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WO2023067619A1 - Appareil et procédé de production de ferrosilicium et de silicium métallique de qualité métallurgique - Google Patents

Appareil et procédé de production de ferrosilicium et de silicium métallique de qualité métallurgique Download PDF

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Publication number
WO2023067619A1
WO2023067619A1 PCT/IN2022/050892 IN2022050892W WO2023067619A1 WO 2023067619 A1 WO2023067619 A1 WO 2023067619A1 IN 2022050892 W IN2022050892 W IN 2022050892W WO 2023067619 A1 WO2023067619 A1 WO 2023067619A1
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Prior art keywords
furnace
electrodes
diameter
charge
ferrosilicon
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English (en)
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Coimbatore Ramasamy NARAYANASWAMY
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    • 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
    • F27B3/08—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces heated electrically, with or without any other source of heat
    • F27B3/085—Arc furnaces
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/04—Making ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/10—Cast-iron alloys containing aluminium or silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • 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
    • Y02P10/20—Recycling

Definitions

  • the present invention generally relates to metal extraction process, and in particular to environmentally friendly process for producing ferrosilicon or silicon.
  • Ferro alloys are compounds of elements like silicon, manganese, chrome etc. They are used as additives during steel making and perform the dual function of removing impurities from the steel and modifying properties of the metal.
  • silicon plays a very important role.
  • steel making it is one of the principal deoxidants and is used on a large scale as an alloying element in proportions.
  • chromium and manganese it is used in spring and valve steels and is used almost exclusively as the alloying element in electrical sheets for dynamos, motors and transformers.
  • electrical sheets silicon steel shows the lowest hysteresis and eddy-current losses.
  • the minerals which are principally of interest in this connection are crystalline quartz, quartzite and certain metamorphosed sandstones.
  • ferrosilicon the requirement is generally +98.5% SiO 2 with certain limitations on the alumina, calcium and phosphorous contents.
  • Fines cannot be tolerated in a submerged electric arc furnace mix because they segregate, and what is more important is that they reduce the porosity of the charge causing premature fusion and crusting, which results in a build-up of gas pressure, the production of which is called “blows”. These take the form of a sudden release of high- temperature gas consisting of CO and SiO, which means a loss of silicon and reduction of overall efficiency.
  • iron In the making of ferrosilicon alloys, the iron is mostly added as scrap. Iron ore is rarely used because it tends to form slag with the silica before the iron is completely reduced, and it can introduce unwanted elements, such as phosphorous, calcium and aluminium.
  • Various carbon-bearing materials may be used as reducing agents in ferrosilicon production, mainly wood charcoal, processed lignite coal (LECO), or as a mix having the tolerable level of impurities to suit furnace operation.
  • ferrosilicon production mainly wood charcoal, processed lignite coal (LECO), or as a mix having the tolerable level of impurities to suit furnace operation.
  • LECO processed lignite coal
  • Ferrosilicon is manufactured in a submerged electric arc furnace by reducing quartz (SiO 2 ) with carbon. Steel scrap is added as an alloying element. The chemical reaction takes place at a temperature of around 2000 degrees centigrade, which the submerged electric arc furnace provides. The molten ferrosilicon is tapped out of the electric furnace at periodical intervals.
  • the chemical composition of ferrosilicon of major global consumption is of the following two grades:
  • Ferrosilicon or Fe-Si alloy is typically produced using submerged arc furnaces.
  • Raw materials used for the production of Fe-Si alloy are low alumina content quartz (SiO 2 ) of 98.5-98.8% purity, steel scrap and wood charcoal with low ash content which serves as the reducing agent. Quartz with low alumina content is used.
  • Typical setup of a 15 MVA submerged arc furnace taking power from a substation is discussed further.
  • the furnace is housed in a three-storied submerged arc furnace building, with an electrical area building and submerged arc furnace equipments in the ground floor, first floor, second floor and third floor.
  • the submerged arc furnace building is one single building accommodating a submerged arc furnace, electricals, control room, first floor for monitoring the process happening, circular steel fabricated furnace hood for collecting smoke and dust, and required area in a rectangular shape in all the sides of the furnace.
  • the furnace transformer of 15 MVA with on-load tap changer will be having voltage range of 96 V to 160 V, to operate at 7-8 voltage steps and corresponding currents.
