1600 ° C, and is coated with refractory cement and insulating material.
  • Transient plasma source (4) is an alternating or direct current electro-electronic equipment with variable power according to the appropriate reduction ratio.
  • the source (4) has a current and power control system, electrical resistors, circuit breakers, special wiring, high voltage fuses and other components necessary for its operation.
  • Non-equilibrium transient plasma torches (2) bring together the benefits of good energy density thermal (high temperature) plasma with the advantages of "corona", “glow”, and cold plasma discharges. which have high selectivity of radicals and energetic electrons.
  • Typical electron temperatures in these plasmas range from 11,000 ° K ( ⁇ 1 eV) to over 23,000 ° K ( ⁇ 2eV), which is sufficient to break the bonds of the gas and oxidizer molecules and is sufficient to produce free radicals.
  • the fluid is cracked into smaller radicals, energized in excited states or transformed into free radicals, which contribute to the formation of the process synthesis gas.
  • it is possible to obtain a high rate in the production of energetic electrons which enables the dissociation of molecules in favor of synthesis gas formation and the generation of enthalpy in the process.
  • the conversion factor is the ratio of the amount of synthesis gas produced by the quantity of natural gas, ie:
  • ⁇ 0,65 to 0,80, ie for 1 m 3 of natural gas around 1,95 to 2,4 m 3 of synthesis gas (CO + H2).
  • the process temperature is controlled from 1500 ° C to 2400 ° C.
  • the transient plasma torch is basically composed of two electrodes - cathode and anode, between which an electric arc is maintained.
  • a gas any gas can in principle be used
  • the passage of a gas initially at room temperature, through the electric arc causes collisions between the electric arc electrons and the molecules or atoms (in the case of inert gases) of the gas. These collisions transfer some of the electron kinetic energy to the gas, dissociating it and ionizing it directly or by thermal ionization.
  • the transient plasma torch is a device based on a cylindrical geometry, generating a plasma in a continuous volumetric flow, providing a uniform flow for discharge and application in the process.
  • the flow is of the reverse vortex type very similar to a tornado that develops inside the torch.
  • the arc begins at the small gap between the electrodes. Due to the strong effect of vortex flow, the arc is forced to lengthen on one of the electrodes inside the cylinder. To lengthen the arc, a greater demand for power is required.
  • the voltage increases and the current decreases; consequently, the electric field and the electron temperature increase, but the gas temperature decreases. Therefore, plasma intensifies its non-equilibrium state. Plasma zone reactive species are trapped within the reactor.
  • Recirculation is critical for catalytic reactions via plasma. All gas passes through the discharge zone and may be pure or a mixture of various types of gases or liquids such as air and ethanol, air and methane, air and pulverized coal, air and butane, pure methane, air pure etc.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

L'invention concerne un procédé de réduction de minerai de fer dans un réacteur avec torches à plasma en régime transitoire, consistant essentiellement en l'utilisation, dans le réacteur (1), de torches (2) à technologie plasma en régime transitoire, comme convertisseur catalytique dans la génération de l'agent réducteur du minerai de fer à partir du gaz naturel, ou d'un autre hydrocarbure, de manière que la réduction, la production de gaz de synthèse et l'enthalpie soient réalisées dans un même environnement.
PCT/BR2013/000461 2013-05-14 2013-11-04 Procédé de réduction de minerai de fer dans un réacteur avec torches à plasma en régime transitoire Ceased WO2014183177A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BRBR1020130119121 2013-05-14
BR102013011912-1A BR102013011912B1 (pt) 2013-05-14 Processo para redução de minério de ferro em reator com tochas de plasma em regime transiente

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WO2014183177A1 true WO2014183177A1 (fr) 2014-11-20

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4514219A (en) * 1983-02-03 1985-04-30 Institut De Recherches De La Siderurgie Francaise Method of producing molten metal
US4765828A (en) * 1987-06-19 1988-08-23 Minnesota Power & Light Company Method and apparatus for reduction of metal oxides
JPH07213892A (ja) * 1994-02-01 1995-08-15 Central Res Inst Of Electric Power Ind プラズマ反応装置
BRPI0604804A (pt) * 2006-11-17 2008-07-01 Alberto Carlos Pereira Jr injetor a plasma em estado trasiente
BRPI0803036A2 (pt) * 2008-08-01 2011-03-22 Polaris Ind E Com De Componentes Mecanicos Ltda Epp processo para tratamento de resìduos sólidos baseado em reator com tecnologia de plasma
CA2745813A1 (fr) * 2011-06-10 2011-12-27 S & S Advanced Metal Technologies Llc Systeme et procede pour le traitement thermique des gisements de minerais

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4514219A (en) * 1983-02-03 1985-04-30 Institut De Recherches De La Siderurgie Francaise Method of producing molten metal
US4765828A (en) * 1987-06-19 1988-08-23 Minnesota Power & Light Company Method and apparatus for reduction of metal oxides
JPH07213892A (ja) * 1994-02-01 1995-08-15 Central Res Inst Of Electric Power Ind プラズマ反応装置
BRPI0604804A (pt) * 2006-11-17 2008-07-01 Alberto Carlos Pereira Jr injetor a plasma em estado trasiente
BRPI0803036A2 (pt) * 2008-08-01 2011-03-22 Polaris Ind E Com De Componentes Mecanicos Ltda Epp processo para tratamento de resìduos sólidos baseado em reator com tecnologia de plasma
CA2745813A1 (fr) * 2011-06-10 2011-12-27 S & S Advanced Metal Technologies Llc Systeme et procede pour le traitement thermique des gisements de minerais

Also Published As

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