PROCESS AND SYSTEM FOR THE PRODUCTION OF IRON NUGGETS

Abstract

A hearth for a traveling hearth furnace for the production of pig iron grade nuggets, the hearth having a synthetic graphite material in direct contact with the process charge in producing a plurality of metallic iron nodules and slag. The process charge including iron containing oxide, a predetermined amount of a reductant and flux, which are carried into and through a reducing, melting and coalescing stages on the hearth, wherein resulting metallic iron nodules and slag are in direct contact with the synthetic graphite material and do not adhere to the synthetic graphite material of the hearth. The absence adherence and ease of removal minimizes any impurities in the pig iron grade nuggets and allows the hearth to be used more than one cycle without the need for any replenishment of the contact surface.

Claims

1. (canceled)

2. A process for reducing iron containing oxides to produce a plurality of metallic iron nodules from a process charge including iron containing oxide, a predetermined amount of a reductant and flux, wherein the process charge is carried into a traveling hearth furnace for reducing, melting and coalescing stages to convert the process charge into the plurality of metallic iron nodules and slag components, the process comprising: providing a process charge on a hearth comprising a synthetic graphite material, wherein the process charge is in direct contact with the synthetic graphite material; and carrying the process charge on the hearth during the reducing, melting and coalescing stages within the traveling hearth furnace, wherein the process charge is in direct contact with the synthetic graphite material such that the plurality of metallic iron nodules and slag components are only in direct contact with the synthetic graphite material of the hearth.

3. (canceled)

4. The process of claim 2, wherein the hearth comprises at least one layer of the synthetic graphite material operably attached to a substrate.

5. The process of claim 4, wherein the at least one layer of synthetic graphite material is bound to the substrate.

6. The process of claim 2, wherein the hearth comprise a substrate at least partially encapsulated by at least one layer of synthetic graphite material.

7. The process of claim 2, wherein the synthetic graphite material has a thickness between about 2 mm and about 5 cm.

8. The process of claim 2, wherein the synthetic graphite material is configured as two or more layers.

9. The process of claim 2, wherein the hearth comprises a monolithic synthetic graphite material.

10. The process of claim 9, wherein the monolithic synthetic graphite material has a thickness between about 1 inch and about 12 inches.

11. The process of claim 2, wherein the plurality of metallic iron nodules and slag components do not adhere to the synthetic graphite material.

12. The process of claim 2, wherein the hearth is devoid of any carbonaceous material in direct contact with the process charge.

13. The process of claim 2, wherein the hearth is devoid of any natural graphite material in direct contact with the process charge.

14. The process of claim 2, wherein each of the plurality of metallic iron nodules has a sulfur impurity level in an amount less than about 200 ppm.

15. The process of claim 2, wherein the plurality of metallic iron nodules comprise pig iron grade nuggets.

16. The process of claim 2, wherein the hearth is capable of being used more than one time in a traveling hearth furnace for producing pig iron grade nuggets.

17. The process of claim 2, wherein the synthetic graphite material of the hearth does not need to be replenished for the hearth to be used in more than one cycle within the traveling hearth furnace for producing pig iron grade nuggets.

18. The process of claim 2, further comprising separating the pig iron phase from the slag phase by one or more of tumbling and/or magnetic separation.

19. The process of claim 2, wherein further comprising lauding the iron nuggets into rail cars, trucks, barges and/or ships for shipment.

20. The process of claim 2, wherein the hearth comprises a raised edge to confine the iron and slag in a molten state within the hearth during processing, the raised edge preferably comprising synthetic graphite material.

21. A hearth for use in a traveling hearth furnace for reducing iron containing oxides to produce a plurality of metallic iron nodules from a process charge including iron containing oxide, a predetermined amount of a reductant and flux, the hearth comprising an outer surface consisting essentially of a synthetic graphite material, such that a process charge provided on the hearth is in direct contact with the synthetic graphite material.

