Post on 27-Aug-2018
transcript
Exploring possibility of exploiting old known
processes to create a new process process
Jayant Sathaye
Exploring possibility of exploiting old known
processes to create a new process process
Jayant Sathaye
History
� Self reducing composites known for a long time. Earliest trial in mid 1950’s. Even India in late sixties
� Started in attempt to utilise fines coalcoal
� Rotary Hearth processes -� submerged arc furnaces –� Shaft furnaces – OxyCup, Tecnored� Others without composites
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Self reducing composites known for a long time. Earliest trial in mid 1950’s. Even India in late sixties
Started in attempt to utilise fines – both iron ore and
Maumee, Fastmet, ITmK3– Redsmelt
OxyCup, TecnoredOthers without composites – Hismelt, Romelt, Ausmelt
Exploring possibility of exploiting old known processes to
create a new process 2
Rotary Hearth Furnaces
� Quick reduction
� Heat transfer – one or two layers only
� re-oxidation – has to be matched to melting vessel
� Sulphur from coal goes into product
� Phosphorus also retained
� cooling/melting after reduction
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Rotary Hearth Furnaces
one or two layers only
has to be matched to melting vessel
Sulphur from coal goes into product
cooling/melting after reduction
Exploring possibility of exploiting old known processes to
create a new process 3
Submerged Arc Furnaces
� Electric energy consumption
� matching rotary hearth output to SAF input
� slag handling
� DRI also can be melted
� still being used for Ti and V bearing ores
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Submerged Arc Furnaces
Electric energy consumption – cost of energy
matching rotary hearth output to SAF input
still being used for Ti and V bearing ores
Exploring possibility of exploiting old known processes to
create a new process 4
Direct use of Iron ore and coal
� Incomplete reduction
� FeO content in slag
� refractory life – corrosive slag
� Top lance and life
� waste energy utilisation - at 1700 Deg C
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Direct use of Iron ore and coal
corrosive slag – campaign life
at 1700 Deg C – sensible and fuel
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create a new process 5
Shaft furnaces
� Size of composite brick, pellet, briquette is a requirement
� Reduction degradation – tall shaft is not suitable
� permeability
� heat transfer
� waste gas energy utilisation
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Size of composite brick, pellet, briquette is a requirement
tall shaft is not suitable
Exploring possibility of exploiting old known processes to
create a new process 6
Raw material possibilities in India ore
� High grade ore fines limited, low grade needs beneficiation
� need to grind to beneficiate to 63.5%
� size – 20 to 80 microns - superfines
� need to agglomerate
� hot agglomeration
� cold bonding
� slag design for after melting the reduced composite
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Raw material possibilities in India – Iron
High grade ore fines limited, low grade needs beneficiation
need to grind to beneficiate to 63.5%
superfines
slag design for after melting the reduced composite
Exploring possibility of exploiting old known processes to
create a new process 7
Raw material possibilities in India
� High carbon low ash preferred
� reactivity – temperature
� melting of ash – temperature
� size restriction for fixed bed
� generation of coal fines and possibilities of utilisation
� what is better? – electric power or chemical reduction
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Raw material possibilities in India - Coal
High carbon low ash preferred
temperature
generation of coal fines and possibilities of utilisation
electric power or chemical reduction
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create a new process 8
Suggestion – Shaft Furnace
� good heat transfer
� reduction degradation requirement
� permeability – paramount importance
� multiple injection points – combusted gas
� discharge – without reoxidation
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Shaft Furnace
reduction degradation requirement
paramount importance
combusted gas
without reoxidation
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create a new process 9
Suggestion - melter
� need for permeability
� need to complete reduction
� slag composition – fluidity/temperature
� refractory for vessel
� handling of sulphur/phosphorus
� permeable coke/slightly caking coal bed
� Fuel generation for shaft
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
fluidity/temperature
handling of sulphur/phosphorus
permeable coke/slightly caking coal bed
Exploring possibility of exploiting old known processes to
create a new process 10
Suggestion – Utilisation of wastes
� slag to be suitable for cement making
� gas to be suitable for thermo
� gas to be suitable for direct use without need for enrichment – in IC engines, reheat furnaces, gas turbines, enrichment – in IC engines, reheat furnaces, gas turbines, fuel cells (?)
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
Utilisation of wastes
slag to be suitable for cement making
gas to be suitable for thermo-electric power generation
gas to be suitable for direct use without need for in IC engines, reheat furnaces, gas turbines, in IC engines, reheat furnaces, gas turbines,
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create a new process 11
Possibility – Flowsheet 1
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create a new process
Flowsheet 1
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create a new process 12
Possibility – Flowsheet 2
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create a new process
Flowsheet 2
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create a new process 13
Possibility ?
� utilisation of superfine iron ores and coals
� simple agglomeration with lime fines as binder
� viable unit processes
� possible overall process� possible overall process
�Thank you for your patience
2/1/2016Exploring possibility of exploiting old known processes to
create a new process
utilisation of superfine iron ores and coals
simple agglomeration with lime fines as binder
Exploring possibility of exploiting old known processes to
create a new process 14