  • the steel fabricated furnace of round shape will be mounted on the bottom of the floor using steel I beams and civil works.
  • the furnace will be lined with high temperature withstanding, high alumina bricks both at the bottom and sides up to the top.
  • high temperature withstanding Soderberg carbon tamping paste will be melted in hot steel trays and rammed into perfection to the required thickness both at the bottom and the sides up to the height of the brick lining.
  • the first floor of the furnace top will be around 4 plus meters from the ground level.
  • the entire structure of the furnace building including the furnace area circular clearances, tapping and metal treatment and casting area mostly will be steel fabricated structures with sheet roofing, except the ground floor, first floor and second floor. All structures of this furnace building are fabricated and erected with heavy steel structures.
  • Three heavy Soderberg carbon electrodes will be suitably placed to move vertically using a heavy hoist placed on the top of the third-floor steel beams, to lift and lower the electrodes by auto and manual modes.
  • the electrodes may be pre-baked carbon electrodes also. The slipping of the electrodes will be on load and depends upon the consumption of electrodes at the tip.
  • the furnace transformer On the back side of the furnace top, the furnace transformer will be placed and separated from the first floor with suitable clearances up to a particular height with high temperature withstanding bricks.
  • High quality suitable copper bus ducts capable of carrying up to 50000 amps of required power for the furnace, will run through up to the penetrating point with the projection of the partition wall.
  • suitable water- cooled copper tubes From bus ducts suitable water- cooled copper tubes will run to connect 6 copper clamps for each electrode which can be loosened and tightened for slipping purposes. Special provision is provided for this purpose.
  • the copper tubes and copper clamps will be cooled 24/7 using the treated water from the cooling towers.
  • furnace bay as explained above will have a huge crane at 15/20 tons capacity to handle in bay area, up to building length which will go up till the packing and loading section.
  • the height of the building is very tall only in the furnace located area.
  • Furnace transformer will also have a suitable crane for maintenance purposes.
  • the screened raw materials are weighed according to a computerized batching system and transferred into charging buckets running on monorails. Charging buckets then discharge the premixed raw materials into the furnace every 10-15 minutes through chutes.
  • the molten alloy product is drained through one of three tap holes at the bottom of the furnace every 2-2.5 hours into tiltable “teeming ladles” mounted on rail tracks. The teeming ladles are then emptied into large stationary heat resistant cast iron trays or moulds.
  • the furnace is a large carbon hearth furnace with 3 electrodes fed with 3- phase alternating current.
  • the voltage supplied to the three electrodes is 3-phase alternating current, typically in the 96-160 V region, with required current.
  • the furnace transformer is supplied from a 110/11 kV substation through 11 kV HT cables.
  • Operating arc currents are typically in the 25-45 kA region, depending on the load. The arc is struck between vertically mounted steel encased consumable Soderberg electrodes and the floor of the carbon hearth. Both the carbon of the self-baking electrodes and its steel casing are consumed in the smelting process, the consumption being 50-60 kg/ton of Fe-Si in the conventional process.
  • Table 1 Typical Quartzite Analyses for Silicon Metal
  • Silicones can be liquid oil, grease, rubber, and solid resin and are chemically inert, water repellent, and stable up to 400°C. They are used for medical applications, electric insulators, protective coatings, hydraulic fluids, and lubricants.
  • the most important property of the silicon to this group of customers is the content of impurity elements, but the structure and grain/lump size of silicon are also important.
  • MG-Si metallurgical grade Si
  • the impurity content in, for example, solar photo-voltaic devices must be in the ppm level and for electronic devices, it must be in the ppb level.
  • the most used refining method for both products is the Siemens process where the raw material silicon is transformed to silicon-chlorine gaseous compounds, which are distilled and then reduced back to pure silicon.
  • the invention proposes a novel apparatus and process for an environmentally friendly and highly energy efficient process for the production of Fe-Si alloy by LENR process.
  • the apparatus (100) for the production of ferrosilicon is configured to receive a weight of charge of 80 tons per day comprising SiCL, wood charcoal (Fixed Carbon) and steel scrap in the ratio of 5:2: 1.