22. The hearth of claim 21, wherein the hearth comprises at least one layer of the synthetic graphite material operably attached to a substrate, at least one layer of synthetic graphite material is bound to the substrate, or a substrate at least partially encapsulated by at least one layer of synthetic graphite material; and wherein the at least one layer of synthetic graphite material has a thickness between about 0.5 mm and about 10 cm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a top view illustration of a hearth loaded with the process charge in the form of pellets resting directly on the surface of the hearth, according to certain embodiments of the present invention;

[0018] FIG. 2 is a cross-section view of the illustration of the hearth of FIG. 1 along line 1-1, according to certain embodiments of the present invention;

[0019] FIG. 3 is an enlarged view of the cross-sectional area A of the hearth of FIG. 2 showing an embodiment of the hearth having a layer of synthetic graphite in direct contact with the process charge, according to certain embodiments of the present invention;

[0020] FIG. 4 is an enlarged view of the cross-sectional area A of the hearth of FIG. 2 showing an embodiment of the hearth being a monolithic synthetic graphite material in direct contact with the process charge, according to certain embodiments of the present invention; and

[0021] FIG. 5 is a cross-sectional view of a hearth having a raised edge and loaded with the process charge in the form of pellets resting directly on the surface of the hearth, according to certain embodiments of the present invention.

[0022] While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION OF THE DRAWINGS

[0023] Representative embodiments of the present disclosure provide a hearth having synthetic graphite in direct contact with the process charge, which prevents the nuggets and slag from adhering to the hearth surface.

[0024] The term synthetic graphite as referred to herein means a solid graphitic carbon material artificially crystallized by the high-temperature treatment of or chemical deposition of hydrocarbon materials and having a molecular weight of about 12 g/mol, specific gravity between 2.190 and 2.260 g/cm.sup.3 and a melting point between 3652? C. and 3697? C. (6606-6687? F.). In some preferred aspects, synthetic graphite capable of achieving the objectives of the present invention is available from Graphite Sales, Inc in Chagrin Falls, Ohio, having an percent ash content of less than 2.0, percent carbon content greater than 98% and a percent sulfur content less than 0.02. The term natural graphite as referred to herein means a solid graphitic carbon material that has been mined and has been naturally crystallized by the transformation of carbon-rich organic material under the long-term action of high temperature and high pressure.

[0025] The term carbonaceous material as referred to herein means carbon-containing material suitable for use as a carbonaceous reductant, such as coal, char and/or coke. One of ordinary skill in the art will appreciate that carbonaceous material used herein does not include natural or synthetic graphite and does not otherwise have a graphite crystal structure.

[0026] The synthetic graphite of the hearth can comprise at least one layer of synthetic graphite overlaying a substrate material. In some aspects, the at least one layer of synthetic graphite is bound to the substrate. In some other aspects, the at least one layer of synthetic graphite at least partially encapsulates the substrate. The hearth can also be formed of synthetic graphite, such that the hearth comprises a monolithic synthetic graphite material. The synthetic graphite of the hearth is in direct contact with the process charge, which with a melting temperature of at least 3652? C. (6606? F.) is well above the reduction temperature of 1490? C. (2714? F.) to which it will be exposed in the furnace. That characteristic means that during the furnace process the hearth and more particularly its surface remains in its original state without any chemical or physical changes that could cause the molten iron and slag to adhere to the hearth.

[0027] Now referring generally to the figures, FIGS. 1 and 2 show a hearth 10 constructed from the high temperature synthetic graphite. The process charge, in the form of pellets 12, rests directly on the surface 14 of the hearth 10.

[0028] As shown in FIG. 3, which is a blow-up of representative section A of FIG. 2, the synthetic graphite in direct contact with the process charge can be at least one layer of synthetic graphite 15 operably attached to a substrate 16. In some aspects, the at least one layer of synthetic graphite 15 is bound to the substrate 16. In some other aspects, the substrate 16 can be at least partially encapsulated by the at least one layer of synthetic graphite 15. Each layer of synthetic graphite can be between about 0.5 mm and about 100 cm, in some aspects between about 1 mm and about 10 cm, in some other aspects between about 2 mm and about 5 cm, and in some other aspects between about 2.5 mm and about 2.5 cm. In some aspects, the synthetic graphite can be provided as two or more layers.

[0029] As shown in FIG. 4, which is a blow-up of representative section A of FIG. 2, the hearth can comprise a monolithic synthetic graphite material 17, such that the process charge is in direct contact with the synthetic graphite. In some aspects, the monolithic synthetic graphite material 17 has a thickness between about 1 inch and about 12 inches, in some aspects between about 1.5 inches and about 10 inches, and in some other aspects between about 2 inches and about 6 inches.

[0030] The pellets are carried on the hearth into and through the furnace where they go through a conventional pre-heat, reduction, melting, coalescence, and finally exiting the furnace as a pig iron grade iron nuggets with attached slag.

