Technical Field
[0001] The present invention relates to a method for accelerating separation of granular
metallic iron as an objective product and slag as a by-product when metallic iron
is produced with reduction melting of raw-material agglomerates that contain an iron-oxide
containing material and a carbonous reducing agent. More specifically, the present
invention relates to an improved method for easily separating a mixed solid of granular
metallic iron, which is produced by supplying raw-material agglomerates to a reduction
melting furnace and reducing, melting and aggregating iron oxides in the raw-material
agglomerates, and slag, which is produced as a by-product, into the granular metallic
iron and the slag.
Background Art
[0002] When metallic iron of a low iron grade (in which large amounts of slag components,
such as SiO
2, Al
2O
3 and CaO, are contained as a veinstone component in iron ore and ash in a carbonous
material, which are used as raw materials) is supplied as raw materials for iron melted
in a steel-making furnace, e.g., a converter or an electric furnace, many problems
occur in that operability of the electric furnace is adversely affected with an increase
of the slag amount, the iron yield is reduced because of mixing of iron into slag,
energy consumption per unit product is increased, and productivity is lowered. Accordingly,
metallic iron of a high iron grade with a less content of slag components is demanded
as raw materials for molten iron. As a process for producing such metallic iron of
a high iron grade, it is known to improve, for example, a direct iron-making method
such as a shaft furnace method in which metallic iron is produced by directly reducing
an iron-oxide containing material, such as iron ore and/or iron oxides, with a carbonous
material and a reducing gas, and a method for producing metallic iron with steps of
mixing a carbonous material and powdery iron oxides into the form of agglomerates
or pellets, and reducing the mixture on a rotary hearth under heating, as disclosed
in, e.g., U.S. Patent No. 3,443,931. By using such improved methods, metallic iron
of a high iron grade is produced.
[0003] For example, Japanese Unexamined Patent Application Publication No. 2000-144224 is
known as an iron-making method for obtaining high-purity metallic iron with reduction
melting of raw-material agglomerates that contain an iron-oxide containing material,
such as iron ore and/or iron oxides, and a carbonous reducing agent such as coke.
In the technology for obtaining granular metallic iron with reduction melting of raw-material
agglomerates by using a reduction melting furnace of the moving hearth type, as disclosed
in that Publication, the iron oxides in the raw-material agglomerates are reduced
while the raw-material. agglomerates are held in a solid state. Then, metallic iron
and slag as a by-product are rendered to melt and aggregate separately. Thereafter,
by cooling the molten metallic iron and the molten slag (with a primary cooling step
in which they are cooled down to, e.g., about 1100 to 900 °C), the molten metallic
iron and the molten slag are brought into solidified states (called respectively "granular
metallic iron" and "slag granules"). After the cooling and the solidification, the
granular metallic iron and the slag granules are discharged out of the furnace. After
being discharged, the granular metallic iron and the slag granules are left to stand
for natural cooling (secondary cooling). Further, the granular metallic iron and the
slag granules are selectively separated from each other by any suitable separating
means such that only the granular metallic iron is employed as raw materials for molten
iron supplied to a steel-making furnace, etc.
[0004] In the above-mentioned metallic iron producing method, the cooling is divided into
a first cooling stage in which the metallic iron and the slag are cooled for solidification
to a level lower than the solidifying point thereof, and a second cooling stage in
which the temperature is further lowered for subsequent transportation and selection
of the metallic iron.
[0005] Although the first cooling stage is performed in the reduction melting furnace in
many cases, the slag granules are often present after the first cooling stage in such
a non-separated state (called a "mixed solid") that the slag granules are adhered
to the granular metallic iron. Also, in the second cooling stage in which the granular
metallic iron and the slag granules are left to stand outside the furnace for natural
cooling, the metallic iron and the slag are not sufficiently separated from each other.
For those reasons, it has been difficult to separately collect only the granular metallic
iron at high efficiency with magnetic screening, a sieve, etc., and to avoid a substantial
amount of slag from mixing into the granular metallic iron. Even with the metallic
iron having a high purity in itself, therefore, an amount of molten slag generated
in the steel-making furnace is increased because of the slag components that are unavoidably
mixed in the metallic iron without being completely separated, thus resulting in adverse
effects upon operability and product quality. From those situations in the art, there
is demanded a technique capable of separating metallic iron and slag as a by-product
at high efficiency before they are subjected to screening for separation.
