Method and apparatus for producing metal oxide materials

Abstract

The invention relates to a method for producing a metal oxide material (5) by means of a metal oxide material production plant (3) and the plant itself. The apparatus comprises a preheating zone (8) configured to preheat a metal ore material (2) into a preheated metal ore material (4); a process gas introduction device (6) coupled with the preheating zone (8) and configured to introduce a process gas (7) into the preheating zone (8); a consolidation zone (10) configured for consolidating the preheated metal ore material (4) into the metal oxide material (5); an oxidant introduction device (12) coupled with the consolidation zone (10) and configured to introduce an oxygen-enriched oxidant (14) into the consolidation zone (10); and a control circuit (50) coupled with the process gas introduction means (6) and the oxidant introduction means (12) for controlling the solidification of the metal ore material (2) into the metal oxide material (5).

Description

Technical Field

[0001] The invention primarily relates to a method according to the preamble of claim 1 and to a metal oxide material production device according to the preamble of claim 9.

[0002] In particular, the present invention relates to a metal oxide material production apparatus configured for heating and / or firing metal ore materials to consolidate the metal ore materials into metal oxide materials (e.g., iron oxide materials) ready for transport to customers and / or loading into direct reduction facilities for producing reduced metal materials (reduced iron materials).

[0003] The present invention relates to the technology of beneficiating metal ore materials, especially iron ore materials, and to improvements in the pelletizing of metal ore materials, especially iron ore concentrates.

[0004] The present invention also relates to a data program programmed to control the production of metal ore materials into metal oxide materials.

[0005] The present invention relates primarily to the mining industry.

[0006] The invention may also relate to manufacturers and suppliers of equipment for producing metal oxide materials, for use in direct reduction facilities and the steelmaking industry, and the like. Background Art

[0007] Typically, the metal ore material such as iron ore material to be processed contains both magnetite material and hematite material, and may also contain other iron ore raw materials such as limonite, siderite, etc. The metal ore material such as iron ore material to be processed is usually formed into so-called green pellets, balls, bodies, etc. with a diameter of about 5 mm to 25 mm, for example.

[0008] Typically, the metal ore material is moist and may contain a binder material, such as bentonite, an organic binder, etc., to provide strength to the metal ore material prior to being fed to the metal oxide material production facility. Of course, the consolidation temperature and holding time required to consolidate the metal ore material in the consolidation zone depends on the mineralogy of the metal ore material and the type and amount of binder.

[0009] In order to remove moisture from the metal ore material and to strengthen the metal ore material, the metal ore material is preheated in a preheating zone of the metal oxide material production plant before being fed into a consolidation zone of the metal oxide material production plant.

[0010] In order to dry and strengthen the moist metal ore material, the moist metal ore material is dried in a drying zone including a downgoing process gas zone and / or an upgoing process gas zone before being fed into the preheating zone.

[0011] The dried metal ore material is strong enough to build a bed of metal ore material on a metal ore material feed device employed in a preheating zone of a metal oxide material production facility.

[0012] Conventionally, according to the prior art, some of the magnetite in the metallic ore material subjected to preheating in the preheating zone will be oxidized to hematite, wherein the exothermic chemical reaction generates heat and causes the hematite to recrystallize before being fed into the consolidation zone.

[0013] Traditionally, the metal ore material is conveyed by a moving chain grate on which the metal ore material is first dried and then preheated in a preheating zone to a temperature of, for example, about 1000°C, after which the preheated metal ore material is moved to a consolidation zone, such as a kiln or furnace, where the preheated metal ore material can be fired to a temperature of about 1300°C to 1450°C by an oil burner. Traditionally, the consolidation zone is configured to oxidize and sinter the preheated metal ore material. However, oxidation of the preheated metal ore material is not fully achieved in the consolidation zone, and a portion of the oxidation may occur in a subsequent cooling step. The cooler is configured to cool the metal ore oxide material, wherein the oxygen-containing cooling atmosphere will result in prolonged oxidation of the metal ore subjected to cooling.

[0014] Traditionally, oil burners are configured to burn preheated metal ore materials for providing said consolidation. Current metal oxide material production facilities consume large amounts of fossil fuels for producing metal oxide materials, which in turn contributes to global warming. Oil burners are configured to burn oil fuel or different gaseous fuels or mixtures thereof.

[0015] Conventionally, known metal oxide material production facilities have wasted a large amount of heat energy.

[0016] Current metal oxide material production equipment is bulky and costly to operate and assemble due to the application of complex oil burner systems, combustion fuel supply lines, combustion fuel pumps, combustion fuel distribution valves, etc. Summary of the invention

[0017] One object is to provide energy-saving and cost-effective production of metal oxide materials by a metal oxide material production plant that is a next generation metal oxide material production plant.

[0018] One purpose is to reduce emissions of carbon dioxide (CO2) and nitrogen oxides (NOx) to reduce the effects of global warming.

[0019] One object is to provide efficient production of metal oxide materials while effectively controlling the oxidation of metal ore materials to metal oxide materials.

[0020] One object is to optimize the heat distribution of the preheated metal ore material to achieve a uniform and high quality of the produced metal oxide material.

[0021] One object is to provide a stable metal oxide material which is prevented from oxidation during the cooling step and during transport to the reduction facility.

[0022] One object is to optimize the production of metal oxide materials with high quality while achieving reduced energy consumption.

[0023] One object is to increase the productivity of metal oxide materials and / or to make it possible to design more compact metal oxide material production plants.

[0024] These or at least one of the purposes have been achieved by a method for oxidizing a metal ore material into a metal oxide material with the aid of a metal oxide material production device, the metal oxide material production device comprising: a preheating zone, the preheating zone being configured to preheat the metal ore material into a preheated metal ore material; a process gas introduction device, the process gas introduction device being connected to the preheating zone and configured to introduce process gas into the preheating zone; a consolidation zone, the consolidation zone being configured to consolidate the preheated metal ore material into the metal oxide material; an oxidant introduction device, the oxidant introduction device being connected to the consolidation zone and configured to introduce oxygen-rich oxidant into the consolidation zone; and a control circuit, the control circuit being connected to the process gas introduction device and the oxidant introduction device for controlling the consolidation of the metal ore material into the metal oxide material.

[0025] In this way, preheating the metal ore material in an oxygen-depleted preheating atmosphere involves virtually no oxidation of the metal ore material. By saving reactivity for oxidizing the metal ore material, effective oxidation can now be achieved in the consolidation zone, where effective and complete oxidation occurs.

[0026] Alternatively, the preheating zone comprises a preheating zone heating device.

[0027] Alternatively, the step of preheating the metal ore material is achieved by a preheating zone heating device, which is configured to introduce thermal energy into the preheating zone for preheating the metal ore material fed into the preheating zone.

[0028] Alternatively, the metal ore material is moved from the drying zone into the preheating zone, and optionally further through the consolidation zone, by a metal ore material feeding device, such as a steel belt conveyor member, a mobile roaster unit, or by other means.

[0029] Alternatively, the consolidation zone includes grate components and a rotary kiln configured to sinter the preheated and oxidized metal ore material.

[0030] Alternatively, the metal oxide material is fed from the consolidation zone to a cooler arrangement, such as a ring cooler, configured to recover thermal energy from the consolidated metal oxide material, which is fed back to the preheating zone and / or drying zone.

[0031] Alternatively, the metal oxide material production apparatus further comprises a metal ore material bed applicator configured to apply a bed of metal ore material to a metal ore material feeding device configured to feed the metal ore material through the preheating zone and / or the consolidation zone.

[0032] Alternatively, the thickness / height of the bed corresponds to a measure of about 10 to 50 times greater than the average size of bodies of metal ore material fed through the preheating zone and / or consolidation zone by the metal ore material feeding means.

[0033] Alternatively, the thickness / height of the bed corresponds to a measure which is about 50 to 100 times the average size of metal ore material bodies (e.g. pellets) of metal ore material fed through the preheating zone and / or consolidation zone by the metal ore material feeding means.

[0034] Alternatively, the thickness / height of the bed corresponds to a measure which is about 10 to 50 times the average size of metal ore material bodies (e.g. pellets) of metal ore material fed through the preheating zone and / or consolidation zone by the metal ore material feeding means.

[0035] By introducing an oxygen-rich oxidant into the consolidation zone, the preferred bed thickness / height can be set thicker than in the prior art. The oxygen-rich oxidant is able to diffuse into the bed of metal ore material throughout the entire thickness due to its high oxygen content, wherein the preferred metal ore material bed thickness is thicker than in the prior art beds.

[0036] Alternatively, the oxygen-enriched oxidant is introduced into the bed of preheated metallic ore material in the consolidation zone from above, from below, from the side, or a combination thereof.

[0037] By introducing an oxygen-rich oxidant into the consolidation zone, effective oxidation of the preheated metal ore material may be achieved throughout the thickness of the bed of preheated metal ore material undergoing oxidation.

[0038] By using an oxygen-enriched oxidant, the flow rate of oxygen-enriched oxidant introduced into the consolidation zone can be kept relatively low relative to prior art metal oxide material production plants which use a high flow rate of low oxygen content oxidising gas introduced into the consolidation zone for effecting oxidation of the preheated metal ore material.

[0039] In this way it is achieved that less energy is required to operate, for example, a process gas fan unit or a blower unit coupled to the consolidation zone, relative to the prior art.

[0040] In this way, oxidation of the preheated metal ore material over its entire bed thickness is achieved while saving energy.

[0041] By using an oxygen-rich oxidant, the consolidation zone can be designed to be shorter than prior art consolidation zones due to the efficient oxidation of the preheated metal ore material by the oxygen-rich oxidant.

[0042] In this way, the metal oxide material production equipment can be designed to be smaller than the prior art metal oxide material production equipment.

[0043] Alternatively, the process gas may be fed upwardly as well as downwardly through a bed of metal ore material undergoing preheating in the preheating zone for providing efficient heat transfer to the metal ore material undergoing preheating in the preheating zone.

[0044] Alternatively, the thickness of the bed is about 25 cm to 75 cm, preferably about 35 cm to 65 cm.

[0045] Alternatively, the thickness of the bed is about 30 cm to 70 cm, preferably about 40 cm to 60 cm.

[0046] Alternatively, the thickness of the bed is about 40 cm to 80 cm, preferably about 50 cm to 70 cm.

[0047] By moving a thicker bed of preheated metal ore material through the consolidation zone, a greater amount of the preheated metal ore material can be oxidized, which in turn allows for cost effective and high rate production of metal oxide material.

[0048] The dried metal ore material is strong enough to build a bed of metal ore material on a metal ore material feed device employed in a preheating zone of a metal oxide material production facility.

[0049] In this way, a well-defined temperature gradient may be established in the bed of metallic ore material undergoing preheating and consolidation.

[0050] In this way, the temperature gradient can be controlled to be as uniform as possible throughout the preheating zone and the consolidation zone for providing a uniform quality of the metal oxide material.

[0051] In this way a poorer quality of the preheated metal ore material is achieved throughout the thickness of the metal ore material bed.

[0052] Alternatively, the process gas is an oxygen-depleted process gas.

[0053] Alternatively, the process gas comprises air.

[0054] Alternatively, the process gas is an oxygen-depleted process gas, which contains about 0 vol% to 25 vol% oxygen, preferably about 5 vol% to 21 vol% oxygen.

[0055] Alternatively, the process gas comprises less than about 22 volume percent oxygen.

[0056] Alternatively, the process gas comprises about 1 vol% to 19 vol% oxygen, preferably about 5 vol% to 15 vol% oxygen.

[0057] Alternatively, the process gas comprises about 2 vol% to 15 vol%, preferably about 4 vol% to 11 vol% oxygen.

[0058] Alternatively, the oxygen content defined by volume % of the process gas is a relative term that is independent of the temperature of the process gas introduced into the preheating zone.

[0059] Alternatively, the flow rate of the oxygen-enriched oxidant may be relatively low, but the high oxygen content in the oxygen-enriched oxidant enables the metal ore material to react with the oxygen to produce the metal oxide material.

[0060] Alternatively, the process gas is fed into the preheat zone to such an extent that the oxygen in the oxygen-depleted process gas prevents oxidation of the metal ore material in the preheat zone.

[0061] Alternatively, the process gas is fed into the preheat zone to an extent that the oxygen in the oxygen-depleted process gas substantially prevents oxidation of the metal ore material in the preheat zone.

[0062] In this way it is achieved that the energy content of the metal ore material is preserved until released in the consolidation zone, in which the oxygen in the oxygen-rich oxidant is able to oxidize the preheated metal ore material within a well-defined consolidation zone and to optimally exploit the thermal energy of the metal oxide material to be discharged from the consolidation zone.

[0063] Alternatively, the process gas is fed into the preheating zone to an extent that oxygen in the oxygen-depleted process gas prevents oxidation of the metal ore material in the preheating zone, preventing development of thermal energy of the metal ore material to an extent that metal ore particles of the metal ore material do not adhere to each other.