[0031] After coalescing, the resulting nuggets are allowed to cool down and, if desired can go through a water quench, so that post processing can continue at a lower temperature. Post processing consists of a combination of sweeping and magnetic lifting the iron nuggets from the hearth and moving the nuggets with attached slag into a water bath and then to a tumbler to separate the slag from the pig iron. Once separated the iron nuggets and slag are separated into two products, a pig iron product and a slag product by a magnetic separator. The iron nuggets are then lauded into rail cars, trucks, barges, ships or are inventoried for eventual use or sale and the slag disposed by sales for road building or other purposes or in a conventional manner.

[0032] During the above-described process, there will be a time when the iron and slag will be in a molten state. To ensure that while in a molten state the process material remains confined within the hearth, according to certain embodiments, the hearth is formed with a raised edge 14. The raised edge prevents any overflow from the hearth that might otherwise occur.

[0033] A linear or tunnel hearth furnace (not shown but disclosed in U.S. Pat. No. 7,695,544) is the preferred furnace. A conventional walking beam (not shown) may be used to move the hearth or hearths through the furnace. As an alternative, the hearths may be moved by pushing a hearth on rails or wheels which in turn pushes the hearth in front of it. More particularly, the hearths as they move through furnace will be aligned in the furnace on a suitable flat support. As an addition hearth is pushed into the alignment it pushes the hearths in front of it and all hearths in the furnace are moved one hearth length. In that manner the hearths are moved through the furnace in a step-by-step fashion. The heath can alternatively include a base made of suitable refractory material with a synthetic graphite layer covering the surface of the base and separating the base surface from the process charge and during the reduction, melting and coalescing stages from the melting and coalescing iron and slag.

[0034] By eliminating the need for a carbonaceous hearth layer, the present invention has provided an improved hearth furnace pig iron process. Namely, the hearth of the present invention: [0035] 1. Eliminates the carbonaceous hearth layer material and the added cost factors attributable thereto. [0036] 2. Eliminates the time-consuming step of configuring the carbonaceous hearth layer to support the process charge in a manner to ensure the production of discrete nuggets. [0037] 3. Eliminates the introduction of unwanted elements that are contained in the carbonaceous materials identified above that would produce impurities in the produced pig iron, for example sulfur, and the presence of which is a problem in iron foundries and steel making. [0038] 4. As there is no source of carbon other than that contained in the process charge only, the stoichiometric amount necessary for reduction is used providing a measure of control over the amount of carbon dioxide emissions that can be generated is achieved in the course of the reduction process. [0039] 5. Eliminates the need for separating the produced pig iron grade iron nuggets from the carbonaceous hearth layer at the end of the furnace process to prepare the product from the furnace for necessary post processing, i.e. physically separate the iron nuggets from the slag and into discrete products or phases. [0040] 6. No need to replenish the carbonaceous material making up hearth layer that was consumed in the furnace process. [0041] 7. Ensures that a hearth can be used for more than a limited number of cycles.

[0042] The preferred reductant, consistent with being environmentally positive, is a suitable biomass.

[0043] In some aspects, the resulting nuggets contain a sulfur impurity in an amount less than about 200 ppm, preferably less than about 190 ppm, preferably less than about 180 ppm, preferably less than about 170 ppm, preferably less than about 160 ppm, preferably less than about 150 ppm, preferably less than about 140 ppm, preferably less than about 130 ppm, preferably less than about 120 ppm, preferably less than about 110 ppm, preferably less than about 100 ppm, preferably less than about 90 ppm, preferably less than about 80 ppm, preferably less than about 70 ppm, preferably less than about 60 ppm, preferably less than about 50 ppm, preferably less than about 40 ppm, preferably less than about 30 ppm, preferably less than about 20 ppm, and more preferably less than about 10 ppm.

[0044] With regard to the environmental aspects of the present invention, the elimination of the carbonaceous hearth layer allows the technology disclosed in of U.S. Pat. Nos. 7,632,330 and 8,906,131 in addition to the protective carbonaceous layer to be in combination with the technology of the invention of this application for an even more environmentally enhanced and cost effective pig iron grade iron nugget production process. Accordingly, the disclosures contained in U.S. Pat. Nos. 7,632,330 and 8,906,131 are incorporated herein by reference as if set forth herein in its entirety as part of this provisional application

[0045] In the final analysis this invention makes available an improved and cost affective process that can produce merchant pig iron grade iron other than in a blast or shaft furnace and in a far more environmentally sound manner.