[0006] In view of the above-described problems in the related art, an object of the present
invention is to provide a method for accelerating separation of granular metallic
iron as an objective product and slag as a by-product when the granular metallic iron
is produced with reduction melting of raw-material agglomerates that contain an iron-oxide
containing material and a carbonous reducing agent, thereby producing metallic iron
of a high iron grade in which slag is satisfactorily separated and removed.
Disclosure of the Invention
[0007] The present invention having succeeded in solving the above-described problems resides
in a method for accelerating separation of granular metallic iron and slag, the method
being employed to produce the granular metallic iron with reduction melting of raw-material
agglomerates that contain an iron-oxide containing material and a carbonous reducing
agent, wherein a mixed solid of the granular metallic iron produced with the reduction
melting and the slag produced as a by-product are quickly cooled to accelerate separation
of the granular metallic iron and the by-product slag from each other. When practicing
the method of the present invention, it is recommended to quickly cool the mixed solid
using a coolant. It is also recommended that the mixed solid be quickly cooled at
a cooling rate of preferably not less than 250 °C/min, more preferably not less than
350 °C/min, in at least a part of the range from a solidifying temperature of the
granular metallic iron to 150 °C. In a preferred embodiment of the present invention,
water is employed as the coolant, the quick cooling of the metallic iron is stopped
until reaching 150 °C, and moisture residing on and attached to the metallic iron
is dried.
Brief Description of the Drawings
[0008]
Fig. 1 is a schematic explanatory view showing one example of a reduction melting
furnace of the circular moving hearth type to which the present invention is applied.
Fig. 2 is a sectional view taken along the line A-A in Fig. 1.
Fig. 3 is an explanatory view showing a section of the reduction melting furnace in
the developed form as viewed in the rotating direction of a moving hearth in Fig.
1.
Fig. 4 is a schematic explanatory view showing a manner of cooling a mixed solid with
water sprays.
Fig. 5 is a schematic explanatory view showing a manner of cooling the mixed solid
with dipping in water.
Fig. 6 is a schematic explanatory view showing a manner of cooling the mixed solid
with a nitrogen gas.
Fig. 7 is a schematic explanatory view showing a manner of cooling a mixed solid with
water.
Best Mode for Carrying Out the Invention
[0009] As a result of carrying out intensive studies to solve the problems in the related
art, the inventors have accomplished the present invention based on the finding that,
by quickly cooling a mixed solid of granular metallic iron, which is produced with
reduction melting of raw-material agglomerates that contain an iron-oxide containing
material and a carbonous reducing agent, and slag produced as a by-product, separation
of the granular metallic iron and the by-product slag is remarkably accelerated.
[0010] In the present invention, the raw-material agglomerates contain an iron-oxide containing
material, such as iron ore and iron oxides or partly reduced materials thereof, and
a carbonous reducing agent, such as coke and coal. The raw-material agglomerates may
contain any suitable additive, etc. if necessary. Also, the raw-material agglomerates
are not limited in shape to a particular one, but can be prepared in the form of pellets,
briquettes, etc. Further, the raw-material agglomerates can be formed by any suitable
method depending on the agglomerate shape. In addition, a mixing ratio of the iron-oxide
containing material to the carbonous reducing agent is not limited to a particular
value, but can be selected to a proper value depending on the purpose for use. The
size of the raw-material agglomerates is also not limited to a particular one.
[0011] The granular metallic iron is produced with reduction melting of the raw-material
agglomerates described above. A practical method for the reduction melting is not
limited to a particular one, but can be carried out using a well-known reduction melting
furnace. It is to be noted that while the present invention will be described below
in connection with, for example, a method for producing metallic iron using a reduction
melting furnace of the moving hearth type, the present invention is not limited to
the following description and the illustrated examples. The present invention will
be described in detail with reference to the drawings showing a practical construction
of the reduction melting furnace.