  • the apparatus comprises a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D with projected area A of 46.08 m 2 and a volume V of 138.24 m 3 .
  • Three carbon electrodes (105-1, 105-2, 105-3) having diameter d 1 and configured to be raised or lowered are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times d 1 .
  • An AC power drive is configured to supply a 3 -phase voltage supply ranging between 96-160 V to the three electrodes.
  • the furnace is configured to convert the entire weight of charge including SiC>2, C and Fe completely to ferrosilicon, through a low energy nuclear transmutation reaction (LENR).
  • the apparatus may comprise a mechanism to vary the pitch circle diameter from 2.4 to 2.5 times d 1 .
  • the apparatus is configured to convert the charge to ferrosilicon with zero emission of CO 2 .
  • a method 200 of operating a furnace for production of ferrosilicon comprising the steps of: providing a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D equal to 7.662 m, projected hearth area A of 46.08 m 2 , height H of 3m and a volume V of 138.24 m 3 .
  • Three carbon electrodes (105-1, 105-2, 105-3) having diameter d 1 of 1.47456m, are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times d 1 .
  • the electrodes are configured to be raised or lowered.
  • the furnace is preheated for 3-4 days to condition the carbon lining of the furnace and cooled and cleaned thereafter.
  • the next step (206) involves starting the arc on an empty furnace at 96 V and running for a few hours, followed by loading silica, carbon and iron in the ratio 5:2: 1 in 300 /400kg batches (208). The loading into the furnace is carried out with voltage at 96V and increasing power level to 3.981312 MW to stabilize ferrosilicon production.
  • the voltage is increased in transitional steps of 110.86 V, 124 V, 135.77 V and 146.65 V and loading of charge increased to operate at correspondingly increasing power levels.
  • the voltage is increased to 156.77V and loading of charge is also increased to operate at full power level of 10.616832 MW to cause conversion of the entire charge to ferrosilicon by a low energy nuclear transmutation reaction without emission of gaseous discharge.
  • the step 204 of preheating is carried out using firewood.
  • the current density at full power level in step 212 is maintained at 230.4 kW/m 2 of hearth area.
  • a method 300 of operating a furnace for production of metallurgical grade silicon metal using the apparatus 100 is disclosed. The method comprising the steps of: providing in step 302 a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D equal to 7.662 m, projected hearth area A of 46.08 m 2 , height H of 3m and a volume V of 138.24 m 3 .
  • Three pre-baked carbon electrodes (105-1, 105-2, 105-3) having diameter d 1 of 1.47456m, are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times d 1 .
  • the electrodes are configured to be raised or lowered.
  • the furnace is preheated for 3-4 days to condition the carbon lining of the furnace and cooled and cleaned thereafter.
  • the next step (306) involves starting the arc on an empty furnace at 98 V and running for a few hours, followed by charging silica and carbon in the ratio 5:2 (308) into the furnace with voltage at 98V and increasing power level to 4.1472 MW to stabilize silicon production.
  • the voltage is increased in transitional steps of 113.2 V, 126.56 V, 138.57 V and 149.67 V and loading of charge increased to operate at correspondingly increasing power levels.
  • the voltage is increased to 160 V and loading of charge is also increased to operate at full power level of 11.0592 MW to cause conversion of the entire charge to silicon, by a low energy nuclear transmutation reaction without emission of gaseous discharge.
  • the step 304 of preheating is carried out using firewood.
  • the current density at full power level is maintained at 240 kW/m 2 of hearth area.
  • FIG. 1A illustrates the plan view and FIG. IB shows a cutaway view of the apparatus for producing ferrosilicon and MG silicon metal according to an embodiment of the present subject matter.
  • FIG. 2A illustrates a detailed flow chart for producing ferrosilicon.
  • FIG. 2B shows a flow chart of a method for producing ferrosilicon, according to embodiments of the subject matter.
  • FIG. 2C illustrates a detailed flow chart for producing MG silicon metal.
  • FIG. 2D shows a flow chart of a method for producing MG silicon metal, according to embodiments of the subject matter.
  • FIG. 3 shows the ground floor layout of a plant for producing ferrosilicon according to embodiments of the invention.
  • FIG. 4 shows the first-floor layout of a plant for producing ferrosilicon according to embodiments of the invention.