[0064] In this way it is achieved that the preheated metal ore material, ie the metal ore particles of the metal ore pellets, retains an optimum porosity until introduced into the consolidation zone.

[0065] In this way it is achieved that oxygen in the oxygen-rich oxidant reaches the preheated metal ore material for oxidation of the preheated metal ore material in a well-defined consolidation zone and that the thermal energy of the metal oxide material to be discharged from the consolidation zone can be optimally exploited.

[0066] Alternatively, the control circuitry is adapted to control the flow of oxygen-enriched oxidant into the consolidation zone for controlling oxidation of the preheated metal ore material.

[0067] In this way, by providing oxidation within a well-defined consolidation zone, the control circuitry is able to control and monitor the oxidation of the preheated metal ore for optimal exploitation of the thermal energy of the metal oxide material to be exhausted from the consolidation zone.

[0068] Oxidation that produces heat energy in the consolidation zone in such a manner provides a temperature of the oxidized metal ore that enables sintering of the preheated metal ore material and / or metal oxide material in the consolidation zone without adding heat energy to the consolidation zone, or only to a certain extent.

[0069] Alternatively, the oxygen-enriched oxidant is preheated prior to introduction into the consolidation zone to an extent which prevents cooling of the preheated metal ore material in the consolidation zone.

[0070] Alternatively, the electrolysis unit is configured to provide at least a portion of the preheated oxygen-enriched oxidant to be fed into the consolidation zone.

[0071] Alternatively, the control circuit is adapted to control the preheated oxygen-enriched oxidant to flow into the consolidation zone in a low flow mode for avoiding generation of a large amount of exhaust gas discharged from the consolidation zone.

[0072] In this way, due to the low flow mode, cost-effective exhaust gas filtration is provided.

[0073] The low flow pattern of the oxygen-enriched oxidant introduced into the consolidation zone is achieved by the high oxygen content of the oxygen-enriched oxidant.

[0074] Alternatively, producing the metal ore material comprises the steps of mining the metal ore containing rock fragments; grinding the metal ore containing rock fragments into crushed fragments; separating the metal ore particles from the crushed fragments in a fluid; forming a body of metal ore material of the metal ore particles; drying the body in a drying zone to provide the metal ore material ready to be fed into a preheating zone.

[0075] Alternatively, the method also includes the following steps: feeding the metal ore material into the preheating zone; introducing process gas into the preheating zone and heating the consolidation zone atmosphere for preheating the metal ore material; feeding the preheated metal ore material into the consolidation zone; introducing an oxygen-rich oxidant into the consolidation zone for oxidizing the preheated metal ore material into the metal oxide material; and discharging the metal oxide material from the consolidation zone.

[0076] Alternatively, heated process gases are used to provide preheating of the metal ore material.

[0077] Alternatively, the consolidation zone is configured to oxidize and sinter the preheated metal ore material.

[0078] Alternatively, an oxygen-enriched oxidant is fed into the consolidation zone for consolidating and / or enriching the preheated metal ore material.

[0079] Alternatively, oxidation and sintering of the preheated metal ore material are provided simultaneously and / or separately in the consolidation zone.

[0080] Alternatively, sintering of the metal ore material is provided partly in the preheating zone.

[0081] Alternatively, the control circuit is configured to control the oxidation rate and / or the consolidation temperature for effectively oxidizing the metal ore material into the metal oxide material.

[0082] Alternatively, the control circuit is configured to control the sintering rate and / or the consolidation temperature and / or the preheating temperature for effectively sintering the metal ore material into the metal oxide material.

[0083] Alternatively, the process gas is an oxygen-depleted process gas comprising about 0 vol% to 21 vol% oxygen, preferably about 5 vol% to 20 vol% oxygen, and / or the oxygen-enriched oxidant comprises about 25 vol% to 100 vol% oxygen, preferably about 40 vol% to 80 vol% oxygen.

[0084] Alternatively, the process gas is an oxygen-depleted process gas comprising about 0 vol% to 20 vol% oxygen, preferably about 8 vol% to 15 vol% oxygen, and / or an oxygen-enriched oxidant comprising about 40 vol% to 80 vol% oxygen, preferably about 50 vol% to 70 vol% oxygen.

[0085] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0086] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0087] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0088] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0089] Alternatively, the oxygen-enriched oxidant comprises pure oxygen.

[0090] Alternatively, the oxygen content defined by the volume % of the oxygen-rich oxidant is a relative term that is independent of the temperature of the oxygen-rich oxidant introduced into the consolidation zone.

[0091] In this way, a strong and hard metal oxide material (eg iron ore agglomerates or pellets) is provided which resists breakage during subsequent handling and transportation prior to the production of sponge iron and steel.

[0092] In this way effective control of the oxidation and / or sintering of the preheated metal ore material including magnetite material is achieved for satisfying the complex physicochemical processes involving oxidation and / or sintering of the chemical consolidation process.

[0093] In this way effective control of heat transfer from the preheated metallic ore material to the consolidation zone atmosphere during oxidation and / or sintering is achieved.

[0094] Alternatively, the control circuit is configured to control the flow of oxygen-rich oxidant into the consolidation zone and / or control the oxygen-rich oxidant gas pressure in the consolidation zone and / or control the temperature of the consolidation zone atmosphere by operating a consolidation zone atmosphere gas burner device and / or a consolidation zone atmosphere electric heater device.

[0095] In this way a highly exothermic chemical reaction is achieved, resulting in a significant temperature gradient within the body or pellet of the metal ore material, providing for rapid and efficient sintering of the metal ore material.

[0096] By using an oxygen-enriched oxidant, a metal oxide material production apparatus is provided that includes a control circuit configured to control the thermal profile of the metal ore material during consolidation taking into account oxidation, sintering and heat transfer parameters.

[0097] In this manner a metal oxide material production plant is provided which provides a specific chemical reaction for oxidation of magnetite material for generating excess heat energy which can be recovered and brought back to the preheating zone, thereby facilitating an energy efficient and effective process.

[0098] In this manner, the time for oxidation in the consolidation zone is minimized due to the high oxygen content, and rapid oxidation is achieved by the large number of oxygen molecules available around each body of metal ore material of the preheated metal ore material. Therefore, the higher the oxygen concentration of the oxygen-rich oxidant, the faster the initial oxidation of the magnetite material, which promotes cost-effective production of metal oxide materials.

[0099] Alternatively, the thermal energy used to oxidise and / or sinter the preheated metal ore material in the consolidation zone is caused by oxidation of the magnetite material itself, which provides thermal energy to the consolidation zone.

[0100] In this way it is achieved that the oxygen-rich oxidant introduced for heating the consolidation zone atmosphere does not have to be heated.

[0101] In this way it is achieved that the consolidation zone atmosphere does not have to be heated by, for example, gas burners or other types of burners.

[0102] In this way it is achieved that the metal oxide material can be produced in an energy-efficient manner.

[0103] In this way a carbon-free production of a metal oxide material is achieved which is resistant to further oxidation, since the use of the introduced oxygen-rich oxidant ensures that complete oxidation of the preheated metal ore material is achieved.

[0104] In this way efficient and rapid oxidation is achieved by having an oxygen-depleted process gas in the preheating zone atmosphere serve to avoid premature oxidation of the magnetite material in the preheating zone, while providing rapid and complete oxidation in the consolidation zone comprising a high oxygen content atmosphere.

[0105] Alternatively, the consolidation zone atmosphere of the consolidation zone is heated by a consolidation zone atmosphere gas burner device and / or a consolidation zone atmosphere electric heater device.

[0106] Alternatively, the metal ore material and the preheated metal ore material comprise iron ore material, and the metal oxide material comprises iron oxide material.

[0107] Alternatively, the preheated metal ore material comprises preheated iron ore pellets.

[0108] Alternatively, the metal oxide material comprises iron oxide pellets.

[0109] Alternatively, the metal oxide material comprises a metal oxide material body, and the metal oxide material body is a metal oxide pellet, a metal oxide sphere, or a metal oxide agglomerate block.

[0110] Alternatively, the control circuit is adapted to control the exothermic chemical reaction of oxidation of the preheated metal ore material for achieving a significant temperature gradient within the preheated metal ore material, thereby achieving energy efficient sintering of the metal ore material.

[0111] Alternatively, the control circuit is adapted to control the temperature of the consolidation zone atmosphere by adjusting the first gas burner means and / or the flow rate of oxygen-enriched oxidant introduced into the consolidation zone.

[0112] In this way it is achieved that the metal oxide material obtained has a predetermined quality characteristic, which is achieved by the fully oxidized metal oxide material resisting further oxidation during the transportation of the metal oxide material. The determined quality characteristic can be a predetermined density of the metal oxide material to be produced, the size of the metal oxide material bodies produced, the porosity of the metal oxide material, etc.

[0113] Alternatively, the control circuit is configured to control the temperature of the preheated metal ore material and / or the oxygen content of the oxygen-rich oxidant and / or the retention time for maintaining the preheated metal ore material in the consolidation zone and / or the oxygen-rich oxidant flow rate in the consolidation zone and / or the oxygen-rich oxidant pressure in the consolidation zone and / or the oxidation rate of the preheated metal ore material.

[0114] In this manner, metal oxide material production equipment can be optimized to produce metal oxide materials exhibiting uniform and high quality.

[0115] Alternatively, the control circuit is adapted to control the temperature of the consolidation zone atmosphere and / or the preheating zone atmosphere and / or the drying zone atmosphere of the drying zone.

[0116] Alternatively, the method comprises feeding process gas upwardly and downwardly through a bed of metal ore material in the preheating zone for providing efficient heat transfer to the metal ore material.

[0117] Alternatively, the control circuit is suitable for controlling the sintering of the preheated metal ore material in the preheating zone and / or consolidation zone by controlling the temperature of the process gas used to preheat the metal ore material and / or controlling the temperature of the consolidation zone atmosphere via a first hydrogen burner and / or controlling the temperature of the preheating zone atmosphere via a second hydrogen burner and / or by controlling the temperature of the oxygen-rich oxidant used to consolidate the preheated metal ore material.

[0118] Thus, it is achieved that the formed preheated metal ore material exhibits crystallographic properties.

[0119] In order to predict the optimal heat distribution to obtain a uniform high-quality metal oxide material body, the control circuit is adapted to control the metal oxide material production equipment according to specific parameters.

[0120] Specific parameters can be:

[0121] - the temperature of the process gas (the temperature of the oxygen-depleted process gas is controlled by means of an electric heater and / or a heat exchanger and / or a gas burner etc. suitable for heating the process gas and connected to a control circuit), and / or

[0122] - the temperature of the preheating zone atmosphere, and / or

[0123] - the temperature of the preheated metal ore material to be fed into the consolidation zone, and / or

[0124] - retaining the metal ore material in the preheating zone for a predetermined specific time taking into account the temperature of the consolidation zone atmosphere, by controlling the rate of a drive arrangement (which is coupled to the control circuit) configured to drive the metal ore material feed means, and / or

[0125] - the pressure and / or flow rate of the process gas in the preheating zone, via a process gas flow rate regulating device connected to the control circuit, and / or

[0126] - the temperature of the consolidation zone atmosphere (the temperature of the consolidation zone atmosphere is controlled by a gas burner, such as a hydrogen burner, suitable for heating the process gas and connected to the control circuit), and / or

[0127] - the temperature of the oxygen-enriched oxidant (the temperature of the oxygen-enriched oxidant is controlled by an electric heater and / or a heat exchanger and / or a gas burner etc. suitable for heating the oxygen-enriched oxidant and connected to the control circuit), and / or

[0128] - the temperature of the metal oxide material to be discharged from the consolidation zone by taking into account the oxidation rate of the magnetite material, and / or

[0129] - a retention time for retaining the preheated metal ore material in the consolidation zone during a predetermined specific time taking into account the temperature of the consolidation zone atmosphere, and / or

[0130] - the pressure and / or flow rate of the oxygen-rich oxidant in the consolidation zone, via a flow regulating device, and / or

[0131] - the oxidation rate of the magnetite material, by controlling the temperature of the atmosphere in the consolidation zone and / or the temperature of the oxygen-enriched oxidant and / or the temperature of the oxygen-enriched oxidant and / or the retention time of the preheated metal ore material in the consolidation zone, and / or the pressure and / or flow rate of the oxygen-enriched oxidant in the consolidation zone, by means of an oxygen-enriched oxidant flow regulating device.

[0132] Therefore, the oxidation of magnetite material to hematite material can be controlled in an efficient manner for producing high quality metal oxide material.

[0133] Alternatively, the oxygen-enriched oxidant and / or the preheated metal ore material is heated by means of a first gas burner means, for example by means of a first hydrogen burner means, for providing thermal energy to the oxygen-enriched oxidant and / or to the preheated metal ore material.

[0134] Alternatively, the oxygen-enriched oxidant obtains thermal energy by transferring recovered thermal energy from the exhausted metal oxide material.

[0135] Alternatively, the oxygen-enriched oxidant obtains thermal energy through a first electric heating device.

