Title of Invention

PROCESS FOR THE PRODUCTION OF CHROMIUM METAL NUGGETS FROM CHROMITE ORES OR CHROMITE CONCENTRATES

Abstract The chromites ores/concentrates with Cr: Fe ratio ranging from 1.0 to 3.3 we oxidized at low temperatures (900° C). The oxidized samples show complete oxidation of FeO phase to Fe2O3. Reduction of oxidized chromite ores/concentrate was carried out using coal ass reductant. Flux used consists of silica source (quarl) and lime. The reduction experiments carried out using the controlled atmosphere high temperature furnace. The raw materials used alongwith there composition given is the following tables. Table 1 Raw materials and their Composition (wt%) The experimental studies for reduction were carried out at low temperatures of 1400-1550°C. The coal reductant is used in 30-50% excess of the stichoimetric carbon requirement for reduction of Iron orxide (Fe2O3) and chrome oxides (Cr2O3) in the ore. Based on the special slag designed, the flux addition was carried out as quartz addition in the range of 0-10% excess of required for aluminium oxides and magnesium oxide dissolution to slag. The lime addition was done in the rage of 3-10% of the chromite ore/concentrate. Reduction was carried out in the temperature range of 1400-1550°C for 1.5-3.0 hours. The chromite nuggets product id shown in fig 1. The sample microstructure of the product alongwith the phase composition is shown in Fig 2. It can be seen that the metal shows two phase one chromium rich and the other rich phase. The presence of chromium in the nugget product is in form of chromium carbides (C7C3) and iron chromium carbides. The Chemistry of the chromium metal, nugget and slag products produced is given in Table 2. The metal nugget diameter ranges from 0.5-25 cms. The metal and slag phase separation is clear which after quenching in water can be separated by physical separation methods. Table 2 Chemistry of Chromium metal nugget and slag Reaction mechanisms: The oxidation of FeO the chromite ore/concentrated opens the spinel structure which increases the reactivity of chromite spinel due to formation of vacancies. The oxidation of the chromite ores also helps in reducing the reduction time. The reduction mechanism of chromite ores/concentrates in absence of lime as flux, generally proceeds as per the following steps. Chromium oxide reacts at 1200 to 1600°C with carbon to form one of the carbides Cr3Cr2, Cr7C3. 3Cr2O3+ 13C→ 2Cr3C2 + 9CO (1150-1200°C) 27CR3C + 5Cr O→13Cr C + 15 CO (1200-1600°C) At still higher temperature Cr7C3 reacts with Cr23C6 and finally above 1820 C the Cr metal is favored product. However due to use of lime as fluxing above component the slag formation reactions plays an important role in carrying out the reduction of chrome oxide at lower temperatures. In presence of lime as fluxing component the slag formation reactions take place t lower temperatures which promotes the reduction by dissolution in slag.
Full Text 2
FIELD OF THE INVENTION
The present invention relates to development of a process for
production of chromium Nuggets. More particularly the present
invention rotates to development of a process for production of
chromium nuggets by low temperature preoxidized chromites
ore/concentrates with 50-70 % metallization.
BACKGROUND OF THE INVENTION
In any integrated metal alloy manufacturing organization, high
carbon Ferro chromium is commonly produce by smelting-reduction
route. This is highly energy intensive and requires an imported low-
ash coke as a reducing agent. Low-ash coke and electricity are both
expensive resources. Therefore, a movel process route is developed
by reduction of pre-oxidized chromium ore using a coal as reductant
for product of 50-70% metallized chromites ore production in the
form of Ferro chromium.

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OBJECTS OF THE INVENTION
It is therefore an object of the present invention to propose a process
for production of chromium nuggets by low temperature reduction of
pre-oxidized chromites ors/concentrated which eliminates the
disadvantages of prior Art.
Another object of the present invention is to propose a process for
production of chromium nuggets by low temperature reduction of
pre-oxidized chromites ores/concentrated which saves energy.
A further object of the present invention is to propose a process for
production of chromium nuggets by low temperature reduction of
pre-oxidized chromites ores/concentrate which reduces the cost of
production of ferro chrome by 20%.
A still further object of the present invention is to propose a process
for production of chromium nuggets by low temperature reduction of

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pre-oxidized chromites ors/concentrated which reduces coke
consumption.
An yet further object of the present inventions is to propose a
process for production of chromium nuggets by low temperature
reduction of pre-oxidized chromites ores/concentrated which possess
a better reaction surface during further processing is steel melting.
A still another object of the present invention is to propose a process
for production of chromium nuggets by low temperature reduction of
pre-oxidized chromites ores/concentrated which can n exportable to
used directly in stainless steel manufacturing.
SUMMARY OF THE INVENTION
The chromites ores/concentrates with Cr: Fe ratio ranging from 1.0
to 3.3 we oxidized at low temperatures (900° C). The oxidized
samples show complete oxidation of FeO phase to Fe2O3. Reduction