  • FIG. 5 shows the second-floor layout of the plant.
  • FIG. 6 illustrates section BB of FIG. 3, showing details of equipment required for plant.
  • FIG. 7 shows the transformer and electrical components of the furnace.
  • FIG. 8 shows pollution control equipment.
  • the invention in its various embodiments discloses apparatus and methods for environmentally friendly and highly energy efficient process for the production of Fe-Si alloy by Low Energy Nuclear Reaction (LENR).
  • LENR Low Energy Nuclear Reaction
  • the invention discloses apparatus 100 including a stationary submerged electric arc furnace for the production of ferrosilicon via a low energy nuclear reaction (LENR) is disclosed with reference to FIG. 1A and IB.
  • the apparatus 100 is configured to receive a weight of charge comprising SiCL, wood charcoal and iron.
  • the iron in various embodiments may be iron or steel scrap.
  • the apparatus comprises a hearth furnace body 101 of cylindrical shape with a bottom 102.
  • the bottom may have a diameter D and projected area A over a height H.
  • the bottom may have a diameter D of 7.662 m, area A of 46.08 m 2 and height H of 3 m.
  • the furnace hearth may enclose a volume V of 138.24 m 3 .
  • the furnace is provided with three carbon electrodes 105-1, 105-2, and 105-3.
  • the electrodes may be Soderberg electrodes of steel-encased carbon.
  • the electrodes may be pre-baked carbon electrodes.
  • Each electrode (say, 105-1) is configured with a diameter of d 1 .
  • the electrodes may be equidistantly placed within the furnace 101 with a pitch circle 103 of diameter d2 varying between 2.4-2.5 times d 1 as illustrated in FIG. 1A.
  • each electrode may have a diameter that is 1.47456 m.
  • the electrodes may be configured to be raised or lowered during operation.
  • the capacity of the submerged arc furnace is configured to consume 80 tons of raw materials per day of 24 hours continuous operation.
  • the apparatus further comprises an AC 3 -phase power supply configured to provide a variable voltage ranging between 96-160 V to the three electrodes.
  • the furnace transformer providing the AC power supply may be provided with a number of tappings that are selectable using an on-load tap changer. In some embodiments, the number of tappings provided in the transformer may range from 7-8 voltage steps.
  • apparatus 100 is configured to convert the entire weight of SiC>2 + C + Fe in the charge to ferrosilicon with zero emission of CO 2 .
  • the combined cross-sectional area of the three electrodes 105-1, 105-2, and 105-3 is configured to be l/9th of the projected internal area A of the furnace.
  • diameter d 1 of each electrode is configured to be 1.47456 m.
  • the apparatus 100 comprises a mechanism to vary the diameter of the pitch circle 103 from 2.4 to 2.5 times d 1 , i.e. from a circle of diameter 3.5389 to 3.6864 m.
  • the furnace body 101 may be constructed of heavy steel plate 110, a refractory lining 111 and a carbon lining 112.
  • the steel plate 110 may be of sufficient thickness with proper reinforcement to withstand the load of the furnace internals along with charge.
  • the furnace 100 may be placed on a suitable foundation F.
  • the refractory lining 111 may include suitable refractory such as high alumina brick.
  • the carbon lining 112 may comprise carbon tamping/lining paste on the portion of the furnace bottom 102 and sides up to the top.
  • a method 200 for operating apparatus 100 to produce ferrosilicon is disclosed with reference to FIG. 2B.
  • the method involves providing in step 202, the apparatus 100 having dimensions as already described with reference to FIG. 1A and IB.
  • the furnace hearth is initially constructed with firebrick and a suitable grade of carbon paste to form the carbon lining 112.
  • the method then comprises the step 204 of preparing the furnace hearth by preheating.
  • the preheating may in various embodiments be done using firewood or wooden logs. In some embodiments, the preheating may be carried out for 3-4 days.
  • the preheating operation in step 204 is configured to condition the hearth 112 by strengthening and rendering the lining leak-proof.
  • the next step 206 involves starting the arc on an empty furnace at 96 V.
  • the arc is run for a few hours to warm up the furnace prior to charging.
  • Charging is started thereafter in the next step 208, in 300/400 kg batches while maintaining the same voltage of 96 V and current at power load of 3.981312 MW.