[0136] Alternatively, the method includes the step of transferring excess heat from the consolidation zone to a preheating zone.

[0137] Alternatively, a first gas burner arrangement in the consolidation zone is arranged to further heat the preheated metal ore material in the consolidation zone, the first gas burner arrangement being arranged to produce a controllable flame by mixing a fuel gas with an oxidant permissible for combustion.

[0138] Alternatively, the first gas burner arrangement is configured to provide additional thermal energy to the metal ore material undergoing oxidation.

[0139] Alternatively, the first gas burner arrangement comprises a first plurality of hydrogen burners.

[0140] Alternatively, the first plurality of hydrogen burners are configured to burn and / or heat preheated metal ore material in the consolidation zone, wherein oxidation of magnetite material to hematite material provides additional thermal energy to the consolidation zone atmosphere and / or to preheated metal oxide material to be discharged from the consolidation zone.

[0141] Alternatively, the metal ore material comprises magnetite material, and the step of oxidizing the preheated metal ore material comprises oxidizing the magnetite material to form hematite material, wherein the exothermic chemical reaction generates heat (thermal energy).

[0142] Alternatively, the exothermic chemical reaction generates heat and causes the hematite material to recrystallize and result in grain growth.

[0143] In this manner, providing heat energy by oxidizing magnetite material to hematite material is achieved, wherein the generated metal oxide material is managed by a control circuit to maintain a specific heat energy.

[0144] The heat-retaining metal oxide material may be charged (eg, directly) to a direct reduction facility after being discharged from the consolidation zone.

[0145] Alternatively, the heat energy can be recovered and reused by the metal oxide material production facility.

[0146] Alternatively, the step of introducing a process gas comprises introducing a heated oxygen-depleted process gas into the preheating zone for reducing or eliminating oxidation of the metallic ore material in the preheating zone prior to being fed into the consolidation zone.

[0147] In this way it is achieved that the metal ore material subjected to preheating and / or the preheated metal ore material is protected from oxidation before introduction into the consolidation zone.

[0148] The step of introducing an oxygen-rich oxidant into the consolidation zone for oxidizing the preheated metal ore material is achieved in such a way that the magnetite material is optimally and energy efficiently oxidized into hematite material, wherein an exothermic chemical reaction occurs fully in the consolidation zone by the oxygen-rich oxidant introduced into the consolidation zone.

[0149] In this manner, the exothermic chemical reaction that occurs sufficiently in the consolidation zone involves complete oxidation of the metal oxide material discharged from the consolidation zone, whereby the metal oxide material will not be re-oxidized when the metal oxide material is subjected to any oxygen-containing atmosphere, such as a cooling zone atmosphere in a cooling zone of a cooler device configured to cool the metal oxide material discharged from the consolidation zone.

[0150] In this manner, the high level of thermal energy provided by the oxidation of the magnetite material to the hematite material is confined to the consolidation zone, which in turn promotes efficient oxidation and / or sintering of the metallic ore material undergoing consolidation.

[0151] In this way it is achieved that the energy content of the magnetite material is preserved until the preheated metal ore material is exposed to the oxygen-rich oxidant in the consolidation zone.

[0152] Alternatively, the process gas obtains thermal energy by passing through a second gas burner arrangement configured to heat the process gas and / or the atmosphere of the preheating zone, for example by passing through a second hydrogen burner arrangement.

[0153] Alternatively, the process gas gains thermal energy by transferring recovered heat energy from the exhausted metal oxide material.

[0154] Alternatively, the process gas obtains thermal energy by passing through a second electric heating device.

[0155] Alternatively, the second gas burner arrangement comprises a second plurality of hydrogen burners.

[0156] Alternatively, the second plurality of hydrogen burners are configured to heat the iron ore material in the preheating zone.

[0157] Alternatively, the oxygen-rich oxidant comprises oxygen produced by an electrolysis unit.

[0158] Alternatively, the first gas burner arrangement and / or the second gas burner arrangement are configured to burn hydrogen produced by the electrolysis unit.

[0159] Alternatively, the electrolysis unit is configured to decompose water into hydrogen and oxygen.

[0160] Alternatively, hydrogen is fed from the electrolysis unit to the first hydrogen burner via a hydrogen conduit arrangement coupled between the electrolysis unit and the first gas burner arrangement and / or the second gas burner arrangement.

[0161] Alternatively, oxygen is fed from the electrolysis cell to the consolidation zone via an oxygen conduit arrangement coupled between the electrolysis cell and the consolidation zone.

[0162] Alternatively, the oxygen retains thermal energy generated by the electrolysis process carried out by the electrolysis unit, which thermal energy is added to the oxygen-enriched oxidant and / or the process gas.

[0163] Alternatively, the control circuit is coupled to the first gas flow regulator of the first gas burner assembly for controlling the thermal energy of the oxygen-enriched oxidant.

[0164] Alternatively, the control circuit is coupled to a second gas flow regulator of the second gas burner device for controlling the thermal energy of the process gas.

[0165] Alternatively, the control circuit is connected to the oxygen-enriched oxidant flow regulating device for controlling the flow of the oxygen-enriched oxidant entering the consolidation zone.

[0166] Alternatively, the control circuit is adapted to control the oxidation of the preheated metal ore material by means of an oxygen-rich oxidant flow regulating device for maintaining a high oxygen pressure during oxidation and / or sintering of the preheated metal ore material.

[0167] Alternatively, the control circuit is connected to the process gas flow regulating device to control the flow of the process gas entering the preheating zone.

[0168] Alternatively, the method further comprises the steps of: cooling the discharged metal oxide material by a cooler device; and transferring recovered heat energy from the discharged metal oxide material to the preheating zone.

[0169] Alternatively, the consolidation step of the preheated metal ore material is achieved by introducing an oxygen-rich oxidant by means of an oxidant introduction means.

[0170] Alternatively, the temperature of the oxygen-enriched oxidant is controlled by a control circuit coupled to a first electrical heating device configured to heat the oxygen-enriched oxidant.

[0171] Alternatively, the control circuit is connected to a second waste thermal energy fluid regulating device, which is configured to control the flow rate of a waste thermal energy fluid, wherein the waste thermal energy fluid contains recovered heat energy to be used in the preheating zone and / or the consolidation zone, and the recovered heat energy is recovered from the metal oxide material cooled by a cooler device, and the cooler device is configured to cool the metal oxide material discharged from the consolidation zone.

[0172] Alternatively, the step of preheating the metal ore material is achieved by a preheating zone heating device configured to introduce thermal energy into the preheating zone, wherein the preheating zone heating device is coupled to a second waste fluid conditioning device for increasing the thermal energy introduced by the preheating zone heating device.

[0173] Alternatively, the step of transferring recovered heat energy from the exhausted metal oxide material into the preheating zone and / or the consolidation zone comprises heating the oxygen-depleted process gas fed into the preheating zone and / or comprises heating the oxygen-enriched oxidant fed into the consolidation zone.

[0174] Alternatively, heating of the oxygen-enriched oxidant and / or process gas by recovery of thermal energy is provided by a heat exchange device.

[0175] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0176] In this way it is achieved that the preheated metal ore material retaining the thermal energy generated by the preheating zone will undergo an effective oxidation process in the consolidation zone.

[0177] Alternatively, the method further comprises the step of controlling, by a control circuit, an oxidation rate for oxidizing the preheated metal ore material into said metal oxide material.

[0178] Alternatively, the control circuitry is adapted to control the oxidation rate by adjusting the residence time or holding time that the preheated metal ore material remains in the consolidation zone.

[0179] Alternatively, the control circuit is adapted to control the oxidation process of the preheated metal ore material to said metal oxide material to reach a temperature of about 1100°C to 1500°C, preferably 1200°C to 1400°C.

[0180] Alternatively, the consolidation zone is divided into at least a first consolidation zone and a second consolidation zone.

[0181] Alternatively, the first consolidation zone is configured to receive a first oxygen-enriched oxidant stream, and the second consolidation zone is configured to receive a second oxygen-enriched oxidant stream.

[0182] Alternatively, the control circuit is adapted to control oxidation of the preheated metal ore material via a first oxygen-rich oxidant flow regulating device coupled to the control circuit for providing a first oxygen pressure during oxidation and / or sintering of the preheated metal ore material in the first consolidation zone.

[0183] Alternatively, the control circuit is adapted to control oxidation of the preheated metal ore material via a second oxygen-enriched oxidant flow regulating device coupled to the control circuit for providing a second oxygen pressure during oxidation and / or sintering of the preheated metal ore material in the second consolidation zone.

[0184] Alternatively, the first oxygen pressure is higher than the second oxygen pressure.

[0185] Alternatively, the consolidation zone includes a first volume configured to receive the first oxygen-enriched oxidant stream, and includes a second volume configured to receive the second oxygen-enriched oxidant stream, wherein the second volume has less oxygen than the first volume.

[0186] Alternatively, the control circuit is adapted to control oxidation of the metal ore material to metal oxide material, wherein the control circuit is configured to control that the metal oxide material discharged from the consolidation zone is fully oxidized during oxidation and / or sintering of the preheated metal ore material.

[0187] This promotes energy-saving processes and simplified design of process systems, wherein there is no subsequent oxidation of magnetite in the cooler unit.

[0188] Alternatively, the control circuit is configured to control cooling of the exhausted metal oxide material.

[0189] Alternatively, the metal ore material is in the form of so-called green pellets.

[0190] Alternatively, the metal ore material may have been processed in several steps before being loaded onto the metal ore material feeding means moving through the preheating zone and the consolidation zone for providing so called green pellets to be introduced into the preheating zone.

[0191] Alternatively, so-called green pellets consist of relatively large amounts of water, magnetite and different additives selected to suit the customer's requirements.

[0192] These or at least one of the purposes have been achieved by a metal oxide material production device, which includes: a preheating zone, which is configured to preheat the metal ore material into a preheated metal ore material; a process gas introduction device, which is connected to the preheating zone and configured to introduce process gas into the preheating zone; a consolidation zone, which is configured to consolidate the preheated metal ore material into the metal oxide material; an oxidant introduction device, which is connected to the consolidation zone and configured to introduce oxygen-rich oxidant into the consolidation zone configured to oxidize the preheated metal ore material into the metal oxide material; and a control circuit, which is configured to control the consolidation of the metal ore material into the metal oxide material.

[0193] Alternatively, the metal oxide material production apparatus comprises a metal ore material feeding device configured to feed the metal ore material into the preheating zone.

[0194] Alternatively, the metal ore material feeding means is configured for feeding preheated metal ore material into the consolidation zone.

[0195] Alternatively, the metal ore material feeding means is configured for feeding metal oxide material from the consolidation zone to the cooler means.

[0196] Alternatively, the oxidant introduction device in the consolidation zone is connected to the control circuit.

[0197] Alternatively, the second electric heating device is configured to heat a process gas to be introduced into the preheating zone and / or to heat the metal ore material fed into the preheating zone.

[0198] Alternatively, the metal ore material feed means forms a common feed means extending through the metal oxide material production plant.

[0199] Alternatively, the oxidant introduction device is connected to a consolidation zone configured to oxidize and / or sinter the preheated metal ore material into the metal oxide material, and the magnetite material in the preheated metal ore material is oxidized into hematite material in the consolidation zone, causing an exothermic chemical reaction of the preheated metal ore material undergoing oxidation and / or sintering to generate heat energy.

[0200] Alternatively, magnetite material in the preheated metal ore material is oxidized to form hematite material in the consolidation zone, provided that the hematite material will effectively recrystallize to provide high quality metal oxide material to be discharged from the consolidation zone.

[0201] Alternatively, the exothermic chemical reaction provides heat energy transfer from the preheated metal ore material undergoing oxidation and / or sintering to the consolidation zone atmosphere of the consolidation zone.

[0202] Alternatively, consolidation of the magnetite material causing an exothermic chemical reaction includes oxidation, sintering and heat transfer, which may occur simultaneously and which may affect each other in the consolidation zone.

[0203] Alternatively, the preheating zone comprises at least one process gas introduction arrangement.

[0204] Alternatively, the process gas introduction arrangement comprises a second burner arrangement and / or a second electric heating arrangement configured to heat the process gas.

[0205] Alternatively, the process gas introduction arrangement comprises heat recovery and feed means.

[0206] Alternatively, the metal oxide material production apparatus includes a cooler device configured to cool the metal oxide material discharged from the consolidation zone.

[0207] Alternatively, the heat recovery and feed apparatus is configured to recover heat energy from the discharged metal oxide material and feed the recovered heat energy to the preheating zone and / or the consolidation zone.

[0208] Alternatively, the heat recovery and feed device is coupled to a cooler device.

[0209] Alternatively, the heat recovery and feed device comprises a heat exchange unit and a fluid line arrangement coupled to the cooler device.

[0210] Alternatively, the cooler means includes a cooling zone for providing a cooling zone atmosphere, the cooling zone atmosphere being provided for cooling the metal oxide material retaining heat energy exhausted from the consolidation zone.

[0211] Alternatively, the cooler device is configured to recover thermal energy from the metal oxide material (retaining thermal energy) discharged from the consolidation zone into the cooler device, wherein the heat exchange unit is configured to exchange the recovered thermal energy for thermal energy of a waste thermal energy fluid that is transferred from the cooler device to the preheating zone and / or the consolidation zone.

[0212] Alternatively, the heat recovery and feed means comprises a first heat transfer means configured to transfer recovered thermal energy from the metal oxide material to the consolidation zone.

[0213] Alternatively, the heat recovery and feed means comprises a second heat transfer means configured to transfer recovered heat energy from the metal oxide material to the preheating zone.

[0214] Alternatively, the metal ore material includes lime, shale, bentonite or other materials.

[0215] Alternatively, the drying zone is configured to dry the moist metal ore material at a temperature of about 50°C to 250°C, preferably 100°C to 200°C.

[0216] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 300°C to 750°C, preferably 400°C to 650°C.

[0217] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C.

[0218] Alternatively, the consolidation zone is configured to sinter the preheated metallic ore material at a temperature of about 750°C to 1350°C.

[0219] In this way, spheroidization of the preheated metal ore material in the consolidation zone is achieved, including transformation of its structure into a spherical form, achieving solid diffusion.

[0220] Alternatively, the control circuitry is adapted to control the spheroidisation of the preheated metal ore material in the consolidation zone by adjusting the residence time and temperature of the metal ore material undergoing consolidation.

[0221] Alternatively, the effects of time, temperature, lime content, ore type, shale content and particle size distribution are parameters controlled by the control circuit.

[0222] In this way it is achieved that the residence time of the preheated metal ore material in the consolidation zone can be short, since the oxygen-rich oxidant will lead to rapid oxidation of the magnetite, and the exothermic reaction provides for the high temperature that the metal oxide material will exhibit after consolidation.

[0223] Such shortened residence times also facilitate the design of smaller and less complex metal oxide material production equipment.

[0224] Alternatively, the control circuit is configured to control the degree of oxidation and / or sintering of the preheated metal ore material by adjusting the temperature and oxygen content of the oxygen-rich oxidant.

[0225] Alternatively, the control circuit is configured to control oxidation of the magnetite to occur rapidly in the first consolidation zone having a higher temperature than the second consolidation zone, while the degree of oxidation increases to a lesser extent in the second consolidation zone.

[0226] Alternatively, a gas burner increases the temperature in the second consolidation zone.

[0227] Alternatively, the metal oxide material production equipment includes a belt roaster furnace or a chain grate rotary kiln furnace.

[0228] Alternatively, a separation barrier is arranged between the preheating zone and the consolidation zone to separate the atmosphere of the preheating zone from the atmosphere of the consolidation zone, so as to prevent the oxygen-depleted process gas from mixing with the oxygen-rich oxidant.

[0229] Alternatively, the separation barrier may be achieved by controlled pressurization of the preheating zone atmosphere and the consolidation zone atmosphere, or may be a wall having an opening through which a feed arrangement, such as a feed belt, extends.

[0230] These or at least one of the objectives have been achieved by a metal oxide material production configuration, which includes: an electrolysis unit, which is configured to decompose water into oxygen and hydrogen; and an electrical energy generation device, which is configured to produce regeneratively produced electrical energy that is fed to the electrolysis unit.

[0231] Alternatively, the metal oxide material production facility includes an oxygen-enriched oxidant fluid line coupled between the consolidation zone and the electrolysis unit and configured to transfer the oxygen-enriched oxidant from the electrolysis unit to the consolidation zone.

[0232] Alternatively, the oxygen-enriched oxidant fluid line comprises a process gas fan unit or blower unit for providing the desired flow rate of oxygen-enriched oxidant introduced into the consolidation zone.

[0233] In this manner, there is an efficient method to utilize oxygen produced by an electrolysis cell that also produces hydrogen for various applications and uses, such as in a direct reduction facility configured for reducing metal oxide materials that retain thermal energy.

[0234] Alternatively, the control circuit is adapted to control the flow of process gas in the preheating zone via a process gas flow regulator coupled to the control circuit until a sufficient temperature is reached to effectively preheat the metal ore material but not to an extent that the metal oxide material is oxidized.

[0235] Alternatively, the control circuit is adapted to control the oxygen-enriched oxidant flow regulating means of the oxidant introduction means for providing efficient oxidation of the preheated metal ore material.

[0236] Alternatively, the oxygen-enriched oxidant flow rate regulating means of the oxidant introduction means comprises a process gas fan unit or a blower unit electrically connected to the control circuit for controlling the desired flow rate of the oxygen-enriched oxidant introduced into the consolidation zone.

[0237] Alternatively, the control circuit is suitable for controlling a metal ore material feeding device configured to feed the metal ore material through a preheating zone and / or a consolidation zone to achieve an effective temperature for oxidation of the metal ore material and until a sufficient temperature is reached for effectively preheating the metal ore material but not to such an extent that the metal oxide material is oxidized.

[0238] Alternatively, the control circuit is electrically connected to the preheating zone temperature sensor component and to the process gas flow rate regulating device to control the flow rate of the process gas entering the preheating zone.

[0239] Alternatively, the control circuit is electrically connected to the second gas burner for adjusting the temperature of the atmosphere in the preheating zone.

[0240] Alternatively, the preheating zone temperature sensor member is configured to detect the temperature of the preheating zone atmosphere through the control circuit.

[0241] Alternatively, the control circuit is suitable for controlling the temperature of the preheating zone atmosphere by controlling the process gas flow regulation device and / or the second gas burner device towards at least one specific parameter of the preheating zone atmosphere, such as a specific temperature, which specific temperature causes the metal ore material to be effectively preheated but not sintered before being fed into the consolidation zone.

[0242] Alternatively, the control circuit is electrically connected to the consolidation zone temperature sensor component and to the oxygen-enriched oxidant flow rate regulating device for controlling the flow rate of the oxygen-enriched oxidant entering the consolidation zone.

[0243] Alternatively, the control circuit is electrically connected to the first gas burner for adjusting the temperature of the consolidation zone atmosphere.

[0244] Alternatively, the consolidation zone temperature sensor member is configured to detect the temperature of the consolidation zone atmosphere through the control circuit.

[0245] Alternatively, the control circuit is suitable for controlling the temperature of the consolidation zone atmosphere by controlling the oxygen-enriched oxidant flow regulating device and / or the first gas burner device towards at least one specific parameter of the consolidation zone atmosphere, such as a specific temperature, which causes the metal ore material to be oxidized and sintered throughout the thickness of the metal ore material bed before being discharged from the consolidation zone.

[0246] These or at least one of the purposes has been achieved by a method for producing iron ore oxide material with the aid of an iron ore oxide material production device, the iron ore oxide material production device comprising a preheating zone, the preheating zone being configured to preheat the iron ore material into a preheated iron ore material, and the iron ore oxide material production device comprising a consolidation zone, the consolidation zone being configured to consolidate (oxidize and / or sinter) the preheated iron ore material into the iron ore oxide material.

[0247] Alternatively, the iron ore oxide material production facility comprises a process gas introduction device configured to introduce a process gas into the preheating zone for preheating the iron ore oxide material.

[0248] Alternatively, the iron ore oxide material production apparatus comprises an oxidant introduction device configured to introduce an oxygen-rich oxidant into the consolidation zone for oxidizing the preheated iron ore oxide material into the iron ore oxide material.

[0249] Alternatively, the iron ore oxide material production facility comprises a control circuit connected to the process gas introduction device and to the oxidant introduction device for controlling the preheating of the iron ore oxide material and for controlling the oxidation of the preheated iron ore oxide material.

[0250] Alternatively, the iron ore oxide material production plant comprises: a feeding device comprising a feeding arrangement configured for feeding the iron ore material into the preheating zone and further through the consolidation zone.

[0251] Alternatively, the feeding device is configured to feed the iron ore material produced by the sorting-enrichment-pulp rolling device into the preheating zone.

[0252] Alternatively, the sorting-enriching-slurry rolling apparatus includes a grinding purification station for removing silicon, sodium, phosphorus, apatite, etc. from the raw iron ore raw material to provide an iron ore material.

[0253] Alternatively, the sorting-enriching-slurry rolling apparatus comprises a slurry rolling drum for producing "green pellets" comprising the iron ore material to be fed into a preheating zone.

[0254] Alternatively, the iron ore material formed into "green pellets" exhibits a diameter of about, for example, 5 mm to 25 mm.

[0255] Alternatively, the iron ore material contains magnetite material (iron oxide compound), and may also contain other iron ore raw materials such as limonite, siderite, and the like.

[0256] Alternatively, the iron ore material comprises iron oxide compounds, such as a magnetite material.

[0257] Alternatively, the iron ore material comprises iron oxide compounds, such as a hematite material.

[0258] Alternatively, advantageously, the iron ore material comprising iron oxide compounds is preheated in a preheating zone comprising a preheating zone atmosphere fed with a process gas which is an oxygen-depleted process gas comprising about 0% to 21% by volume oxygen.

[0259] Alternatively, the process gas is an oxygen-depleted process gas, which contains about 0 vol% to 5 vol% oxygen, preferably about 1 vol% to 4 vol% oxygen.

[0260] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0261] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0262] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0263] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0264] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0265] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0266] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0267] Alternatively, the iron ore oxide material production plant comprises a cooler arrangement configured to cool the iron ore oxide material (ie the oxidised preheated iron ore material).

[0268] Alternatively, the iron ore oxide material production plant comprises a control circuit adapted to control an oxidation process arranged to oxidise the preheated iron ore material.

[0269] Alternatively, the control circuit is adapted to control an oxidation temperature and a holding time for oxidation.

[0270] Alternatively, the control circuitry is adapted to control an oxidation temperature and a hold time for oxidizing the preheated iron ore material to form iron ore oxide material in the consolidation zone.

[0271] Alternatively, the oxidation temperature required to oxidize the preheated iron ore material is controlled by a control unit depending on the actual mineralogy of the iron ore material.

[0272] Alternatively, the retention time required to oxidize the metallic ore material in the consolidation zone is controlled by the control unit based on the actual mineralogy of the iron ore material.

[0273] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0274] Alternatively, the control circuit is adapted to control the oxidation process for oxidizing the preheated metal ore material to said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0275] Alternatively, the drying zone is configured to dry the moist metal ore material at a temperature of about 100°C to 500°C, preferably 200°C to 400°C.

[0276] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0277] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0278] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0279] Alternatively, the feeding arrangement comprises a travelling grate device configured to move the iron ore material through the preheating zone and further through the consolidation zone.

[0280] Alternatively, the feed arrangement comprises a travelling grate arrangement configured to move the iron ore material through the preheating zone, and the feed arrangement further comprises a rotary kiln configured to oxidize and sinter the preheated iron ore material and move the preheated iron ore material subjected to consolidation from the preheating zone to the cooler arrangement.

[0281] Alternatively, the feeding arrangement comprises a travelling grate arrangement configured to move the iron ore material through the preheating zone and further through the post-burning zone for oxidising the preheated iron ore material, and further the feeding arrangement comprises a rotary kiln configured to oxidise the preheated iron ore material undergoing consolidation.

[0282] Alternatively, the consolidation zone comprises a travelling grate arrangement located in a post-firing zone and includes a rotary kiln.

[0283] Alternatively, the control circuitry is adapted to control the retention time required to oxidise the metallic ore material in the consolidation zone material by adjusting the rate at which a travelling grate means of the feed arrangement is advanced.

[0284] Alternatively, a traveling grate speed sensor is electrically connected to the control circuit for sensing the speed of the traveling grate device.

[0285] Alternatively, a temperature sensor is electrically coupled to the control circuitry for sensing the temperature of the preheated iron ore material undergoing consolidation and / or the temperature of the produced iron ore oxide material exiting the consolidation zone.

[0286] Alternatively, the control circuit is adapted to regulate the temperature of the preheated iron ore material undergoing consolidation and the rate of travel of the grate means according to a predetermined consolidation (oxidation) parameter value taking into account the actual rate (holding time) and said temperature.

[0287] Alternatively, the travelling grate device is mechanically coupled to a drive motor for driving the travelling grate device at a certain rate taking into account the predetermined consolidation (oxidation) parameter value.

[0288] In this way, the control circuit is configured to control the oxidation of the preheated iron ore material into the iron ore oxide material by adjusting the retention time and temperature of the preheated iron ore material undergoing oxidation in the consolidation zone.

[0289] The expression "metal oxide material" may be replaced by the expression "iron ore oxide material".

[0290] The expression "metal oxide material production equipment" may be replaced by the expression "iron ore oxide material production equipment".

[0291] The expression "metal ore material" may be replaced by the expression "iron ore material".

[0292] The expression "process gas" can be replaced by the expression "oxygen-depleted process gas".

[0293] The present disclosure may not be limited to the examples described above, but many possibilities of modifications or combinations of the examples described herewith will be apparent to a person skilled in the art without departing from the basic idea as defined in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0294] In the following, the invention will be described with reference to examples and the accompanying schematic drawings, wherein some unimportant details may be omitted from the drawings for the sake of clarity and understanding of the invention.

[0295] Figure 1 A metal oxide material production apparatus according to a first example is shown;

[0296] Figure 2 A metal oxide material production apparatus according to a second example is shown;

[0297] Figure 3 A metal oxide material production apparatus according to a third example is shown;

[0298] Figures 4a to 4c A metal oxide material production apparatus according to a fourth example is shown;

[0299] Figure 5 A metal oxide material production apparatus according to a fifth example is shown;

[0300] Figure 6 A metal oxide material production apparatus according to a sixth example is shown;

[0301] Figure 7 A metal oxide material production apparatus according to a seventh example is shown;

[0302] Figures 8 to 9 A flow chart showing an exemplary method of producing a metal oxide material is shown;

[0303] Fig.10 shows a control circuit for an exemplary metal oxide material production apparatus; and

[0304] Fig.11a and Fig.11b Further examples of iron ore oxide material production facilities are shown. DETAILED DESCRIPTION

[0305] Figure 1A metal oxide material production apparatus 3 is shown, the metal oxide material production apparatus 3 comprising a preheating zone 8, the preheating zone 8 being configured to preheat a metal ore material 2 into a preheated metal ore material 4. The metal oxide material production apparatus 3 further comprises: a process gas introduction device 6 connected to the preheating zone 8, which is configured to introduce a process gas 7 into the preheating zone 8; a consolidation zone 10, which is configured to consolidate the preheated metal ore material 4 into the metal oxide material 5; and an oxidant introduction device 12 connected to the consolidation zone 10, which is configured to introduce an oxygen-rich oxidant 14 into the consolidation zone 10. The oxygen-rich oxidant 14 (e.g., pure oxygen produced by an electrolysis unit 15) is configured to oxidize the preheated metal ore material 4 into the metal oxide material 5. The metal oxide material production apparatus 3 further comprises a control circuit 50, the control circuit 50 being configured to control the consolidation of the metal ore material 2 into the metal oxide material 5. The metal oxide material production apparatus 3 further comprises a feed belt 20 configured for feeding the metal ore material 2 into the preheating zone 8 and further into the consolidation zone 10 .

[0306] The control circuit 50 is adapted to control the oxidation of the preheated metal ore material 4 in the consolidation zone 10 through an oxygen-enriched oxidant flow regulating device (not shown) of the oxidant introduction device 12. The oxidant introduction device 12 is coupled to the control circuit 50 for providing a desired oxygen pressure in the consolidation zone 10 during oxidation and / or sintering of the preheated metal ore material 4 in the consolidation zone 10. The control circuit 50 is configured to control the flow of the oxygen-enriched oxidant 14 entering the consolidation zone 10 via the oxidant introduction device 12.

[0307] The control circuit 50 may be adapted to control at least one specific parameter of the method of consolidating the metal ore material 2 into the metal oxide material 5 by the metal oxide material production apparatus 3 .

[0308] Specific parameters can be:

[0309] - the temperature of the process gas (the temperature of the oxygen-depleted process gas is controlled by an electric heater and / or a heat exchanger and / or a second gas burner etc. suitable for heating the process gas and connected to the control circuit 50), and / or

[0310] - the temperature of the preheating zone atmosphere, and / or

[0311] - the temperature of the preheated metal ore material to be fed into the consolidation zone, and / or

[0312] - retaining the metal ore material in the preheating zone 8 for a predetermined specific time taking into account the temperature of the consolidation zone atmosphere, by controlling the speed of a drive motor (not shown) adapted to drive the feed belt 20, said drive motor being coupled to the control circuit 50, and / or

[0313] - the pressure and / or flow rate of the process gas in the preheating zone 8, via a process gas flow rate regulating device (not shown) of the process gas introduction device 6 connected to the control circuit 50, and / or

[0314] - the temperature of the consolidation zone atmosphere (the temperature of the consolidation zone atmosphere is controlled by a first gas burner, such as a hydrogen burner 60, adapted to heat the consolidation zone atmosphere and connected to the control circuit 50), and / or

[0315] - the temperature of the oxygen-enriched oxidant (the temperature of the oxygen-enriched oxidant is controlled by an electric heater and / or a heat exchanger and / or a gas burner etc. suitable for heating the oxygen-enriched oxidant and connected to the control circuit 50), and / or

[0316] - the temperature of the metal oxide material to be discharged from the consolidation zone by taking into account the oxidation rate of the magnetite material, and / or

[0317] - a retention time for retaining the preheated metal ore material in the consolidation zone 10 during a predetermined specific time taking into account the temperature of the consolidation zone atmosphere, and / or

[0318] - the pressure and / or flow rate of the oxygen-enriched oxidant in the consolidation zone 10, through an oxygen-enriched oxidant flow rate regulating device (not shown) of the oxidant introduction device 12, and / or

[0319] - the oxidation rate of the magnetite material, by controlling the temperature of the consolidation zone atmosphere and / or the temperature of the oxygen-rich oxidant and / or the temperature of the oxygen-rich oxidant and / or the retention time of the preheated metal ore material in the consolidation zone 10, and / or the pressure and / or flow rate of the oxygen-rich oxidant in the consolidation zone 10, through the oxygen-rich oxidant flow regulating device.

[0320] Therefore, the oxidation of magnetite material to hematite material can be controlled to achieve high quality metal oxide material.

[0321] The oxidant introduction device 12 may include a first electric heater (not shown) configured to heat the oxygen-rich oxidant to be introduced into the consolidation zone 10, wherein the first electric heater is coupled to the control circuit 50 for controlling the temperature of the consolidation zone atmosphere.

[0322] The process gas introduction device 6 of the metal oxide material production equipment 3 is connected to the control circuit 50 to control the flow rate of the process gas 7 fed into the preheating zone 8. The process gas 7 can be heated by a second electric heater (not shown) of the process gas introduction device 6 to heat the preheating zone atmosphere. The second electric heater can be connected to the control circuit 50 to control the temperature of the preheating zone atmosphere of the preheating zone 8.

[0323] The process gas 7 constitutes an oxygen-depleted process gas and is fed from a process gas supply 9. The electrolysis unit 15 and / or the process gas supply 9 may be connected to a control circuit 50 for controlling the gas production.

[0324] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with an oxygen-depleted process gas.

[0325] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0326] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0327] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0328] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0329] The metal oxide material production apparatus 3 further comprises a metal ore material bed applicator (not shown) configured to apply the metal ore material onto a feed belt 20 for feeding a bed of the metal ore material through the preheating zone 8 and the consolidation zone 10 .

[0330] The oxygen-enriched oxidant 14 may be fed upwardly and downwardly through the bed of metal ore material undergoing consolidation in the consolidation zone 10 for providing efficient heat transfer to the metal ore material undergoing consolidation in the consolidation zone 10 .

[0331] Oxygen-rich oxidant 14 , such as pure oxygen, for example produced by an electrolysis unit 15 .

[0332] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0333] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0334] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0335] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0336] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0337] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0338] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0339] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0340] The process gas 7 may be fed upwardly and downwardly through the bed of metal ore material undergoing preheating in the preheating zone 8 for providing efficient heat transfer to the metal ore material undergoing preheating in the preheating zone 8 .

[0341] Introducing an oxygen-depleted process gas into the preheating zone 8 reduces or eliminates the risk of oxidation of the preheated metal ore material 4 in the preheating zone 8 before being fed into the consolidation zone 10 .

[0342] Preheating of the metal ore material in an oxygen-depleted preheating atmosphere involves virtually no oxidation of the metal ore material. By saving reactivity for oxidizing the metal ore material, effective oxidation can now be achieved in the consolidation zone, where effective and complete oxidation occurs.

[0343] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0344] Alternatively, the control circuit is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0345] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0346] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0347] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0348] Figure 1 Also shown is a metal oxide material production arrangement 71, comprising an electrolysis unit 15 configured to decompose water into oxygen and hydrogen, and an electrical energy production device 76 configured to produce regeneratively produced electrical energy that is fed to the electrolysis unit 15. The metal oxide material production device 3 comprises an oxygen-rich oxidant fluid line 73 coupled between the consolidation zone 10 and the electrolysis unit 15 and configured to transfer the oxygen-rich oxidant 14 from the electrolysis unit 15 to the consolidation zone 10.

[0349] In this manner, there is an efficient method to utilize oxygen produced by an electrolysis unit that also produces hydrogen for various applications and uses, such as in a direct reduction facility configured for reducing metal oxide materials that retain thermal energy.

[0350] Figure 2 A metal oxide material production plant 3 according to a second example is shown. Ore metal concentrate is mixed with a binder component, moisture and other suitable process components for producing green pellets (wet metal ore material). In order to dry the wet metal ore material (not shown) and to provide the metal ore material 2 with increased strength before feeding the metal ore material 2 into the preheating zone 8 of the metal oxide material production plant 3, the wet metal ore material is dried in a drying zone 44 including a down-flowing process gas zone and / or an up-flowing process gas zone (not shown). Thus, the drying zone 44 is configured to dry the wet metal ore material for providing the metal ore material 2 to be fed into the preheating zone 8.

[0351] The preheating zone 8 is configured to preheat the metal ore material 2 into a preheated metal ore material 4 to be fed into the consolidation zone 10 of the metal oxide material production facility 3 .

[0352] The process gas introduction device 6 is connected to the preheating zone 8 for introducing the oxygen-depleted process gas 7. The process gas introduction device 6 is configured to heat the oxygen-depleted process gas 7 by an electric heating device (not shown) or by any suitable heating means. Introducing the oxygen-depleted process gas 7 into the preheating zone 8 reduces or eliminates the possibility of oxidation of the preheated metal ore material 4 in the preheating zone 8 before being fed into the consolidation zone 10.

[0353] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with an oxygen-depleted process gas.

[0354] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0355] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0356] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0357] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0358] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0359] Alternatively, the control circuit (not shown) is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0360] Alternatively, the drying zone is configured to dry the moist metal ore material at a temperature of about 100°C to 500°C, preferably 200°C to 400°C.

[0361] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0362] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0363] The consolidation zone 10 of the metal oxide material production plant 3 is configured for consolidating the preheated metal ore material 4 into a metal oxide material 5 which is subsequently fed into a cooler 18 of the metal oxide material production plant 3 .

[0364] The oxidant introduction device 12 is coupled to the consolidation zone 10 and is configured to introduce an oxygen-enriched oxidant 14 into the consolidation zone 10. The oxygen-enriched oxidant 14 may include pure oxygen or any content of oxygen ranging from about 20% to 100% by volume.

[0365] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0366] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0367] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0368] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0369] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0370] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0371] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0372] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0373] The feeding device 20 comprises a feeding arrangement 21 configured for feeding the metal ore material 2 into the preheating zone 8 and further through the consolidation zone 10 and subsequently into the cooler 18 .

[0374] A separation barrier 26 is arranged between the preheating zone 8 and the consolidation zone 10 and separates the preheating zone atmosphere from the consolidation zone atmosphere to prevent the oxygen-depleted process gas 7 from mixing with the oxygen-rich oxidant 14. The separation barrier 26 may be realized by controlling the pressurization of the preheating zone atmosphere and the consolidation zone atmosphere, or may be a wall with an opening through which the feed arrangement 21 (e.g., a feed belt) extends.

[0375] Alternatively, the oxygen-enriched oxidant and / or the preheated metal ore material is heated by a first gas burner arrangement (not shown) for providing thermal energy to the oxygen-enriched oxidant and / or to the preheated metal ore material 4 in the consolidation zone atmosphere.

[0376] The cooler 18 is configured to cool the metal oxide material 5 discharged from the consolidation zone 10, and includes a heat recovery and feed device 30 (the heat recovery and feed device 30 is configured to recover heat energy from the metal oxide material 5 that retains the heat energy obtained through the preheating and oxidation processes), and is configured to feed the recovered heat energy back to the preheating zone 8 via a waste heat energy fluid pipeline 31.

[0377] The heat recovery and feed device 30 comprises a heat exchange unit 40 configured to transfer heat energy from the metal oxide material 5 to a waste heat energy absorbing fluid fed through the waste heat energy fluid line 31 .

[0378] The waste heat energy fluid pipeline 31 is connected between the heat exchange unit 40 and the preheating zone 8 and / or the consolidation zone 10, and is configured to transfer the thermal energy of the process fluid carrying waste heat from the heat exchange unit 40 to the preheating zone 8 and / or the consolidation zone 10 for heating the process gas 7 and / or the oxygen-enriched oxidant 14. The heat exchange unit 40 is connected to an atmosphere gas fluid supply source 42, which is configured to feed the fluid that absorbs the waste heat energy through the heat exchange unit 40.

[0379] The cooler 18 comprises a cooling zone 33 exhibiting a cooling zone atmosphere from which a heat exchange unit 40 recovers heat energy from the metal oxide material 5 undergoing cooling. The cooled metal oxide material 5 is transferred to a pile 46 of metal oxide materials.

[0380] Figure 3 There is shown a metal ore material 4 comprising magnetite material moving through a preheating zone 8 of a metal oxide material production apparatus 3 and further through a consolidation zone 10. The atmosphere of the preheating zone 8 is heated for preheating the metal oxide material 2 comprising magnetite material fed into the preheating zone 8.

[0381] The introduction of oxygen-depleted process gas 7 into the preheating zone 8 via the process gas introduction device 6 reduces or eliminates the possibility of oxidation of the magnetite material of the preheated metal ore material 4 in the preheating zone 8 before being fed into the consolidation zone 10 .

[0382] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with an oxygen-depleted process gas.

[0383] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0384] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0385] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0386] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0387] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0388] Alternatively, the control circuit (not shown) is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0389] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0390] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0391] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0392] Oxidizing the preheated metal ore material 4 in the consolidation zone 10 involves oxidizing the magnetite material to the hematite material, providing an exothermic chemical reaction that generates heat and recrystallizes the hematite, producing the metal oxide material 5 .

[0393] An oxidant introduction device 12 is coupled to the consolidation zone 10 and is configured to introduce an oxygen-rich oxidant 14 (eg, an oxygen-containing process gas having about 50% oxygen by volume) into the consolidation zone 10. An oxidant supply source 15 is coupled to the oxidant introduction device 12.

[0394] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0395] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0396] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0397] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0398] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0399] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0400] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0401] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0402] Figures 4a to 4c A metal material production device 3 is shown, which includes: a preheating zone 8, which is configured to preheat the metal ore material 2 for providing a preheated metal ore material 4; and a consolidation zone 10, which is configured to consolidate the preheated metal ore material 4 into a metal oxide material 5. Figures 4a to 4c The energy flows and temperatures shown in exemplify the principle of recovering thermal energy from oxidizing the magnetite material of the metal ore material 2 to the hematite material of the metal oxide material 5 .

[0403] The process gas introduction device 6 is configured for introducing oxygen-depleted process gas 7 into the preheating zone 8. The process gas introduction device 6 may include a heating arrangement H including a process start-up heater and / or a supplementary heater and / or a recovery heat energy inlet for preheating the metal ore material 2 in the preheating zone 8.

[0404] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with an oxygen-depleted process gas.

[0405] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0406] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0407] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0408] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0409] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0410] Alternatively, the control circuit 50 is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0411] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0412] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0413] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0414] The consolidation zone 10 is configured to consolidate the preheated metal ore material 4 into the metal oxide material 5 by means of an oxygen-enriched oxidant 14 via an oxygen agent introduction device 12, which is coupled to the consolidation zone 10 and configured to introduce the oxygen-enriched oxidant 14 from an oxidant supply source 15 into the consolidation zone 10. The oxygen-enriched oxidant 14 is introduced into the consolidation zone 10 for oxidizing and / or sintering the preheated metal ore material 4.

[0415] Oxygen-rich oxidant 14 , such as pure oxygen, for example produced by an electrolysis unit 15 .

[0416] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0417] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0418] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0419] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0420] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0421] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0422] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0423] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0424] The consolidation zone 10 may be part of a belt roaster furnace, wherein a feed belt moves the preheated metal ore material 4 through the consolidation zone 10 .

[0425] The consolidation zone may be a grate for oxidation and a portion of a kiln configured to sinter the metallic ore material.

[0426] The magnetite material of the preheated metal ore material 4 is oxidized to hematite in the consolidation zone 10, causing an exothermic chemical reaction that produces thermal energy of the oxidized preheated metal ore material 4, wherein the hematite will recrystallize, and then the metal oxide material 5 is discharged from the consolidation zone 10 and transferred to the cooler 18.

[0427] Figure 4a Schematically shown is the start-up of a metal oxide material production plant 3 for producing a cooled metal oxide material 5. Metal ore material 2 (green pellets) maintaining a first specific heat energy (kJ / kgK) is fed into a preheating zone 8. The metal ore material 2 is preheated to a second specific heat energy (kJ / kgK) in the preheating zone 8 by an electric heater and / or a gas burner (not shown) of a heating arrangement H. A third specific heat energy (kJ / kgK) is added to the preheating zone 8.

[0428] The magnetite material of the preheated metal ore material 4, which retains the second specific heat energy (kJ / kgK), is fed into the consolidation zone 10 and will be oxidized and / or sintered in the consolidation zone 10, wherein a fourth specific heat energy (kJ / kgK) is added to the second specific heat energy (kJ / kgK) due to the exothermic chemical reaction of the magnetite material being converted into hematite material. The obtained metal oxide material 5 now retains a fifth specific heat energy (kJ / kgK) due to the oxidation and is transferred to the cooler 18.

[0429] The sixth specific heat energy (kJ / kgK) is recovered from the discharged metal oxide material 5 by the cooler 18 and fed back to the preheating zone 8 by the process fluid. The cooled metal oxide material 5 retaining a heat energy substantially similar to the first specific heat energy (kJ / kgK) is discharged from the cooler 18. The recovery of heat energy is repeated during the production of the metal oxide material 5.

[0430] Figure 4bIt is shown in Figure 5 that the metal oxide material 5 maintaining the fifth specific heat energy (kJ / kgK) is directly charged into the direct reduction facility 100. The metal oxide material 5 is fed to the direct reduction facility 100 without being cooled or cooled to a certain extent, wherein the heating arrangement H must be put into operation for heating the preheating zone 8 for preheating the metal ore material 4 to be fed into the consolidation zone 10.

[0431] In the consolidation zone 10, the preheated metal ore material is oxidized and, through an exothermic chemical reaction of the magnetite material being converted into the hematite material, a fourth specific heat energy (kJ / kgK) is added to the preheated metal ore material 4. The obtained metal oxide material 5 retains a fifth specific heat energy (kJ / kgK) and is charged to the direct reduction facility 100 substantially without any step of cooling the metal oxide material 5 discharged from the consolidation zone 10.

[0432] Figure 4c 1 shows a metal oxide material production device 3, which is configured to direct the production of metal oxide material 5 towards the production of cooled metal oxide material through a cooler 18 and / or towards charging the produced metal oxide material 5 maintaining the fifth specific heat energy (kJ / kgK) into the direct reduction facility 100. In the case where a selected amount of metal oxide material 5 maintaining the fifth specific heat energy (kJ / kgK) is to be charged into the direct reduction facility 100, the heat energy recovered by the cooler 18 must be added to the heat energy from the heating arrangement H.

[0433] In the event that a cooled metal oxide material is chosen to be produced, a sixth specific heat energy (kJ / kgK) is recovered from the discharged metal oxide material 5 and fed back to the preheating zone 8 .

[0434] Alternatively, in the case of the option of producing cooled metal oxide material, the sixth specific heat energy (kJ / kgK) is recovered from the discharged metal oxide material 5 and fed back for heating the process gas introduced into the preheating zone 8 .

[0435] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with an oxygen-depleted process gas.

[0436] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0437] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0438] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0439] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0440] Oxygen-rich oxidant 14 , such as pure oxygen, for example produced by an electrolysis unit 15 .

[0441] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0442] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0443] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0444] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0445] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0446] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0447] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0448] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0449] Figure 5 A metal oxide material production apparatus 3 according to a fifth example is shown.

[0450] The dried metal ore material is strong enough to build a bed B of metal ore material on a metal ore material feeder 20 ′ used by the preheating zone 8 and consolidation zone 10 of the metal oxide material production plant 3 .

[0451] The metal oxide material production apparatus 3 comprises a metal ore material bed applicator, such as a hopper arrangement, configured for loading green pellets onto the metal ore material feeder 20'. The metal ore material bed applicator (not shown) is configured to apply a bed B of metal ore material onto the metal ore material feeder 20'.

[0452] The thickness / height of the bed B corresponds to a measure of about 10 to 50 times greater than the average size of the metal ore material bodies (pellets) of metal ore material fed through the preheating zone 8 and / or consolidation zone 10 by the metal ore material feeding device 20 .

[0453] Alternatively, the thickness of bed B may be about 300 mm to 800 mm, preferably 350 mm to 750 mm.

[0454] The thickness / height of bed B can be set thicker than prior art beds by oxygen-rich oxidant 14 introduced into consolidation zone 10. Oxygen-rich oxidant 14 is able to diffuse into bed B of metallic ore material throughout its entire thickness due to its high oxygen content.

[0455] By moving a thick bed B of metal ore material through a metal oxide material production apparatus 3 including a consolidation zone 10, larger quantities of preheated metal ore material 4 may be oxidised, which in turn allows for cost effective and high rate production of metal oxide material.

[0456] In this way, a well-defined temperature gradient can be achieved in the bed of metal ore material undergoing preheating and consolidation, wherein the temperature gradient can be controlled to be as uniform as possible throughout the preheating and consolidation zones for providing metal oxide material 5 of uniform quality.

[0457] The metal oxide material production equipment 3 includes a control circuit (not shown), which is connected to the process gas introduction device 6 and optionally connected to the oxidant introduction device 12 for controlling the preheating and / or oxidation and / or sintering of the metal ore material 2 into the metal oxide material 5.

[0458] Alternatively, the control circuit is adapted to control an oxidation process for oxidizing the preheated metal ore material 4 into said metal oxide material 5 to reach a temperature of 1100°C to 1500°C, preferably 1200°C to 1400°C.

[0459] The consolidation zone 10 includes a first consolidation zone 10' and a second consolidation zone 10". The first consolidation zone 10' is configured to receive a flow 14' of a first oxygen-rich oxidant, and the second consolidation zone 10" is configured to receive a flow 14". of a second oxygen-rich oxidant. The control circuit is suitable for controlling the oxidation of the preheated metal ore material by a first oxygen-rich oxidant flow regulating device (not shown) connected to the control circuit, the first oxygen-rich oxidant flow regulating device being used to provide a first oxygen pressure during oxidation and / or sintering of the preheated metal ore material in the first consolidation zone 10'. The control circuit is suitable for controlling the oxidation of the preheated metal ore material by a second oxygen-rich oxidant flow regulating device (not shown) connected to the control circuit, the second oxygen-rich oxidant flow regulating device being used to provide a second oxygen pressure during oxidation and / or sintering of the preheated metal ore material in the second consolidation zone. The first oxygen pressure can be set to be higher than the second oxygen pressure for providing effective oxidation and sintering. The second oxygen pressure can be set to be higher than the first oxygen pressure, or can be similar.

[0460] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0461] Alternatively, the control circuit is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0462] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0463] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0464] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0465] Figure 6 A metal oxide material production apparatus 3 according to a sixth example is shown.

[0466] The dried metal ore material is strong enough to build up a bed B of metal ore material on the roaster supports 83 used by the consolidation zone 10 of the metal oxide material production plant 3.

[0467] Alternatively, the metal ore material is moved from the drying zone into the preheating zone, and optionally further through the consolidation zone, by a metal ore material feeding device (eg, a steel belt conveyor member, a mobile roaster car) or by other means.

[0468] Preheated metal ore material has been introduced into the consolidation zone 10, and oxygen-rich oxidant 14 has been introduced into the consolidation zone 10 from above, and the upper surface layer of bed B begins to oxidize severely, and oxidation of magnetite generates heat energy from the upper surface layer and further downward. Since the metal ore material in the upper surface layer has oxidized to a great extent, the deeper layers of bed B begin to oxidize severely. Finally, the bottom surface layer of bed B oxidizes, and the entire bed B of metal oxide material is ready to be discharged from the consolidation zone 10. This position PO is at Figure 5 . By introducing an oxygen-enriched oxidant 14 into the consolidation zone 10, the thickness / height of the bed B can be set to be thicker than prior art beds. The oxygen-enriched oxidant 14 is able to diffuse into the bed B of the metal ore material throughout the entire thickness of the bed B due to its high oxygen content. A fan arrangement 86 is arranged to the bottom of the consolidation zone 10 for operating the flow of the oxygen-enriched agent 14 through the bed B of the metal oxide material.

[0469] Oxygen-rich oxidant 14 , such as pure oxygen, for example produced by an electrolysis unit 15 .

[0470] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0471] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0472] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0473] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0474] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0475] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0476] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0477] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0478] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0479] Alternatively, the control circuit is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0480] Alternatively, the drying zone is configured to dry the moist metal ore material at a temperature of about 100°C to 500°C, preferably 200°C to 400°C.

[0481] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0482] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0483] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0484] Figure 7 A metal oxide material production device 3 according to a seventh example is shown. The metal oxide material production device 3 includes a cooler 18 configured to cool the hot metal oxide material 5 discharged from the consolidation zone 10 of the metal oxide material production device 3 and fed into the cooler 18. The heat exchange unit 40 of the cooler 18 is configured to recover thermal energy from the metal oxide material 5 discharged from the consolidation zone 10. The cooler 18 is configured to recover thermal energy and transfer it to a process fluid 84 carrying waste heat, which is fed to the preheating zone 8 of the metal oxide material production device 3 via the cooler 18. A waste heat energy fluid pipeline 31 is connected between the cooler 18 and the preheating zone 8 for transferring the thermal energy of the process fluid 84 carrying waste heat to the preheating zone 8 for heating the oxygen-depleted process gas 7.