[0012] Figs. 1 to 3 are schematic explanatory views showing one example of a reduction melting
furnace of the moving hearth type developed by the inventors, to which the present
invention is applied. The furnace is of a dome-shaped structure having a rotary moving
hearth in the doughnut form. Specifically, Fig. 1 is a schematic perspective view,
Fig. 2 is a sectional view taken along the line A-A in Fig. 1, and Fig. 3 is a schematic
explanatory view showing a section of the reduction melting furnace in the developed
form as viewed in the rotating direction of the rotary hearth in Fig. 1 for easier
understanding. In the drawings, numeral 1 denotes a rotary hearth, and 2 denotes a
furnace body covering the rotary hearth. The rotary hearth 1 is constructed such that
it can be driven by a driving device (not shown) to rotate at a proper speed.
[0013] As a matter of course, however, the construction of the reduction melting furnace
of the moving hearth type, to which the present invention is applied, is not limited
to the shape and structure shown in Figs. 1 to 3. So long as the reduction melting
furnace includes a moving hearth as a constituent element, various reduction melting
furnaces of the moving hearth type having any other structures, e.g., the straight
grate type, can also be effectively employed in the present invention.
[0014] A plurality of combustion burners 3 are disposed at appropriate places in a wall
surface of the furnace body 2. Combustion heat and radiation heat generated by the
combustion burners 3 are transmitted to the raw-material agglomerates on the rotary
hearth 1 for performing heating reduction of the raw-material agglomerates. In a preferred
example of the furnace body 2 as shown, the interior of the furnace body 2 is divided
by three partition walls K
1, K
2, K
3 into a first zone Z
1, a second zone Z
2, a third zone Z
3, and a fourth zone Z
4. A raw-material supply means 4 is disposed in an opposed relation to the rotary hearth
1 at the most upstream side in the rotating direction of the furnace body 2, and a
discharging means 6 is provided at the most downstream side in the rotating direction
(in other words, at the side immediately upstream of the supply means 4 because of
the rotary structure).
[0015] In operation of such a reduction melting furnace, the rotary hearth 1 is rotated
at a predetermined speed, and the raw-material agglomerates are supplied from the
supply means 4 onto the rotary hearth 1 such that a layer of the raw-material agglomerates
has a proper thickness. The raw-material agglomerates charged on the rotary hearth
1 are subjected to combustion heat and radiation heat generated by the combustion
burners 3 while moving in the first zone Z
1. Iron oxides in the raw-material agglomerates are reduced under heating, while maintaining
a solid state, with the aid of the carbonous material in the raw-material agglomerates
and carbon monoxide generated upon combustion of the carbonous material. Then, the
raw-material agglomerates are further reduced under heating in the second zone Z
2, whereby metallic iron is produced with almost complete reduction of the iron oxides.
The generated metallic iron is further heated in the third zone Z
3, and hence it is carburized and melted. The thus-produced molten metallic iron and
molten slag as a by-product are present in such a state that the molten slag lies
on the molten metallic iron, because of a difference in specific gravity between them.
The molten metallic iron and the molten slag are cooled by any suitable cooling means
C down to temperature not higher than the solidifying point thereof in the fourth
zone Z
4 for solidification. The solidified metallic iron and slag are successively discharged
by the discharging means 6. With the cooling and the solidification, the molten metallic
iron and the molten slag are mostly separated into granular metallic iron and slag
granules, but there also exists granular metallic iron (mixed solid) including slag
adhered to the iron because of incomplete separation. Therefore, the granular metallic
iron, the slag granules and the mixed solid are discharged to the outside of the furnace.
The mixed solid, etc. (hereinafter "the mixed solid, etc." means not only the mixed
solid, but also the granular metallic iron and the slag granules) discharged at that
time are in a relatively high temperature state (e.g., approximately from the solidifying
temperature to 900 °C).
[0016] In the present invention, the mixed solid discharged in such a relatively high temperature
state is quickly cooled to accelerate separation of the metallic iron and the slag
from each other by utilizing a difference in shrinkage rate between the metallic iron
and the slag both contained in the mixed solid. As a result, the mixed solid is separated
into the granular metallic iron hardly containing slag components and the slag granules
(made up of slag components, such as SiO
2, Al
2O
3 and CaO, contained as a veinstone component in iron ore and ash in a carbonous material,
which are used as raw materials).