  • step 210 we have to enter into step 210 of first two transitional steps of 110.86 V and corresponding load of 5.308416 MW and voltage of 124 V and corresponding load of 6.63552 MW and proportional currents.
  • step 210 Balance two transitional steps of step 210 are entered where the voltage of 135.77 V and a power load of 7.962624 MW and voltage of 146.65 V and a power load of 9.289728 MW with corresponding currents. Higher voltage steps are entered seeing the operation condition of the furnace carefully.
  • step 212 the process involves increasing the voltage to 156.77 V and increasing the loading of charge to operate at the full power level of 10.616832 MW. Operation at full power at this voltage level is configured to cause conversion of the entire charge to ferrosilicon by a LENR reaction.
  • steps 210 and 212 may involve adjusting the spacing between the electrodes by varying the pitch circle diameter to attain LENR conversion of the charge to ferrosilicon. Since the reaction causes the entire C and O to Si, there is no emission of gaseous CO 2 discharge from the furnace.
  • the silica, wood charcoal (fixed carbon) and iron in the charge may be mixed as homogeneously as possible before charging into the furnace.
  • the charge of silica, wood charcoal (fixed carbon) and iron may be added in 300 or 400 kg quantities in a ratio of 5:2: 1.
  • the current density at the full power level during step 212 is maintained at 230.4 kW/m 2 of hearth area.
  • the furnace at this stage is configured to consume 80 tons of charge per day to produce 80 tons of ferrosilicon.
  • the stabilization of operation at full capacity may be accompanied by a reduction of CO/CO 2 emissions to zero or near-zero levels.
  • a method 300 of operating a furnace for production of metallurgical grade silicon metal using the apparatus 100 comprises the steps of: providing in step 302 a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D equal to 7.662 m, projected hearth area A of 46.08 m 2 , height H of 3m and a volume V of 138.24 m 3 .
  • Three pre-baked carbon electrodes (105-1, 105-2, 105-3) having diameter dl of 1.47456m, are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times dl.
  • the electrodes are configured to be raised or lowered.
  • the furnace is preheated for 3-4 days to condition the carbon lining of the furnace and cooled and cleaned thereafter.
  • the next step (306) involves starting the arc on an empty furnace at 98 V and running for a few hours, followed by charging silica and carbon in the ratio 5:2 (308) into the furnace with voltage at 98 V and increasing power level to 4.1472 MW to stabilize silicon metal production.
  • the voltage is increased in transitional steps of 113.2 V, 126.56 V, 138.57 V and 149.67 V and loading of charge increased to operate at correspondingly increasing power levels.
  • the transitional steps may comprise operating at 5.5296 MW power level at 113.2 V, followed by operating at 6.912 MW power level corresponding to 126.56 V, at 8.2944 MW power level corresponding to 138.57 V, and at 9.6768 MW power level corresponding to 149.67 V.
  • a final step 312 the voltage is increased to 160 V and loading of charge is also increased to operate at full power level of 11.0592 MW to cause conversion of the entire charge to silicon, also known as MG silicon metal, by a low energy nuclear transmutation reaction without emission of gaseous discharge.
  • the step 304 of preheating is carried out using firewood.
  • the current density at full power level is maintained at 240 kW/m 2 of hearth area. The furnace at this stage is configured to consume 70 tons of charge per day to produce 70 tons of MG silicon metal.
  • the silica, and wood charcoal (fixed carbon) in the charge may be mixed as homogeneously as possible before charging into the furnace in batches of 350 kg.
  • the charge may have silica, and wood charcoal (fixed carbon) in a ratio of 5:2.
  • the furnace is tapped every 2-2.5 hours to draw molten ferrosilicon or silicon through tapping holes provided at the bottom of the hearth.
  • one each of C and O nuclei combine via a low energy nuclear transmutation reaction to form ferrosilicon or silicon and no discharge of gas takes place.
  • the reaction may be expressed as: 12 C + 16 0 ⁇ 28 Si.