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of oxidized chromite ores/concentrate was carried out using coal ass
reductant. Flux used consists of silica source (quarl) and lime. The
reduction experiments carried out using the controlled atmosphere
high temperature furnace. The raw materials used alongwith there
composition given is the following tables.
Table 1 Raw materials and their Composition (wt%)

The experimental studies for reduction were carried out at low
temperatures of 1400-1550°C. The coal reductant is used in 30-50%
excess of the stichoimetric carbon requirement for reduction of Iron

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orxide (Fe2O3) and chrome oxides (Cr2O3) in the ore. Based on the
special slag designed, the flux addition was carried out as quartz
addition in the range of 0-10% excess of required for aluminium
oxides and magnesium oxide dissolution to slag. The lime addition
was done in the rage of 3-10% of the chromite ore/concentrate.
Reduction was carried out in the temperature range of 1400-1550°C
for 1.5-3.0 hours. The chromite nuggets product id shown in fig 1.
The sample microstructure of the product alongwith the phase
composition is shown in Fig 2. It can be seen that the metal shows
two phase one chromium rich and the other rich phase. The
presence of chromium in the nugget product is in form of chromium
carbides (C7C3) and iron chromium carbides.
The Chemistry of the chromium metal, nugget and slag products
produced is given in Table 2. The metal nugget diameter ranges
from 0.5-25 cms. The metal and slag phase separation is clear which

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after quenching in water can be separated by physical separation
methods.
Table 2 Chemistry of Chromium metal nugget and slag

Reaction mechanisms:
The oxidation of FeO the chromite ore/concentrated opens the spinel
structure which increases the reactivity of chromite spinel due to
formation of vacancies.

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The oxidation of the chromite ores also helps in reducing the
reduction time. The reduction mechanism of chromite
ores/concentrates in absence of lime as flux, generally proceeds as
per the following steps. Chromium oxide reacts at 1200 to 1600°C
with carbon to form one of the carbides Cr3Cr2, Cr7C3.
3Cr2O3+ 13C→ 2Cr3C2 + 9CO (1150-1200°C)
27CR3C + 5Cr O → 13Cr C + 15 CO (1200-1600°C)
At still higher temperature Cr7C3 reacts with Cr23C6 and finally above
1820 C the Cr metal is favored product. However due to use of lime
as fluxing above component the slag formation reactions plays an
important role in carrying out the reduction of chrome oxide at lower
temperatures. In presence of lime as fluxing component the slag
formation reactions take place t lower temperatures which promotes
the reduction by dissolution in slag.

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DETAILS DESCRIPTION OF THE ACCOMPANYING DRAWING
Fig 1: Shows a photo-view of chromium nugget produces other
reduction of oxidized chromite ore/concentrates.
Fig 2: Shows a micro-structure of the chromium metal nugget
Fig 3: Shows a process flow sheet for production of chromium
nuggets.
DETAILS DESCRIPTION OF A PREFERRED EMBODIMENT OF
THE INVENTION
Fig 3- shows A Process flow sheet for the commercial production of
the chromium nuggets. The oxides of the chromium
ore/concentration (1) will be carried out in fluidized bed (2) rotary
furnace (2) and a hot air (3) blow means also provided there. The
oxidized ore/concentrates are fed into storage bin (4), a bin of
reduction (5) and a bin of flux (6) are provided near the oxidation
unit.

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The oxidized ores are then mixed in a mixer (7) and after mixing with
the coal reductant and flux (silica, lime) is fed to s palletized (8). The
pellets are fed to a rotary hearth the furnace (9) for carrying out the
reduction in it. The metal and slag product obtained from the rotary
hearth furnace (9) is fed to a physical separation unit (11) for the
separation of chromium metal nuggets (12) and slag (13).

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KEY FEATURES


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WE CLAIM
1. A process for production of Chromium nuggets by low
temperature peroxides chromite ore/Concentrate Comprises:-
- a chromium metal nuggets having a chemical composition
Cr 50-60%
C 3.0-6.0%
Si 0.7-1.0%
S 0.01-0.03%
P 0.003-0.04%
- the metal nugget diameter ranges from 0.5-2.5 cms
2. The process pf producing chromium nuggets comprising:
an oxidizing of chromite ore/chromium concentrate (Cr: Fe ration
ranging from 1.0 to 3.3) in a furnace at a low temperature of
900°C;
- mixing oxidizing ore with reductant coal and flux (lime, silica) in a
mixture (7);
- palletizing the mixing in a palletizer (8);

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- reducing the pattet in rotary hearth furnace (9) at a temperature
1400-1600°C and.
- Separating chromium nuggets from slag in a separation unit (11)

3. The process as claimed in claim two wherein the meallization of
chrome ore 50-70% is obtained.
4. The process for production of chromium nuggets by low
temperature pre-oxidized chromite ore/concentrates as
substratially described and illustrated herein with reference to
accompanying drawings and figures.
5. The chromium nuggets produced from the above process as
substantially described and illustrated herein with reference to
accompanying drawing and figures.
Dated this 24th day of May 2007