[0017] In the present invention, the term "quick cooling" means quicker cooling than in
the case of leaving the mixed sold to stand in the atmosphere for natural cooling.
It is, however, particularly recommended to quickly cool the mixed solid using a coolant,
for example, and to apply thermal impacts to the mixed solid from the viewpoint of
increasing the effect of accelerating separation of the metallic iron and the slag
from each other. Also, quick cooling of the mixed solid at a cooling rate of not less
than 250 °C/min is preferred in that distortions occur in contact areas between the
metallic iron and the slag because of a sudden change in shrinkage rate (i.e., difference
in thermal expansion coefficient) between the metallic iron and the slag both contained
in the mixed solid, whereby separation of the metallic iron and the slag is accelerated.
A more preferable cooling rate is not less than 350 °C/min. The cooling rate can be
calculated by continuously measuring a temperature change of the mixed solid that
is discharged to the outside of the furnace.
[0018] The quick cooling method is not limited to a particular one, but it is preferred
to perform the quick cooling using a liquid and/or inert gas as the coolant. The quick
cooling with a liquid is recommended because a liquid can provide a higher cooling
rate and hence a higher separation effect than inert gas. The liquid used for the
quick cooling is not limited to a particular one, and there is no limitation as to
whether any additive is added to the liquid or not. The use of water is preferred
from the viewpoints of economy, safety and cooling efficiency. Also, there is no particular
limitation in use of inert gas, but the use of a nitrogen gas is preferred from the
viewpoints of economy and safety.
[0019] When performing the quick cooling using water, for example, the desired cooling rate
may be obtained by spraying water to the mixed solid while regulating the amount of
the supplied water with any suitable spraying means. As shown in Fig. 4, by way of
example, the mixed solid, etc. discharged out of the moving hearth type furnace are
transferred onto a moving means 9, such as a belt conveyor, through a feed duct 8
for movement therewith, and water is sprayed toward the mixed solid, etc. from spraying
means 11 that are provided in any desired number with any suitable intervals. The
sprayed water quickly cools the mixed solid, etc. and accelerates separation of the
slag and the metallic iron because of a difference in shrinkage rate between them,
whereby the granular metallic iron and the slag granules are obtained. Alternatively,
the mixed solid, etc. may be quickly cooled at the desired cooling rate by pooling
water in a cooling tank and controlling the water temperature with selective supply
and drain of water. As shown in Fig. 5, by way of example, the mixed solid, etc. discharged
out of the moving hearth type furnace 7 are introduced to a cooling tank 13 filled
with water 12 through a feeding means 8, such as a feed duct, for dipping in the water.
After being quickly cooled down to the predetermined temperature, the mixed solid,
etc. are taken out of the cooling tank with any suitable conveying means such as a
conveyor. The quick cooling method of dipping the mixed solid, etc. in water is more
preferable than the quick cooling method of spraying water because the former method
can provide a higher cooling rate, a greater difference in shrinkage rate, and hence
a higher separation rate.
[0020] When quickly cooling the mixed solid, etc. by using inert gas such as a nitrogen
gas, though not shown, the inert gas may be directly sprayed to the mixed solid, etc.,
or the mixed solid, etc. may be exposed to an atmosphere of inert gas.
[0021] Additionally, the quick cooling method is not limited to the above-described ones,
and those quick cooling methods can be implemented in any desired combination. For
example, the mixed solid, etc. may be quickly cooled by spraying water under a nitrogen
gas atmosphere, or the mixed solid, etc. may be quickly cooled under a nitrogen gas
atmosphere after spraying water.
[0022] Further, the higher the temperature of the mixed solid, etc. at the start of the
quick cooling, the greater is the separation effect resulting from the quick cooling.