  • the invention has multiple advantages as set forth here. Using the claimed equipment and LENR process, the emerging CO from the furnace bottom is converted into silicon inside the furnace itself through nuclear transmutation, and emission of CO 2 to the atmosphere is eliminated. Hence the recovery of silicon in the product goes up tremendously to more than 2-2.4 times of the regular conventional process and pollution is also eliminated. The pollution control equipment installed will be used only during the starting times till stabilization. kindly note total power and raw materials consumption per day remains same as in the conventional process. Hence the advantage can be understood.
  • FIG 2A and FIG. 2B show flow charts for the production of ferrosilicon and MG silicon metal according to the embodiments presented here.
  • Power is supplied to the furnace and its auxiliaries through a 110/11 KV power line connection and substation.
  • FIG. 3-7 Three storied submerged arc furnace building, electrical area building and submerged arc furnace equipments in the ground floor, first floor, second floor, and third floor are constructed as detailed in FIG. 3-7.
  • A) the Smelting furnace is provided with B) Tapping mouths for metal.
  • the furnace hearth with three electrodes is shown as C, while small rail track (D) with tilting ladle for receiving and carrying the liquid metal on the tracks and pouring in the high-quality receiving ladles all falling under H.
  • industrial lift E steel staircase F, entrance area into the ground floor G, and molten metal receiving ladles H.
  • a jaw crusher J is available for breaking carbon paste.
  • Mechanical arrangement K is provided on both sides of the rail tracks with wire ropes for hauling the ladles having frame and wheel arrangements.
  • Mechanical maintenance area M and electrical maintenance area L are also shown. Areas N and O are provided for metal breaking, weighing, packing and other activities.
  • the submerged arc furnace building is one single building accommodating submerged arc furnace electricals, control room, first floor for monitoring the process happening, circular steel fabricated furnace hood for collecting smoke and dust if any and required area in a rectangular shape in all the sides of the furnace.
  • the furnace is connected with a 15 MVA transformer with on-load tap changer having voltage range of 96 V to 160 V, to operate at various voltage steps and currents.
  • the layout of first floor transformer arrangements is shown in FIG. 4.
  • P furnace transformer with on-load tap changer
  • Q furnace and electrical control room
  • R is for emergency maintenance and other purposes.
  • S is industrial lift.
  • FIG. 5 shows 2nd floor with three openings for the 3 electrodes going into the furnace.
  • FIG. 6 shows section B-B across the building, referenced in FIG. 3.
  • Ground floor bunker AA is shown with rope car bucket AB for transporting raw materials to the bunkers which is in raised level at the second floor.
  • Material storage bunker on 2 nd floor top, AC is provided with discharge facilities and electronic weighing system.
  • AD shows monorail at a raised level from the second floor for transporting raw materials from the bunkers, moving on monorail wheels and discharging raw materials into the charging chutes for furnace feeding.
  • AE refers to heavy steel fabricated beams with chequered plates for locating 3 heavy lifting hoists for electrodes and connected by steel ropes to electrodes and slipping devices attached to it.
  • Furnace hood AG, pollution control chimney AH, and furnace hearth Al are also shown.
  • the steel fabricated furnace of round shape is mounted on the bottom of the floor using steel I beams and civil works.
  • the furnace is lined with high temperature withstanding, high alumina bricks both at the bottom and sides up to the top.
  • FIG. 7 Furnace hearth area/volume Al and furnace transformer P are shown. Copper flats AJ leading to copper tubes, copper flexibles AK connected to the copper tubes and terminating at the copper clamps AL, are shown connected to the electrodes AM. The copper tubes, copper flexibles AK and copper clamps AL are all water cooled. Electrode slipping device AN, three electrodes C, hoists AO, and heavy steel fabricated beams with chequered plates AP, for locating 3 heavy lifting mechanical or hydraulic hoists for electrodes are shown. Also shown are furnace hood AQ and pollution control chimney AR. Pollution control filter elements are shown in FIG. 8, with 500 kVA exhaust fan U and filter bags with fitting arrangements V.
  • the entire structure of the furnace building including the furnace area circular clearances, tapping and metal treatment, casting area are steel fabricated structure except the ground floor, first floor and second floor concreting. All structures of this furnace building are fabricated and erected with heavy steel structures and sheet roofing.
  • Three heavy carbon electrodes are suitably placed and are enabled to move vertically upwards till the heavy hoist placed on the top of the third-floor, to lift and lower the electrodes by auto and manual modes, as required.