The chromites ores/concentrates with Cr: Fe ratio ranging from 1.0
to 3.3 we oxidized at low temperatures (900° C). The oxidized
samples show complete oxidation of FeO phase to Fe2O3. Reduction

of oxidized chromite ores/concentrate was carried out using coal ass
reductant. Flux used consists of silica source (quarl) and lime. The
reduction experiments carried out using the controlled atmosphere
high temperature furnace. The raw materials used alongwith there
composition given is the following tables.
Table 1 Raw materials and their Composition (wt%)
The experimental studies for reduction were carried out at low
temperatures of 1400-1550°C. The coal reductant is used in 30-50%
excess of the stichoimetric carbon requirement for reduction of Iron

orxide (Fe2O3) and chrome oxides (Cr2O3) in the ore. Based on the
special slag designed, the flux addition was carried out as quartz
addition in the range of 0-10% excess of required for aluminium
oxides and magnesium oxide dissolution to slag. The lime addition
was done in the rage of 3-10% of the chromite ore/concentrate.
Reduction was carried out in the temperature range of 1400-1550°C
for 1.5-3.0 hours. The chromite nuggets product id shown in fig 1.
The sample microstructure of the product alongwith the phase
composition is shown in Fig 2. It can be seen that the metal shows
two phase one chromium rich and the other rich phase. The
presence of chromium in the nugget product is in form of chromium
carbides (C7C3) and iron chromium carbides.
The Chemistry of the chromium metal, nugget and slag products
produced is given in Table 2. The metal nugget diameter ranges
from 0.5-25 cms. The metal and slag phase separation is clear which

after quenching in water can be separated by physical separation
methods.
Table 2 Chemistry of Chromium metal nugget and slag
Reaction mechanisms:
The oxidation of FeO the chromite ore/concentrated opens the spinel
structure which increases the reactivity of chromite spinel due to
formation of vacancies.

The oxidation of the chromite ores also helps in reducing the
reduction time. The reduction mechanism of chromite
ores/concentrates in absence of lime as flux, generally proceeds as
per the following steps. Chromium oxide reacts at 1200 to 1600°C
with carbon to form one of the carbides Cr3Cr2, Cr7C3.
3Cr2O3+ 13C→ 2Cr3C2 + 9CO (1150-1200°C)
27CR3C + 5Cr O→13Cr C + 15 CO (1200-1600°C)
At still higher temperature Cr7C3 reacts with Cr23C6 and finally above
1820 C the Cr metal is favored product. However due to use of lime
as fluxing above component the slag formation reactions plays an
important role in carrying out the reduction of chrome oxide at lower
temperatures. In presence of lime as fluxing component the slag
formation reactions take place t lower temperatures which promotes
the reduction by dissolution in slag.

Documents:

00802-kol-2007-abstract.pdf

00802-kol-2007-claims.pdf

00802-kol-2007-correspondence others 1.1.pdf

00802-kol-2007-correspondence others.pdf

00802-kol-2007-description complete.pdf

00802-kol-2007-drawings.pdf

00802-kol-2007-form 1.pdf

00802-kol-2007-form 18.pdf

00802-kol-2007-form 2.pdf

00802-kol-2007-form 3.pdf

00802-kol-2007-gpa.pdf

802-KOL-2007-(27-02-2012)-ABSTRACT.pdf

802-KOL-2007-(27-02-2012)-AMANDED CLAIMS.pdf

802-KOL-2007-(27-02-2012)-AMANDED PAGES OF SPECIFICATION.pdf

802-KOL-2007-(27-02-2012)-DESCRIPTION (COMPLETE).pdf

802-KOL-2007-(27-02-2012)-DRAWINGS.pdf

802-KOL-2007-(27-02-2012)-EXAMINATION REPORT REPLY RECEIVED.pdf

802-KOL-2007-(27-02-2012)-FORM-1.pdf

802-KOL-2007-(27-02-2012)-FORM-2.pdf

802-KOL-2007-(27-02-2012)-FORM-3.pdf

802-KOL-2007-(27-02-2012)-OTHERS.pdf

802-KOL-2007-(27-02-2012)-PCT SEARCH REPORT.pdf

802-KOL-2007-(27-02-2012)-PETITION UNDER RULE 137.pdf

802-KOL-2007-CORRESPONDENCE.pdf

802-KOL-2007-FORM 1.pdf

802-KOL-2007-REPLY TO EXAMINATION REPORT.pdf


Patent Number 264113
Indian Patent Application Number 802/KOL/2007
PG Journal Number 50/2014
Publication Date 12-Dec-2014
Grant Date 08-Dec-2014
Date of Filing 24-May-2007
Name of Patentee TATA STEEL LIMITED
Applicant Address JAMSHEDPUR
Inventors:
# Inventor's Name Inventor's Address
1 MR. GAJANAN KAPURE TATA STEEL LIMITED, JAMSHEDPUR-831001 INDIA
2 DR. VILAS D TATHAVADKAR TATA STEEL LIMITED, JAMSHEDPUR-831001 INDIA
3 DR. SARIPALLI M RAO TATA STEEL LIMITED, JAMSHEDPUR-831001 INDIA
PCT International Classification Number C22B34/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA