Title

Experiences with a New Smelting Reduction Process

Experiences with a New Smelting Reduction Process

Authorship

GRANATI, PAOLO; DONATO, ANTONELLO DI; TOLINO, ERMELANDO; FEDERICO, GIUSEPPE

GRANATI, PAOLO

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DONATO, ANTONELLO DI

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TOLINO, ERMELANDO

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FEDERICO, GIUSEPPE

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DOI

10.5151/2594-5327-C00124-1952-1970

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Abstract

Hot metal has been produced in several experimental campaigns performed in a Smelting Reduction pilot plant sized for 3 tons/h production level. The Smelting Reduction process occurring in the CleanSmelt® pilot plant is characterized by intensive utilization of the thermochemical energy generated in the bottom part of the reactor, the smelter, where in the slag phase final reduction of iron oxide to hot metal occurs. Intensive and efficient energy utilization in the smelter is achieved through process conditions which guarantee high post combustion levels coupled with high heat transfer efficiency. Fine iron ores, from concentrate to sinter feed, and fine coals are used as raw materials. The reactor configuration consists of a single vessel, in which two distinct zones can be identified when considering the various steps of the process. The upper, where iron ores are injected, preheated and prereduced; the lower, where in a thick slag layer, the final reduction occurs sustained by coal and oxygen injected through side tuyeres, efficiently enhanced by intensive bottom blown gas stirring. Carbon and sulphur content in hot metal resulted respectively in the ranges: 3.5 to 4.1%C and 500–600 ppm S. Coal consumption per ton of hot metal ranged from 750 to 850 kg.

Hot metal has been produced in several experimental campaigns performed in a Smelting Reduction pilot plant sized for 3 tons/h production level. The Smelting Reduction process occurring in the CleanSmelt® pilot plant is characterized by intensive utilization of the thermochemical energy generated in the bottom part of the reactor, the smelter, where in the slag phase final reduction of iron oxide to hot metal occurs. Intensive and efficient energy utilization in the smelter is achieved through process conditions which guarantee high post combustion levels coupled with high heat transfer efficiency. Fine iron ores, from concentrate to sinter feed, and fine coals are used as raw materials. The reactor configuration consists of a single vessel, in which two distinct zones can be identified when considering the various steps of the process. The upper, where iron ores are injected, preheated and prereduced; the lower, where in a thick slag layer, the final reduction occurs sustained by coal and oxygen injected through side tuyeres, efficiently enhanced by intensive bottom blown gas stirring. Carbon and sulphur content in hot metal resulted respectively in the ranges: 3.5 to 4.1%C and 500–600 ppm S. Coal consumption per ton of hot metal ranged from 750 to 850 kg.