It is therefore preferable to quickly cool the mixed solid, etc. when they are in
a high-temperature state immediately after being discharged out of the furnace. Because
the temperature of the mixed solid, etc. discharged out of the furnace depends on
how far the mixed solid, etc. have been cooled in the furnace, a practical temperature
at the start of the quick cooling is not limited to a particular value. However, since
the mixed solid, etc. discharged out of the furnace are usually in a solid state,
a preferable range for the quick cooling is at least a part of the range from the
solidifying point (about 1280 °C) of the metallic iron to 150 °C. If the quick cooling
is started from temperature lower than 150 °C, sufficient thermal impacts cannot be
applied to the mixed solid, etc. and the separation effect at satisfactory level cannot
be obtained in some cases.
[0023] The expression "at least a part" of the range means that the quick cooling does not
require to be continued over the entire temperature range. For example, it is meant
that when performing the quick cooling at a cooling rate of not less than 250 °C/min
in at least a part of the range from the solidifying point of the metallic iron to
150 °C, the mixed solid, etc. may be left to stand for natural cooling in the other
temperature range than in a certain part of the range from the solidifying point of
the metallic iron to 150 °C in which the mixed solid, etc. are quickly cooled at a
cooling rate of not less than 250 °C/min. In other words, it is not meant that the
quick cooling of the mixed solid, etc. must be continued over the entire range from
the solidifying point of the metallic iron to 150 °C. Further, the quick cooling may
be continued beyond the above temperature range, and it is not meant that the quick
cooling must be stopped at the time when the temperature reaches 150 °C. For example,
after quickly cooling the mixed solid, etc. in the range from the solidifying point
of the metallic iron to 150 °C, the quick cooling may be further continued in a temperature
range lower than 150 °C. Anyway, the quick cooling requires to be stopped at the time
when the desired temperature is reached.
[0024] Because the separation accelerating effect based on quick cooling, which is employed
in the present invention, is developed, as described above, by utilizing distortion
fracture at the interface between the metallic iron and the slag attributable to thermal
impacts caused upon the quick cooling, the quick cooling time may be selected to be
very short. For example, even the quick cooling for several seconds is sufficient
to fulfill the intended purpose. In particular, when a coolant is employed to perform
the quick cooling, the mixed solid is quickly cooled and the separation accelerating
effect is obtained at the moment when the mixed solid is brought into contact with
the coolant. For example, in the case of dipping the mixed solid in water, the temperature
of the mixed solid is abruptly lowered at the moment when the mixed solid is brought
into contact with the water, whereupon there occurs distortion fracture at the interface
between the metallic iron and the slag, thus resulting in separation of the metallic
iron and the slag. As a matter of course, during the period in which the mixed solid
is dipped in the water, the quick cooling of the mixed solid is still continued, and
the difference in shrinkage rate between the metallic iron and the slag at the interface
therebetween is increased in the mixed solid that remains in a non-separated state.
Therefore, the separation accelerating effect is further enhanced and a non-separation
rate of the slag from the metallic iron is reduced.
[0025] Furthermore, in the present invention, it is also preferable that in addition to
the use of water for the quick cooling, the quick cooling of the metallic iron be
stopped until reaching 150 °C, and thereafter the metallic iron be left to stand for
natural cooling. Stated otherwise, by stopping the quick cooling (stopping contact
of the mixed solid, etc. with water) after cooling the mixed solid, etc. to 150 °C
using water, and then leaving the mixed solid, etc. to stand for natural cooling,
moisture attached to the metallic iron is evaporated with heat of the metallic iron
itself. Accordingly, the metallic iron can be dried with no need of providing any
drying means such as a drier.
[0026] In the above, the method of the present invention is described in connection with
the case of quickly cooling the mixed solid discharged from the reduction melting
furnace together with the granular metallic iron and the slag granules. However, the
present invention is also applicable to the case of separating the metallic iron and
the slag from each other by any suitable screening means (such as a sieve or a magnetic
screening device) at the time when the granular metallic iron, the slag granules and
the mixed solid are discharged out of the reduction melting furnace, and then selectively
taking out only the mixed solid or both of the mixed solid and the granular metallic
iron through selective collection of the granular metallic iron, the slag granules
and the mixed solid. Thus, the method of the present invention can be implemented
regardless of the presence of the granular metallic iron and/or the slag granules
in addition to the mixed solid.
