Methods and Compositions for Producing Reduced Metallic Materials - Patent application

Abstract

The present invention relates to a metallic material production arrangement (1) adapted for the reduction of a metal oxide material (5) and for the reduction of the metal oxide material (5) that retains thermal energy into a reduced metallic material (16). The metal oxide material (5) is introduced into an upper interior (UP) of a reduction facility (7). A hydrogen-containing reducing agent (6) is introduced into the reduction facility (7) and is adapted to react with the metal oxide material (5) that retains thermal energy for the reduction of the metal oxide material (5) by utilizing said thermal energy of the metal oxide material (5) to heat or further heat the introduced hydrogen-containing reducing agent (6). The reduction facility (7) of the metallic material production arrangement (1) is adapted for effecting a heat treatment process of the reduced metallic material (16). A control circuit (50) is adapted for regulating the temperature of the hydrogen-containing reducing agent (6) and for controlling the temperature of the introduced hydrogen-containing reducing agent (6) in order to reach at least one desired passivation parameter value (DPPV) of the reduced metallic material (16).

Description

[Technical field]

[0001] The present invention relates primarily to a method for the reduction of thermal energy-retaining metal oxide materials to reduced metal materials.

[0002] The present invention further relates to a metallic material manufacturing arrangement adapted for the reduction of thermal energy-retaining metal oxide materials into reduced metallic materials.

[0003] The invention further relates to a data program programmed to control a heat treatment process for the heat treatment of metal oxide material and / or reduced metal material to produce reduced metal material resistant to reoxidation.

[0004] The present disclosure may relate to methods and metallic material production configurations for producing carbon-free reduced metallic materials that are resistant to reoxidation.

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

[0006] Furthermore, the present invention may also be relevant to manufacturers and suppliers of metal oxide material feed units, reduction plants, steel industries, and the like. [Background technology]

[0007] Today, various techniques are known for the passivation of reduced metallic materials with different types of reducing agents.

[0008] However, current methods and configurations are ineffective and suboptimal in terms of utilization of the reducing agent introduced into the reduction equipment to reduce the metal oxide material: in order to provide sufficient heat to support the reduction process, the reducing agent is heated strongly, which also destroys the reduction potential of the reducing agent. Summary of the Invention [Problem to be solved by the invention]

[0009] The objective is to achieve efficient reduction of metal oxide materials while at the same time achieving efficient control of the heat treatment process by maintaining the reduction potential of the reducing agent to achieve efficient production of reduced metal materials that are resistant to reoxidation.

[0010] The aim is to provide a cost-effective transportation supply chain for reduced metallic materials to other industries such as steelmaking.

[0011] The aim is to produce reduced metallic materials that can be used for cost-effective steel production using, for example, electric arc furnaces.

[0012] The object is to provide a method for the reduction of a thermal energy-bearing metal oxide material to a reduced metal material by fossil fuel-free energy, or at least substantially fossil fuel-free energy, to produce a reduced metal material.

[0013] The aim is to provide a method by which reduced metal materials can be produced on an industrial scale in a CO2-neutral and / or low CO2-emission and / or CO2-free manner.

[0014] The objective is to provide carbon-free reduced metal materials by an energy-efficient method. [Means for solving the problem]

[0015] At least one of these or said objects is achieved by a method for reducing a metal oxide material bearing thermal energy to a reduced metal material, in which the metal oxide material bearing thermal energy is supplied by a metal oxide material supply unit and charged into an upper interior of a reduction installation of a metal material production arrangement via a metal oxide material charging device, and a control circuit is electrically connected to a reducing agent temperature regulating device configured to regulate the temperature of a hydrogen-containing reducing agent to be introduced into the middle part and / or the lower interior of the reduction installation via a reducing agent inlet device, the method being characterized by the steps of: reducing the metal oxide material in the upper interior by utilizing the thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent to bring about a chemical reaction between the hydrogen-containing reducing agent and the metal oxide material; bringing about a heat treatment process for the heat treatment of the metal oxide material to be subjected to reduction and / or the reduced metal material before being discharged from the lower interior; and controlling the temperature of the introduced hydrogen-containing reducing agent for the regulation of the chemical reaction and / or the heat treatment process to reach at least one desired passivation parameter value of the reduced metal material.

[0016] In that way, it is achieved to a large extent to maintain the chemical reactivity and / or high driving force of hydrogen, which is essential to effect efficient reduction of metal oxide materials.

[0017] Alternatively, the step of controlling the temperature of the introduced pre-heated hydrogen-containing reducing agent comprises adapting the temperature towards a predetermined temperature for effecting sintering of the metal oxide material subjected to reduction and / or sintering and / or heat treatment of the reduced metal material, during a predetermined period of time, in order to reach at least one desired passivation parameter value.

[0018] Alternatively, the introduced hydrogen-containing reducing agent contains 80-100% hydrogen, preferably 100% hydrogen.

[0019] Alternatively, the control circuit is adapted to coarsely set the thermal energy and to finely set the temperature of the introduced (pre-heated or cooled) hydrogen-containing reducing agent to achieve at least one desired passivation parameter value.

[0020] In that way, efficient regulation of the temperature for the reduction of the metal oxide material is achieved and at the same time efficient regulation of the temperature for the heat treatment of the reduced metal material is achieved.

[0021] Alternatively, the step of reducing the metal oxide material in the upper interior is accomplished by utilizing the thermal energy of the metal oxide material and utilizing the heat content of the partially reduced metal material in the upper interior to heat or further heat the introduced pre-heated hydrogen.

[0022] Alternatively, the temperature of the metal oxide material to be charged into the upper interior is controlled by a control circuit so as to be within the range of 900 to 1500°C, preferably 1000 to 1400°C.

[0023] Alternatively, the temperature of the preheated hydrogen-containing reducing agent is controlled by a control circuit to be within a range of 100 to 400°C, preferably 200 to 300°C, or 0 to 300°C, preferably 100 to 200°C, or 50 to 250°C, preferably 125 to 175°C.

[0024] Alternatively, the temperature of the metal oxide material to be charged into the upper interior is controlled by a control circuit so as to be within the range of 900 to 1500°C, preferably 1000 to 1300°C.

[0025] Alternatively, the temperature of the hydrogen-containing reducing agent is controlled by a control circuit so as to be within a range of 100 to 400°C, preferably 200 to 300°C, or 0 to 300°C, preferably 100 to 200°C.

[0026] By directly charging the metal oxide material from the metal oxide material supply unit to the reduction equipment, and the metal oxide retains the thermal energy from the heat treatment provided by the metal oxide material supply unit, efficient reduction and chemical reaction between the metal oxide material and the reducing agent is achieved, and at the same time, efficient control of the process is achieved by introducing a hydrogen-containing reducing agent at a non-destructive reduction potential to effect a heat treatment process to provide a reduced metal material that is resistant to reoxidation.

[0027] Alternatively, the metal oxide material is formed as an aggregate and the thermal energy comes from a heating process provided by a metal oxide material supply unit.

[0028] Alternatively, the upper interior is adapted for the reduction of a metal oxide material that retains thermal energy.

[0029] Alternatively, the control circuit is electrically connected to a reducing agent temperature adjustment device configured to preheat the hydrogen-containing reducing agent to be introduced into the middle interior and the lower interior of the reduction equipment.

[0030] Alternatively, the middle and lower interiors are configured for the introduction of a pre-heated hydrogen-containing reducing agent, which is adapted to react (reduce) with a metal oxide material that retains thermal energy.

[0031] Alternatively, the hydrogen-containing reductant is introduced into the middle interior and the lower interior.

[0032] Alternatively, the bottom section of the upper interior is configured for the introduction of a pre-heated hydrogen-bearing reducing agent, the pre-heated hydrogen-bearing reducing agent adapted to react (reduce) with a metal oxide material that retains thermal energy.

[0033] Alternatively, the hydrogen-containing reductant is introduced into the bottom section of the upper interior.

[0034] Alternatively, the reduction equipment is configured to allow the reduced metal material to descend into the lower interior and / or intermediate interior to effect a heat treatment process for heat treatment of the reduced metal material using additional thermal energy provided by the preheated hydrogen-containing reducing agent.

[0035] Alternatively, additional thermal energy is defined as thermal energy added to the thermal energy of the metal oxide material retaining thermal energy and / or added to the thermal energy of the reduced metal material descending through the middle interior and / or lower interior.

[0036] Alternatively, the reduction equipment is configured to allow the reduced metal material to descend into the lower interior and / or intermediate interior to effect a heat treatment process for heat treatment of the reduced metal material using additional thermal energy provided by the preheated hydrogen-containing reducing agent.

[0037] Alternatively, additional thermal energy is defined as thermal energy added to the thermal energy of the metal oxide material retaining thermal energy and / or added to the unutilized thermal energy of the reduced metal material descending through the middle interior and / or lower interior.

[0038] Alternatively, the control circuit is configured to control the additional thermal energy by adjusting a temperature of the introduced pre-heated hydrogen-containing reducing agent to result in at least one desired passivation parameter value of the reduced metallic material.

[0039] Alternatively, the additional thermal energy provided by the introduced pre-heated hydrogen-containing reducing agent is accommodated by the control circuitry controlling the temperature of the reduced metal oxide material in the middle interior and / or lower interior towards a predetermined temperature for a predetermined period of time to effect sintering and / or sintering and / or heat treatment of the reduced metal oxide material.

[0040] Alternatively, the temperature of the introduced pre-heated hydrogen-containing reducing agent is controlled by the control circuit to maintain the reduced metallic material in the middle interior and / or lower interior at an elevated predetermined temperature for an extended period of time to accomplish the heat treatment process.

[0041] As such, the reduced metal material is resistant to reoxidation and / or decomposition.

[0042] It is thus achieved that the reduced metallic material discharged from the reduction facility forms an intermediate product which is resistant to reoxidation.

[0043] In that way, the intermediate product does not need to be resistant to reoxidation, thereby facilitating cost-effective transportation to the steel industry.

[0044] It is thus achieved that the intermediate product can be used for cost-effective production, for example for the production of steel using an electric arc furnace (EAF).

[0045] In that way it is achieved that the scrap metal can be reused for the production of steel, despite the high content of carbon present in the scrap metal.

[0046] Alternatively, the temperature of the introduced pre-heated hydrogen-containing reducing agent provides the first thermal energy.

[0047] Alternatively, the control circuit is adapted to control the additional thermal energy by adjusting the temperature of the introduced pre-heated hydrogen-containing reductant.

[0048] Alternatively, the temperature of the introduced preheated hydrogen-containing reducing agent is controlled to be within the range of 100 to 400°C, preferably 200 to 300°C, or 0 to 300°C, preferably 100 to 200°C.

[0049] Alternatively, the temperature of the introduced preheated hydrogen-containing reducing agent is controlled to be within the range of 300 to 600°C, preferably 400 to 500°C.

[0050] Alternatively, the control circuitry is adapted to control the thermal energy in such a way that the thermal energy decreases as the metal oxide material moves downward within the upper side.

[0051] Alternatively, the control circuitry is adapted to control the thermal energy in a manner such that the thermal energy decreases as the reduced metallic material descends in the middle interior and / or the lower interior.

[0052] Alternatively, the control circuit is adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent such that the temperature of the introduced pre-heated hydrogen-containing reducing agent increases as the introduced pre-heated hydrogen-containing reducing agent rises within the upper interior.

[0053] Alternatively, the control circuit is adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent in a manner such that the thermal energy decreases as the reduced metallic material descends in the middle interior and / or the lower interior.

[0054] Alternatively, the control circuitry is adapted to reduce the additional heat energy as the reduced metallic material descends in the middle interior and / or the lower interior.

[0055] Alternatively, the control circuit is adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent and / or the temperature of the metal oxide material retaining thermal energy to achieve that the temperature in the upper interior does not drop below a specific temperature required for the reduction of the metal oxide material in the upper interior.

[0056] In that way, it is ensured that the reduction of the metal oxide material using thermal energy is carried out efficiently, and the reduction potential of the pre-heated hydrogen-containing reducing agent is maintained upon introduction.

[0057] In this way, the thermal energy of the metal oxide material can be used to a large extent due to its high thermal energy content, advantageously in the top section of the upper interior where the metal oxide material retaining the thermal energy first interacts with the preheated hydrogen-containing reducing agent containing a consuming reduction potential (low reduction capacity), this consumption of the reduction potential of the preheated hydrogen-containing reducing agent being based on the fact that the metal oxide material retaining the thermal energy descends through the upper interior, interacts with the preheated hydrogen-containing gas flowing upward, and is subjected to a reduction that consumes a reduction potential.