[0485] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with an oxygen-depleted process gas.

[0486] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0487] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0488] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0489] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0490] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0491] Alternatively, the control circuit (not shown) is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0492] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0493] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0494] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0495] The metal oxide material production facility 3 includes a diverting mechanism 88 configured to change the path of the metal oxide material 5 discharged from the consolidation zone 10. This is achieved by operating a conveyor belt 89 to move out of the charging inlet of the direct reduction facility DR. The hot metal oxide material 5 is charged directly into the direct reduction facility DR.

[0496] Figure 8A flow chart showing an exemplary method of producing a metal oxide material 5 by means of a metal oxide material production device 3 is shown, wherein the metal oxide material production device 3 includes: a preheating zone, which is configured to preheat a metal ore material into a preheated metal ore material; a process gas introduction device, which is connected to the preheating zone and configured to introduce a process gas into the preheating zone; a consolidation zone, which is configured to consolidate the preheated metal ore material into the metal oxide material; an oxidant introduction device, which is connected to the consolidation zone and configured to introduce an oxygen-rich oxidant into the consolidation zone; and a control circuit, which is connected to the process gas introduction device and to the oxidant introduction device, and is used to control the consolidation of the metal ore material into the metal oxide material.

[0497] Figure 8 The method in starts at step 801. Step 802 includes adapting the method. Step 803 includes stopping the method. Step 802 may include: feeding metal ore material into a preheating zone; introducing a preheated process gas for preheating the metal ore material; feeding the preheated metal ore material into a consolidation zone; introducing an oxygen-rich oxidant into the consolidation zone for oxidizing the preheated metal ore material into the metal oxide material; and discharging the metal oxide material from the consolidation zone.

[0498] Fig. 9 A flow chart of an exemplary method of producing a metal oxide material 5 by a metal oxide material production apparatus 3 of any example disclosed herein is shown. The method starts at step 901. Step 902 includes feeding a metal ore material into a preheating zone. Step 903 includes introducing a preheated process gas for preheating the metal ore material. Step 904 includes feeding the preheated metal ore material into a consolidation zone. Step 905 includes introducing an oxygen-enriched oxidant into the consolidation zone for oxidizing the preheated metal ore material into the metal oxide material. Step 906 includes generating oxygen for the oxygen-enriched oxidant by an electrolysis unit. Step 907 includes controlling the preheating of the metal ore material by a control circuit before feeding the preheated metal ore material into the consolidation zone, for bringing the preheated metal ore material to a temperature of about 700° C. to 900° C., preferably about 800° C. Step 908 includes a step of cooling the discharged metal oxide material by a cooler device. Step 909 includes transferring recovered heat energy from the discharged metal oxide material to the preheating zone. Step 910 includes discharging the metal oxide material from the consolidation zone. Step 911 includes stopping the method.

[0499] Fig.10A metal oxide material production apparatus 3 including a control circuit 50 is shown. The control circuit includes a computer (not shown) and is configured to control any of the exemplary methods disclosed herein. The control circuit 50 may include a non-volatile memory NVM 1020, which is a computer memory that can retain stored information even when the control circuit 50 or the computer is not powered. The control circuit 50 also includes a processing unit 1010 and a read / write memory 1050.

[0500] The NVM 1020 comprises a first memory unit 1030. A computer program (which may be of any type suitable for any operating database) is stored in the first memory unit 1030 for operating the functions of the control circuit 50.

[0501] In addition, the control circuit 50 includes a bus controller (not shown), a serial communication port (not shown) providing a physical interface, through which information is transmitted in both directions, respectively. The control circuit 50 also includes: any suitable type of I / O module (not shown) providing input / output signal transmission; an A / D converter (not shown) for converting different signals from the preheating zone temperature sensor component, the consolidation zone temperature sensor component, the temperature sensor device for detecting the temperature of the metal oxide material retaining heat energy and the temperature of the process gas, the oxygen-depleted process gas, the oxygen-rich oxidant, or any various monitoring units (not shown) into a binary code suitable for processing by the computer of the control circuit 50.

[0502] The control circuit 50 also includes an input / output unit (not shown) for adapting the time and date. The control circuit 50 may also include an event counter (not shown) for counting the number of event quantities occurring during the preheating and consolidation of the metal ore material for regulating the chemical reaction and / or oxidation for achieving effective sintering of the metal ore material in the consolidation zone.

[0503] In addition, the control circuit 50 includes an interrupt unit (not shown) for providing multi-tasking performance and real-time calculation. The NVM 1020 also includes a second memory unit 1040 for external control operations.

[0504] The data medium suitable for storing the data program P comprises drive routines suitable for instructing the operation of the metal oxide material production device 3 .

[0505] The data program P is suitable for operating the control circuit 50 when performing any of the exemplary methods described herein. The data program P includes routines for executing instructions to the metal oxide material production device 3, for enabling the metal oxide material production device 3 to perform any of the exemplary methods disclosed herein. The data program P includes program codes readable on a computer, for causing the computer to control the metal oxide material production device 3 to perform the exemplary methods described herein.

[0506] The data program P may also be stored in the independent memory 1060 and / or in the read / write memory 1050. The data program P in this embodiment is stored in an executable or compressed data format.

[0507] It should be understood that when processing unit 1010 is described as performing a specific function, this involves processing unit 1010 executing a specific portion of a program stored in independent memory 1060 or a specific portion of a program stored in read / write memory 1050 .

[0508] The processing unit 1010 is associated with a signal (data) port 1099 for communication via the first data bus 1015, which may be adapted to be electrically coupled to electronic control circuitry of an operator station (not shown).

[0509] In this way it is achieved that an operator can control and monitor the metal oxide material production device 3 via the display of the electronic control circuit.

[0510] The non-volatile memory NVM 1020 is adapted to communicate with the processing unit 1010 via the second data bus 1012. The independent memory 1060 is adapted to communicate with the processing unit 1010 via the third data bus 1011. The read / write memory 1050 is adapted to communicate with the processing unit 1010 via the fourth data bus 1014. The signal (data) port 1099 may be connectable to a data link (e.g., a network coupled to the control circuit 50).

[0511] When data is received by the signal port 1099, the data will be temporarily stored in the second memory unit 1040. After temporarily storing the received data, the processing unit 1010 will prepare to execute the program code according to the exemplary method.

[0512] Preferably, the signal (received by the signal (data) port 1099 ) includes information about the operating status of the metal oxide material production device 3 .

[0513] Signals received at the signal port 1099 , such as a serial bus, may be used by the control circuit 50 for controlling and monitoring preheating and consolidation.

[0514] The signal received by the signal (data) port 1099 can be used for historical data and data about the operation of the metal oxide material production equipment 3.

[0515] The metal oxide material production device 3 can be configured to be connected to a data network via a signal bus, which is configured as an electrical interface for explicitly providing electrical compatibility and related data transmission, which data may include information about the status of the metal oxide material production device 3 and its sensor devices (e.g., preheating zone temperature sensor components, consolidation zone temperature sensor components, temperature sensor devices for detecting the temperature of metal oxide materials, etc.). Data can also be manually fed to a computer and / or presented by a computer via a suitable communication device such as a display (not shown) or a touch screen.

[0516] The independent sequences of the method can be executed by a computer, wherein the computer runs a data program P stored in an independent memory 1060 or a read / write memory 1050. When the computer runs the data program P, the method steps according to any example disclosed herein will be performed by the metal oxide material production device 3.

[0517] A data program product including program code stored on a data medium may be provided, which is readable on a computer when the data program P is run on the computer and is used to instruct the metal oxide material production device 3 to perform any exemplary method steps disclosed herein.

[0518] Fig.11a and Fig.11b Additional exemplary iron ore oxide material production facilities are shown.

[0519] Fig.11a An iron ore oxide material production facility 3, such as a belt roaster, is shown, which includes a preheating zone 8 configured to preheat the iron ore material 2 into a preheated iron ore material 4. The iron ore material 2 may be provided by a sorting-enrichment-slurry rolling device 24 and fed into the preheating zone 8. The metal oxide material production facility 3 also includes a process gas introduction device (not shown) coupled to the preheating zone 8 and configured to introduce a process gas for preheating the iron ore material 2.

[0520] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with an oxygen-depleted process gas.

[0521] Alternatively, a preheat zone comprising a preheat zone atmosphere fed with a process gas which is an oxygen-depleted process gas comprises about 0 vol% to 21 vol% oxygen, preferably about 5 vol% to 20 vol% oxygen.

[0522] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0523] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0524] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0525] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0526] Alternatively, the method further comprises the step of controlling the preheating of the metal ore material by means of a control circuit for causing the preheated metal ore material to reach a temperature of about 700°C to 900°C, preferably about 800°C.

[0527] Alternatively, the control circuit 50 is adapted to control an oxidation process for oxidizing the preheated metal ore material into said metal oxide material to reach a temperature of about 700°C to 1350°C, preferably 850°C to 1200°C.

[0528] Alternatively, the preheating zone is configured to preheat the metal ore material at a temperature of about 650°C to 950°C, preferably 700°C to 900°C.

[0529] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 750°C to 1350°C, preferably 800°C to 1300°C.

[0530] Alternatively, the consolidation zone is configured to oxidize the preheated metal ore material at a temperature of about 700°C to 1350°C, preferably 750°C to 1300°C.

[0531] The metal oxide material production facility 3 comprises a consolidation zone 10 configured for consolidating (oxidizing) the preheated iron ore material 4 into iron ore oxide material 5 .

[0532] The metal oxide material production apparatus 3 comprises a feeding arrangement 21 ′ comprising a travelling grate 28 configured to move the iron ore material 2 through the preheating zone 8 and further move the preheated iron ore material 4 through the consolidation zone 10 for oxidizing the preheated iron ore material 4 into iron ore oxide material 5.

[0533] Alternatively, the separation barrier 26 is arranged between the preheating zone 8 and the consolidation zone 10 and separates the atmosphere of the preheating zone from the atmosphere of the consolidation zone for preventing the oxygen-depleted process gas 7 from mixing with the oxygen-rich oxidant 14 .

[0534] The preheating zone 8 includes an oxidant introduction device 12 coupled to the consolidation zone 10 , wherein the oxidant introduction device 12 is configured to introduce an oxygen-rich oxidant 14 into the consolidation zone 10 .

[0535] Oxygen-rich oxidant 14 , such as pure oxygen, for example produced by an electrolysis unit 15 .

[0536] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0537] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0538] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0539] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0540] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0541] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0542] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0543] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0544] Alternatively, the consolidation zone atmosphere of the consolidation zone is heated by a consolidation zone atmosphere gas burner arrangement and / or a consolidation zone atmosphere electric heater arrangement (not shown).

[0545] The iron ore oxide material production facility 3 comprises a control circuit 50 configured to control the oxidation of the preheated metal ore material into the iron ore oxide material 5 by controlling the retention time and temperature of the iron ore material in the consolidation zone 10 .

[0546] Alternatively, the control circuit 50 is electrically connected to the process gas introduction device and to the oxidant introduction device 12 for controlling the preheating of the iron ore material and for controlling the oxidation of the preheated iron ore material 4 into the iron ore oxide material 5 .

[0547] Alternatively, the control circuit 50 is adapted to control the oxidation temperature and holding time of oxidizing the preheated iron ore material to iron ore oxide material in the consolidation zone.

[0548] Alternatively, the control circuit 50 is adapted to control the retention time required for oxidation of the preheated iron ore material 4 in the consolidation zone 10 by adjusting the rate at which the travelling grate 28 of the feed arrangement 21 ′ is advanced by adjusting the speed of the drive motor 32 .

[0549] Alternatively, a traveling grate speed sensor 34 is electrically coupled to the control circuit 50 for sensing the velocity of the traveling grate 28 .

[0550] Alternatively, the temperature sensor arrangement 36 is electrically coupled to the control circuit 50 for sensing the temperature of the preheated iron ore material undergoing consolidation and / or the temperature of the iron ore oxide material 5 ready to leave the consolidation zone 10 .

[0551] Alternatively, the control circuit 50 is adapted to regulate the temperature of the preheated iron ore material 4 undergoing consolidation (oxidation) and the rate of travel of the grate 28 according to predetermined consolidation (oxidation) parameter values ​​taking into account the actual rate (holding time) and said temperature.

[0552] Alternatively, the travelling grate 28 is mechanically coupled to a drive motor 32 for driving the travelling grate 28 at a rate taking into account said predetermined consolidation (oxidation) parameter value for providing efficient oxidation of the preheated iron ore material.

[0553] In this way, the control circuit 50 is configured to control the oxidation of the preheated iron ore material 4 into the iron ore oxide material by adjusting the retention time and temperature of the preheated iron ore material undergoing oxidation in the consolidation zone 10 .

[0554] In this way, an energy-efficient and time-saving method and arrangement for producing iron ore oxide material 5 is achieved.

[0555] Fig.11b An iron ore oxide material production plant 3 is shown, such as a grate-rotary kiln configuration. The iron ore oxide material production plant 3 comprises a preheating zone 8 configured to preheat an iron ore material (not shown) into a preheated iron ore material (not shown).

[0556] The metal oxide material production facility 3 further comprises a process gas introduction device (not shown) coupled to the preheating zone 8 and configured to introduce process gas for providing preheating of the iron ore material.

[0557] Alternatively, it may be advantageous to preheat the iron ore material comprising iron oxide compounds in a preheating zone comprising a preheating zone atmosphere fed with a process gas which is an oxygen-depleted process gas.

[0558] Alternatively, the separation barrier 26 is arranged between the preheating zone 8 and the consolidation zone 10 and separates the atmosphere of the preheating zone from the atmosphere of the consolidation zone for preventing the oxygen-depleted process gas 7 from mixing with the oxygen-rich oxidant 14 .

[0559] Alternatively, a preheat zone comprising a preheat zone atmosphere fed with a process gas which is an oxygen-depleted process gas comprises about 0 vol% to 21 vol% oxygen, preferably about 5 vol% to 20 vol% oxygen.

[0560] Alternatively, the process gas constitutes an oxygen-depleted process gas comprising approximately 0% to 5% by volume of oxygen, preferably approximately 1% to 4% by volume of oxygen.

[0561] Alternatively, the oxygen-depleted process gas contains less than 5 volume percent oxygen.

[0562] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 10 vol% oxygen, preferably about 3 vol% to 7 vol% oxygen.

[0563] Alternatively, the oxygen-depleted process gas contains about 1 vol% to 6 vol%, preferably about 2 vol% to 5 vol% oxygen.

[0564] The iron ore oxide material production plant 3 further comprises a feeding arrangement 21 ″ comprising a travelling grate 48 configured to move the iron ore material through the preheating zone 8 . A drive motor M is mechanically coupled to the travelling grate 48 .

[0565] The motor M also drives the preheated iron ore material through the consolidation zone 10 for oxidizing the preheated iron ore material.

[0566] The obtained iron ore oxide material 5 is further fed to a rotary kiln 49 .

[0567] The rotary kiln 49 is arranged to move the iron ore oxide material subjected to sintering from the consolidation zone 10 to a cooler device (not shown) by tilting the rotary kiln 49 and rotating it at a specific rotation speed.

[0568] The kiln rotation speed sensor (not shown) is electrically connected to the control circuit 50 for sensing the rotation speed of the rotary kiln 49 .

[0569] The temperature sensor arrangement 36 is electrically coupled to the control circuit 50 for sensing the temperature of the interior of the consolidation zone 10 .

[0570] The drive motor M is electrically coupled to a control circuit 50 for regulating the speed of the motor M and thereby regulating the retention time of the preheated iron ore material undergoing oxidation in the consolidation zone.

[0571] The temperature sensor arrangement 36 is electrically coupled to the control circuit 50 for sensing the temperature of the interior of the consolidation zone 10 and / or the preheated iron ore material undergoing consolidation (oxidation) and / or the temperature of the iron ore oxide material 5 ready to leave the consolidation zone 10 .

[0572] Alternatively, the control circuit 50 is adapted to adjust the rotation speed of the motor M based on a predetermined consolidation (oxidation) parameter value.

[0573] Alternatively, the control circuit 50 is adapted to regulate the temperature of the preheated iron ore material 4 undergoing consolidation (oxidation) and the rate of travel of the grate 48 based on predetermined consolidation (oxidation) parameter values.

[0574] Alternatively, the predetermined consolidation (oxidation) parameter value may take into account the external shape of the iron ore oxide material (pellet size) and / or the porosity of the iron ore oxide material 5 and / or the agglomeration grade and / or density of the produced iron ore oxide material 5 and / or the temperature of the produced iron ore oxide material 5 and / or the strength of the produced iron ore oxide material 5.

[0575] Alternatively, the control circuit 50 is adapted to adjust the temperature of the consolidation zone 10 and / or the rotary kiln 49 by means of a gas burner device (not shown) and / or a consolidation zone atmosphere electric heater device electrically coupled to the control circuit 50 and arranged to the consolidation zone 10 .

[0576] In this way, the control circuit is configured to control the oxidation of the preheated iron ore material into said iron ore oxide material by adjusting the retention time and temperature of the preheated iron ore material undergoing oxidation in the consolidation zone.

[0577] In this way, an energy-efficient and time-saving method and arrangement for producing iron ore oxide material 5 is achieved.

[0578] Oxygen-rich oxidant 14 , such as pure oxygen, for example produced by an electrolysis unit 15 .

[0579] Alternatively, the oxygen-enriched oxidant comprises about 22 vol% to 50 vol% oxygen, preferably about 25 vol% to 40 vol% oxygen.

[0580] Alternatively, the oxygen-enriched oxidant comprises about 30% to 70% oxygen by volume, preferably about 40% to 60% oxygen by volume.

[0581] Alternatively, the oxygen-enriched oxidant comprises about 40% to 80% oxygen by volume, preferably about 50% to 70% oxygen by volume.

[0582] Alternatively, the oxygen-enriched oxidant comprises about 50% to 90% oxygen by volume, preferably about 60% to 80% oxygen by volume.

[0583] Alternatively, the oxygen-rich oxidant comprises about 30% to 100% oxygen by volume, preferably about 50% to 80% oxygen by volume.

[0584] Alternatively, the oxygen-rich oxidant comprises about 80 vol% to 100 vol% oxygen, preferably about 85 vol% to 95 vol% oxygen.

[0585] Alternatively, the oxygen-enriched oxidant comprises about 60% to 80% oxygen by volume, preferably about 65% to 75% oxygen by volume.

[0586] Alternatively, the oxygen-enriched oxidant comprises about 40% to 60% oxygen by volume, preferably about 55% to 65% oxygen by volume.

[0587] The present disclosure may not be limited to the examples described above, but many possibilities of modifications or combinations of the examples described herewith will be apparent to a person skilled in the art without departing from the basic idea as defined in the appended claims.

Claims

1. A method for producing a metal oxide material (5) by a metal oxide material production device (3), the metal oxide material production device (3) comprising: - a preheating zone (8) configured to preheat the metal ore material (2) into a preheated metal ore material (4); a process gas introduction device (6) connected to the preheating zone (8) and configured to introduce a process gas (7) into the preheating zone (8); - a consolidation zone (10) configured for consolidating the preheated metal ore material (4) into the metal oxide material (5); - an oxidant introduction device (12), the oxidant introduction device (12) being coupled to the consolidation zone (10) and configured to introduce an oxygen-rich oxidant (14) into the consolidation zone (10); and - a control circuit (50), the control circuit (50) being connected to the process gas introduction device (6) and the oxidant introduction device (12) for controlling the consolidation of the metal ore material (2) into the metal oxide material (5); The method is characterized by the following steps: - feeding the metal ore material (2) into the preheating zone (8); - introducing a preheated process gas (7) for preheating the metal ore material (2); - feeding the preheated metal ore material (4) into the consolidation zone (10); - introducing the oxygen-rich oxidant (14) into the consolidation zone (10) for oxidizing the preheated metal ore material (4) into the metal oxide material (5); and - Discharging the metal oxide material (5) from the consolidation zone (10).

2. The method according to claim 1, wherein the process gas (7) is an oxygen-depleted process gas, which contains about 0% to 21% oxygen by volume, preferably about 5% to 20% oxygen by volume, and / or the oxygen-rich oxidant (14) contains about 25% to 100% oxygen by volume, preferably about 40% to 80% oxygen by volume.

3. The method according to claim 1 or 2, wherein the oxygen in the oxygen-rich oxidant (14) is produced by an electrolysis unit (15).

4. A method according to any one of claims 1 to 3, wherein the metal ore material (4) comprises magnetite material, and the step of oxidizing the preheated metal ore material (4) comprises oxidizing the magnetite material into hematite material, wherein an exothermic chemical reaction generates heat.

5. A method according to any one of the preceding claims, wherein the step of introducing the process gas (7) comprises introducing a heated oxygen-depleted process gas into the preheating zone (8) for preventing oxidation of the metal ore material (2) in the preheating zone (8) before being fed into the consolidation zone (10).

6. The method according to any one of the preceding claims, wherein the method further comprises the following steps: Before feeding the preheated metal ore material (4) into the consolidation zone (10), the preheating of the metal ore material (2) is controlled by the control circuit (50) so as to make the preheated metal ore material (4) reach a temperature of 700°C to 900°C, preferably 800°C.

7. The method according to any one of the preceding claims, wherein the method further comprises the following steps: The oxidation rate of the preheated metal ore material (4) into the metal oxide material (5) is controlled by the control circuit (50).

8. The method according to any one of the preceding claims, wherein the method further comprises the following steps: - cooling the discharged metal oxide material (5) by means of a cooler device (18); as well as - Transferring recovered heat energy from the discharged metal oxide material (5) to the preheating zone (8).

9. A metal oxide material production device (3), comprising: - a preheating zone (8) configured to preheat the metal ore material (2) into a preheated metal ore material (4); a process gas introduction device (6) connected to the preheating zone (8) and configured to introduce a process gas (7) into the preheating zone (8); - a consolidation zone (10) configured for consolidating the preheated metal ore material (4) into the metal oxide material (5); characterised in that - an oxidant introduction device (12) coupled to the consolidation zone (10) and configured to introduce an oxygen-rich oxidant (14) into the consolidation zone (10) configured for oxidizing the preheated metal ore material (4) into the metal oxide material (5); - a control circuit (50) configured to control the oxidation of the preheated metal ore material (4) to the metal oxide material (5) by controlling the retention time and temperature of the metal ore material in the consolidation zone (10).

10. The metal oxide material production equipment (3) according to claim 9, wherein the oxidant introduction device (12) is connected to the consolidation zone (10), and the consolidation zone (10) is configured to oxidize and / or sinter the preheated metal ore material (4) into the metal oxide material (5), and the magnetite material in the preheated metal ore material (4) is oxidized into hematite material in the consolidation zone (10), causing an exothermic chemical reaction of the preheated metal ore material (4) undergoing oxidation and / or sintering to generate heat energy.

11. A metal oxide material production apparatus (3) according to claim 9 or 10, wherein the exothermic chemical reaction provides thermal energy transfer from the preheated metal ore material (4) undergoing oxidation and / or sintering to the consolidation zone atmosphere of the consolidation zone (10).

12. The metal oxide material production equipment (3) according to any one of claims 9 to 11, wherein the metal oxide material production equipment (3) further comprises: - a cooler device (18) configured to cool the metal oxide material (5) discharged from the consolidation zone (10) and fed into the cooler device (18); - a heat exchange unit (40) of the cooler device (18), the heat exchange unit (40) being configured to recover thermal energy from the metal oxide material (5) and transfer it to a process fluid carrying waste heat; - a waste heat energy fluid pipeline (31), which is connected between the heat exchange unit (40) and the preheating zone (8) and / or the consolidation zone (10), and is configured to transfer the thermal energy of the process fluid carrying waste heat from the heat exchange unit (40) to the preheating zone (8) and / or the consolidation zone (10) for heating the process gas (7) and / or the oxygen-rich oxidant (14).

13. The metal oxide material production equipment (3) according to any one of claims 9 to 12, wherein the metal oxide material production equipment (3) further comprises: - a metal ore material bed applicator, the metal ore material bed applicator being configured to apply a bed (B) of the metal ore material (2) onto a metal ore material feeding device (20), the metal ore material feeding device (20) being configured to feed the metal ore material through the preheating zone (8) and / or the consolidation zone (10).

14. The metal oxide material production apparatus (3) according to claim 13, wherein the thickness / height of the bed (B) corresponds to a measurement that is greater than about 10 to 50 times the average size of the metal ore material bodies of the metal ore material fed through the preheating zone (8) and / or the consolidation zone (10) by the metal ore material feeding device (20).

15. A metal oxide material production arrangement (71), comprising: - an electrolysis unit (15) configured to decompose water into oxygen and hydrogen; - an electric energy generation device (76) configured to produce regeneratively produced electric energy fed to the electrolysis unit (15); - a metal oxide material production plant (3) according to any one of claims 9 to 14; and - an oxygen-rich oxidant fluid pipeline (73), which is connected between the consolidation zone (10) and the electrolysis unit (15) and is configured to transfer the oxygen-rich oxidant (14) from the electrolysis unit (15) to the consolidation zone (10).

16. A data program (P) programmed to cause the metal oxide material production device (3) according to any one of claims 9 to 14 to perform the method according to any one of claims 1 to 8, wherein the data program (P) includes a program code readable on a computer of the control circuit (50) for causing the metal oxide material production device (3) to perform the method according to any one of claims 1 to 8.

17. A data medium configured to store a data program (P) according to claim 16, wherein the data medium comprises a computer-readable program code for causing the metal oxide material production device (3) to execute the method according to any one of claims 1 to 8.

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