[0027] Also, by separating the metallic iron and the slag contained in the mixed solid from
each other as the granular metallic iron and the slag granules according to the method
of the present invention, and then selectively collecting the granular metallic iron
and the slag granules by any suitable screening means (such as a sieve or a magnetic
screening device), metallic iron raw-materials having purity of not less than about
95 %, more preferably of not less than about 98 %, and containing a very small amount
of slag components can be finally obtained.
[0028] The method of the present invention will be described below in connection with Example.
It is, however, to be noted that the following Example is not purported to limit the
present invention, and the present invention can be modified in appropriate ways based
on the purports of the present invention mentioned above and below.
Example
[0029] Raw-material agglomerates containing iron ore and coal were supplied to the reduction
melting furnace of the moving hearth type shown in Figs. 1 and 3, and then subjected
to heating reduction (temperature in the furnace: 1300 °C) with combustion heat and
radiation heat generated by combustion burners while the raw-material agglomerates
were maintained in a solid state. The raw-material agglomerates were further heated
and molten under a reducing atmosphere, thus generating a mixture of metallic iron
as an objective product and slag as a by-product. The mixture was cooled down to 1000
°C in the furnace. Granular metallic iron, slag granules and a mixed solid all solidified
with the cooling were discharged by a discharging means provided at the downstream
side in the moving direction of a hearth. The discharged mixed solid, etc. were introduced
through a feed duct to a cooling tank for quick cooling, to which coolants shown in
Table 1 were supplied. The cooling tank using nitrogen as the coolant is shown in
Fig. 6. The mixed solid, etc. were quickly cooled by supplying a nitrogen gas to the
cooling tank at all times (flow rate: 10 Nm
3/hr) while adjusting the flow rate of the nitrogen gas so that the cooling rate was
held at 250 °C/min. Additionally, the flow rate of the supplied nitrogen gas was adjusted
by exhausting the nitrogen gas through an exhaust duct 14. At the time when the temperature
of the metallic iron, etc. was lowered to room temperature, the metallic iron, etc.
were taken out of the cooling tank as required, and a total amount of the mixed solid
was measured (see "Mass of Mixed Solid" and "Slag Non-Separation Rate" in Table 1).
In the case of the nitrogen cooling, the temperature of the metallic iron, etc. was
measured by inserting a thermocouple in a mass of the mixed solid accumulated in the
cooling tank. The cooling tank using water as the coolant is shown in Fig. 7. Water
was pooled in the cooling tank beforehand to cool the mixed solid, etc. introduced
to the cooling tank. As a result of separately measuring a cooling rate of the mixed
solid, etc. in a water dipped state, the cooling rate was 350 °C/min. At the time
when the temperature of the mixed solid, etc. was lowered to room temperature, the
mixed solid, etc. were taken out of the cooling tank as required, and a total amount
of the mixed solid was measured. Measured results are shown in Table 1.
[0030] Further, in the case of the water cooling, the cooling rate obtained with water dipping
was separately measured. More specifically, a thermocouple was inserted in a mass
of the mixed solid heated to 1000 °C in the heating furnace, and the cooling rate
of the mixed solid was measured in a water dipped state.

[0031] As seen from Table 1, slag can be separated and removed from the mixed solid by employing
nitrogen or water as the coolant. Also, it is seen that the tests employing water
as the coolant show lower non-separation rates than the tests employing nitrogen as
the coolant, and hence the quick cooling means with water dipping is more preferable
quick cooling means.
Comparative Example
[0032] Granular metallic iron was produced using the reduction melting furnace of the moving
hearth type under the same conditions as those in Example described above. The mixed
solid, etc. discharged out of the furnace were left to stand in the atmosphere for
natural cooling to room temperature, but a very high non-separation rate (15 %) was
resulted.
Industrial Applicability
[0033] According to the method of the present invention, as described above, metallic iron
and slag as components of a mixed solid discharged out of a furnace can be separated
from each other with ease. Since the present invention provides metallic iron raw-materials
being free from slag and having high iron purity, molten steel having stable quality
can be produced with high productivity while reducing electric power consumed by an
electric furnace per unit product, by constructing a continuous system that utilizes
the thus-provided metallic iron raw-materials as raw materials for steel making.