  • the electrodes may either be self-baking carbon electrodes or pre-baked electrodes. The slipping of the electrodes will be on load and depends upon the consumption of electrodes at the tip.
  • the furnace transformer On the back side of the furnace top, the furnace transformer is placed behind a separating wall on the first floor with suitable clearances up to a particular height with high temperature withstanding bricks.
  • High quality suitable copper bus ducts capable of carrying up to 50000 amps required power for the furnace are run through up to the penetrating point with the projection of the partition wall.
  • suitable water-cooled copper tubes From the bus ducts suitable water-cooled copper tubes are provided to connect 6 copper clamps for each electrode which can be loosened and tightened. Special provision is provided for clamping the copper clamps to the carbon electrodes.
  • the copper tubes and copper clamps are cooled 24/7 using treated water from the cooling towers.
  • This number can again be written as a product of a base and the excitation constant derived before, i.e. 0.0072 x 1.0046939300469393.
  • the square root of the fine structure constant 0.00723379629629 is equal to 0.08505172714, the electron coupling constant referred by Richard Feynman (1985, reprinted 2004, Universities Press, ISBN 8173712115, p.129).
  • 138.24 represent the volume in cubic meters and 1 represents a mass of 1 ton or 1 kg or 1 gram for 138.24 cubic meters.
  • 1 represents a mass of 1 ton or 1 kg or 1 gram for 138.24 cubic meters.
  • Ascending order of space volume and mass content can be and descending order can be
  • the inventor has arrived at the invention based on rigorous experimentation with ferrosilicon plant, and has proposed the above explanation and derivation of the dimensions of the furnace for attaining LENR reaction for production of ferrosilicon. Similar calculations have been done to derive the dimensions of the electrodes, the furnace hearth area and height. The steps required to ignite LENR reaction and to obtain complete conversion of the C and O from the reactants into ferrosilicon by LENR in the detailed description has also been arrived at after thorough investigaion. It is believed that the LENR reaction is produced under certain special dimensional and energetic conditions that are related to fundamental properties of space and matter.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Vertical, Hearth, Or Arc Furnaces (AREA)

Abstract

L'invention divulgue un appareil (100) pour la production de ferrosilicium ou de silicium métallique de qualité métallurgique par l'intermédiaire d'un procédé respectueux de l'environnement. L'appareil (100) comprend un four à sole (101) de forme cylindrique avec un fond (102) de diamètre D, une surface projetée A de 46,08 m2 et un volume V de 138,24 m3. Il est pourvu de trois électrodes en carbone (105-1, 105-2, 105-3) placées de façon équidistante et ayant un diamètre d de 1,47456 m avec un cercle primitif (103) dont le diamètre d2 varie entre 2,4 et 2,5 fois d1. Les électrodes sont conçues pour être élevées ou abaissées. Une source d'alimentation à courant alternatif est configuré pour fournir une tension triphasée de 96 à 160 V aux trois électrodes. L'invention divulgue en outre un procédé de fonctionnement du four pour convertir la masse totale de la charge en ferrosilicium ou en silicium sans émissions gazeuses. Dans le procédé, un noyau de carbone et un noyau d'oxygène s'associent par l'intermédiaire d'une réaction de transmutation nucléaire à faible énergie (LENR) pour former du ferrosilicium ou du silicium, et aucun dégagement gazeux n'a lieu.
PCT/IN2022/050892 2021-10-22 2022-10-06 Appareil et procédé de production de ferrosilicium et de silicium métallique de qualité métallurgique Ceased WO2023067619A1 (fr)

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0342374A1 (fr) * 1988-05-19 1989-11-23 Nkk Corporation Procédé de réduction en bain de fusion dans un four électrique

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0342374A1 (fr) * 1988-05-19 1989-11-23 Nkk Corporation Procédé de réduction en bain de fusion dans un four électrique

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
NARAYANASWAMY C R: "Observation of Anomalous Production of Si and Fe in an Arc Furnace Driven Ferro Silicon Smelting Plant at levels of Tons per day", JOURNAL OF CONDENSED MATTER NUCLEAR SCIENCE, vol. 24, 1 January 2017 (2017-01-01), pages 244 - 251, XP093064881, ISSN: 2227-3123 *

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