Title of Invention | AN ECOFRIENDLY, ENERGY EFFICIENT METHOD OF STEEL PRODUCTION FROM IRON ORE EMPLOYING LOW GRADE COAL |
---|---|
Abstract | Heretofore low grade coal had hardly any metallurgical or other industrial applications. With depletion of coal reserve with high carbon content, attention was given to low grade coal but gainful mode of utilization was not forthcoming. The present invention has made a considerable advancement in this field and provides an eco-friendly, energy efficient method of steel production from iron ore employing low-grade coal, wherein (a) iron ore mixed with low-grade non-coking coal and flux are charged into a rotary reactor to produce sponge iron; (b) sponge iron thus produced is fed into an iron-smelting unit to which is added carbon and flux for removal of impurities, residual reduction and carburization; (c) transferring the molten mass to steel making unit with additional sponge iron for production of crude steel and (d) subjecting the crude steel to refinement in refining vessel or vessels to give rise to refined steel, characterized in that the Fixed Carbon Content of the low-grade non-coking coal may be as low as 15% by wt and the waste! combustible gases, waste coal fines and char generated in the course of sponge iron production is utilized for power generation, simultaneously ensuring trapping of fines in suitable receptacles to ensure substantial prevention of environmental pollution. |
Full Text | The present invention relates to an eco-friendly, energy efficient method of steel production from iron ore employing low grade non-coking coal. More particularly, this invention pertains to steel production using low grade non-coking coal with fixed carbon content as low as 15% by weight to heat iron ore and limestone/dolomite in a reactor under reducing conditions to remove oxygen and sulphur from iron ore. The product called sponge iron is then smelted together with fluxes in a furnace using power generated from waste energy recovered from the sponge iron plants and remove impurities like silica and alumina. This molten iron together with additional sponge iron is then melted and refined in a steel making furnace and further refined in a refining furnace as necessary to make steel to meet quality requirements for the steel products. Procedures for steel making hitherto followed are based mainly on reductive extraction of iron from iron ore like haematite or magnetite or a mixture of both (Fe2O3/Fe3O4), attended with removal of impurities like alumina (N2O3) and silica (SiO2). Steel making is essentially two-step process, namely, iron ore to metallic iron and then iron to steel. Different routes of iron steel making practised till date may be enunciated as follow : a) In one route, oxygen is removed from iron ore without melting it using either non-coking coal/coal gas or natural gas. Removal of oxygen from the ore makes it porus and the product is called sponge iron. This sponge iron is then melted to remove other impurities —2— SRD/R5/FILE-1/PATENT like alumina and silica in an electric steel making vessel to make Steel, which may be further refined in a refining vessel. b) In another route, oxygen and impurities like alumina and silica are removed by melting iron ore together with coke and limestone in a iron making furnace e.g. Blast Furnace where oxygen is removed as a gas when carbon combines with oxygen while lime form limestone combines with alumina and silica to from a slag which floats over the molten iron and is removed by skimming. The molten iron is then taken to a steel making converter to make steel, by removing excess carbon, phosphorous, silicon etc. by blowing oxygen. Further refinement may be carried out in a refining vessel. c) In yet another route, molten iron from Blast Furnace and Sponge iron are melted together in an electric furnace to make steel and may be further refined in a refining vessel. d) Several other processes are either under development or are in commercial operation using iron ore lumps or fines and high grade low-ash non-coking coal together with oxygen to produce —3— SRD/R5/FILE-1/PATENT molten iron as an alternate to the Blast Furnace route in an effort to remove dependence on coke and thereby on coking coal, reserves of which are only a fraction of the reserves of non-coking coals in the world. The molten iron is then taken to a steel making converter and to a refining vessel for further refining as necessary. The aforesaid routes of steel making may be represented by means of flow sheet diagrams as shown in Figs. 1, 2, 3 and 4 of the accompanying drawings. These steel-making procedures invariably suffer from drawbacks which are enunmerated in a tabular form as shown below : CONVENTIONAL METHODS DRAWBACKS a) Electric Steel making : Lower yield and higher energy using primarily Sponge consumption; consequent cost escalation. b) Converter steel using Blast : Dependence on coking coals, Furnace Hot Metal higher costs. c) Electric steel using partly : Dependence on high grade Blast Furnace Hot Metal and coking coals, higher costs, partly Sponge -4- SRD/R5/FILE-1/PATENT d) Converter steel using smelter : Dependence on high quality based Hot Metal non-coking coals. The present invention attempts to overcome the shortcomings stated above and provide a viable alternative route for steel production. The principal object of this invention is to provide an eco- friendy, energy-effective method of steel production. A further object of this invention is to provide a method of steel production wherein there is used low-grade non-coking coal with as low as 15% carbon-content and ash content as high as 40%. Thuselliminating the need to use coking coal and traditional blast furnaces. A still further object of this inention is to provide a method of steel production wherein the waste gases and waste coal fines/coal char generated in the course of production of sponge iron is employed for generation of steam which in turn is used for producing electricity in a power plant. Another object of this invention is to provide a method of steel production which ensures substantial elimination of dust/fines emission to prevent environmental pollution. Yet another object of this invention is to provide a method -5- SRD/R5/FILE-1/PATENT of steel production which employs a mixture of hot metal and sponge iron produced in the smelting unit not being a Blast Furnace (e.g. Submerged Arc Furnace) before being sent to steel making and/or refining unit. The foregoing objects are achieved by the present invention which provides an eco-friendly, energy efficient method of steel production from iron ore employing low-grade coal, wherein - (a) iron ore mixed with low-grade non-coking coal and flux are charged into a sponge iron plant to remove bulk of the oxygen and sulphur; (b) sponge iron thus produced is fed into an iron-smelting unit to which coke and further amounts of flux are added for removal of other impurities, residual reduction and carburisation etc; (c) the molten metal is then processed further in a steel making unit together with additional sponge for production of crude steel; (d) the crude steel is refined in a refining vessel to produce refined steel, characterized in that the low-grade non-coking coal may have carbon-content as low as 15% by wt. and waste gases and waste coal fines/char generated in the course of sponge-iron production is utilised -6- SRD/R5/FILE-1/PATENT for power generation, simultaneously ensuring trapping of fines in suitable receptacles to ensure substantial prevention of environmental pollution. The overall procedure of the subject invention has been represented by the flow-sheet diagram as shown in Fig.5 of the drawings and the sequential steps of the process are given below. Step-I 1. PRODUCTION OF SPONGE IRON Coal based sponge iron is produced using sized iron ore, together with sized coal heated in a rotary kiln under reducing atmosphere through controlled distribution of air and coal. The kiln is rotated at a controlled speed to ensure adequate reduc- tion time to achieve the desired degree of oxygen removal from iron ore. The chemical reactions are represented by the following equations : Fe2O3 + C = 2 FeO + CO FeO + CO = Fe + CO2 CO2 + C = 2 CO C + O2 = CO2 CO2 + C = 2 CO SRD/R5/FILE-1/PATENT The chemical reactions are either exothermic or endothermic and therefore require close process control to limit incidence of hot spots. The energy content in waste process gases are recovered in a waste heat recovery boiler before releasing the same to environment through a full stack. The steam at high temperature and pressure is utilized to generate electricity which subsequently is used in steel making. Coal based sponge iron is also produced by using reducing gasses such as those produced during gasification of coal, either in a rotary kiln or in a shaft furnace.The degree of metallization usually exceeds 90%. Coal based sponge iron has a typical composition as follows with a very low carbon content. Metallic Fe : 82% FeO : 12% Silica, Alumina and other impurities : 6% Typical range of composition of ore and coal used are given below : Iron ore : Fe : 63-66% Silica + Alumina : 4-6% Non-coking coal : Fixed carbon : 15-40% Ash : 25-45% -8- SRD/R5/FILE-1/PATENT 2. COAL BENEFICATION The use of low carbon and high ash coal as feed is beneficiated to reduce ash content to less than 30% and increase fixed carbon content. 3. POWER GENERATION Electric power is generated using waste energy recovered from the off gases as well as from the waste coal fines and coal char generated as process by-products in the iron and steel plants which can meet nearly the entire electric energy requirement of the plant. Grid support is typically taken to meet power surges required during arcing etc. and to meet emergency needs. Total power generation is approximately 1000 KWH per tonne of sponge production. Step-11 : PRODUCTION OF MOLTEN IRON Sponge iron is smelted in an iron smelting furnace in presence of fluxes to remove alumina/ silica and other impurities as slag. The molten metal is carburized by using a carbon source such as petroleum coke, nut coke etc. -9- SRD/R5/FILE-1/PATENT Step-Ill : STEEL MAKING (i) Molten iron is converted into steel in a steel making vessel using either nearly 100% liquid iron or a mix of liquid iron and sponge iron. The steel making vessel will have the necessary features required for fuel/gas/oxygen injection. (ii) Further refining can be done in a refining furnace with or without power to meet quality requirements of the end products. Further refining processes include, inter alia, ladle refining, vaccuum degassing, etc. DEGREE OF PURITY OF PRODUCT The process envisages the provision of steel refining vessel e.g. Laddie Refining Furnace together with vacuum degassing when required by the product specification. This ensures cleanliness of the product through argon purging, deoxidation through Si-Al killing and further of entrapped gasses by vacuum degassing as necessary. -10- SRD/R5/FILE-1/PATENT ADVANTAGES/DISADVANTAGES ECOFRIENDLINESS The process is eco-friendly. The sulphur in coal is removed by using dolomite/limestone in the sponge iron kiln. Lime reacts with sulphur to make calcium sulphide, which together with charred remains of coal are removed by magnetic separation after sponge iron along with the wastes is cooled in a cooler. NCL generation is reduced by use of relatively low temperature processes. For example, the sponge iron process operates at around 1000°C. CO2 generation is comparable to the standard BF + BOF route. ENERGY EFFICIENCY The process utilizes waste energy recovered from Sponge iron making, liquid iron making, as well as steel making for heating as well as electric power generation. To sum up, the present invention is concerned with a method of making steel capable of using even low quality non-coking coal -11- SRD/R5/FILE-1/PATENT for production of sponge iron, smelting part or all of sponge into hot metal in an iron making furnace, and using hot metal itself or in admixture with more sponge in a steel making furnace to make steel. Thereafter the steel is refined in a refining vessel as desired or necessary. The result is attainment of a higher metallic field a lower cost of production, as well as a low energy consumption and a cleaner environment with substantial prevention of emission of greenhouse gases. SUMMARY OF ADVANTAGES/DISADVANTAGES The following table summarizes the advantages/disadvantages of the new method compared to Blast Furnace and Basic Oxygen converter route of steel making from iron ore treated as the standard. 1 recovery of iron Total energy consumption CO2 emission Cost of production (Without financial charges) BF + BOF 100 100 100 100 New Method >101 The principle used for calculating energy consumption is -12- SRD/R5/FILE-1/PATENT based on guidelines of IPCC 2006, an international body. (Inter Government Panel for Climate Change). Additional modifications and improvements of the present invention may also be apparent to those skilled in the art. Thus, the particular combination of parts/steps described and illustrated herein is intended to represent only one aspect/ embodiment of the present invention, and is not intended to serve as limitations of alternative features within the spirit and scope of the invention. Dated this 12th day of February, 2008. -13- SRD/R5/FILE-1/PATENT |
---|
00235-kol-2008-correspondence others.pdf
00235-kol-2008-description provisional.pdf
235-KOL-2008-AMANDED CLAIMS.pdf
235-KOL-2008-CORRESPONDENCE OTHERS 1.1.pdf
235-KOL-2008-CORRESPONDENCE.pdf
235-KOL-2008-CORRESPONDENCE1.1.pdf
235-KOL-2008-DESCRIPTION (COMPLETE) 1.1.pdf
235-KOL-2008-DESCRIPTION (PROVISIONAL).pdf
235-KOL-2008-DESCRIPTION COMPLETE.pdf
235-KOL-2008-EXAMINATION REPORT REPLY RECIEVED.pdf
235-KOL-2008-EXAMINATION REPORT.pdf
235-KOL-2008-GRANTED-ABSTRACT.pdf
235-KOL-2008-GRANTED-CLAIMS.pdf
235-KOL-2008-GRANTED-DESCRIPTION (COMPLETE).pdf
235-KOL-2008-GRANTED-DRAWINGS.pdf
235-KOL-2008-GRANTED-FORM 1.pdf
235-KOL-2008-GRANTED-FORM 2.pdf
235-KOL-2008-GRANTED-SPECIFICATION.pdf
235-KOL-2008-REPLY TO EXAMINATION REPORT.pdf
Patent Number | 250468 | ||||||||
---|---|---|---|---|---|---|---|---|---|
Indian Patent Application Number | 235/KOL/2008 | ||||||||
PG Journal Number | 02/2012 | ||||||||
Publication Date | 13-Jan-2012 | ||||||||
Grant Date | 04-Jan-2012 | ||||||||
Date of Filing | 12-Feb-2008 | ||||||||
Name of Patentee | ORISSA SPONGE IRON & STEEL LIMITED | ||||||||
Applicant Address | CHATTERJEE INTERNATIONAL CENTRE, 11TH FLOOR, 33A, JAWAHARLAL NEHRU ROAD, KOLKATA | ||||||||
Inventors:
|
|||||||||
PCT International Classification Number | C21B13/00 | ||||||||
PCT International Application Number | N/A | ||||||||
PCT International Filing date | |||||||||
PCT Conventions:
|