[0058] Alternatively, the control circuit is adapted to control the temperature of the preheated hydrogen-containing reducing agent such that consumption of the reduction potential of the preheated hydrogen-containing reducing agent during reduction is effected to such an extent that the preheated hydrogen reducing agent in the top section contains a low content of hydrogen and a high content of water vapor (i.e., the covalent bonds holding the hydrogen and oxygen together produce water vapor, and the remaining hydrogen of the hydrogen-containing reducing agent is used to remove oxygen from the metal oxide material).

[0059] Thus, the high temperature of the thermal energy retaining metal oxide material that is initially charged to the top section of the upper interior can result in efficient reduction of the thermal energy retaining metal oxide material.

[0060] In that way, pure or substantially pure hydrogen can be used for both the energy-efficient reduction of charged metal oxide materials by thermal energy and for the energy-efficient heat treatment process for the heat treatment of reduced metal materials, the hydrogen-containing reducing agent being preheated to a temperature that does not destroy the reduction potential of hydrogen.

[0061] In that way, the temperature of the pre-heated hydrogen-containing reducing agent can be adjusted to provide the necessary temperature for efficient reduction within the upper interior.

[0062] In that manner, the temperature of the pre-heated hydrogen-containing reducing agent can be adjusted to provide the temperature necessary for efficient regulation of chemical reactions and / or heat treatment processes in the intermediate and / or lower interiors to provide at least one desired passivation parameter value of the reduced metallic material.

[0063] Alternatively, the control circuit is configured to adjust the temperature of the pre-heated hydrogen-containing reductant to a predetermined temperature for effecting a heat treatment process established in the intermediate interior and / or the lower interior, the predetermined temperature being determined from optimal energy consumption, i.e., actively limiting excess heating of the hydrogen-containing reductant to save energy.

[0064] Alternatively, the control circuit is configured to adjust the duration required for the heat treatment process with respect to optimal energy consumption in the production of reduced metallic material, which duration can be determined from the actual temperature of the pre-heated hydrogen-containing reducing agent.

[0065] As such, energy-saving production of reduced metallic materials is provided.

[0066] In that way, the heat treatment process is provided in terms of optimal use of energy.

[0067] Alternatively, the direct reduction facility comprises a reductant inlet device configured to introduce a hydrogen-containing reductant into the direct reduction facility to effect reduction of the thermal energy-retaining metal oxide material.

[0068] Alternatively, the introduced pre-heated hydrogen-containing reductant may be considered a supplement to the hydrogen-containing reductant introduced to the reductant inlet device, which hydrogen-containing reductant is used for reduction in the direct reduction facility.

[0069] Alternatively, the introduced hydrogen-containing reducing agent and / or the pre-heated hydrogen-containing reducing agent is of a volume such that complete reduction of the metal oxide material is achieved, and an excess volume of hydrogen-containing reducing agent is provided to the reduction facility to effect said reduction of the metal oxide material and / or heat treatment of the reduced metal material.

[0070] Alternatively, the thermal energy retaining metal oxide material is formed as agglomerates that are further sintered within the upper side during reduction of the metal oxide material.

[0071] Alternatively, the reduced and sintered agglomerates transferred to the intermediate interior and / or lower interior may comprise reduced metal particles that have bonded together to form pellets of reduced metal material.

[0072] Alternatively, the control circuit is configured to adjust the temperature of the pre-heated hydrogen-containing reducing agent to provide a predetermined period of time for sintering of pellets in the intermediate interior and / or lower interior and / or heat treating of pellets of reduced metal material to provide at least one desired passivation parameter value of the reduced metal material.

[0073] In that way it is achieved that it is possible to subject the reduced metal material in the intermediate interior and / or in the lower interior to a further sintering process and / or heat treatment of the reduced metal material.

[0074] Alternatively, the reduced iron ore material leaves the reduction facility in the form of dense ferrous bodies of reduced iron ore material (iron balls, or iron pellets, or so-called iron droplets), each pellet having a dense and dense structure for producing an intermediate product resistant to reoxidation.

[0075] Alternatively, the metal oxide material retaining the thermal energy can be substantially continuously lowered within the upper portion and contacted with a preheated hydrogen-containing reducing agent to reduce the metal oxide material.

[0076] Alternatively, the reduced metallic material may descend substantially continuously in the intermediate and / or lower interiors and be contacted with the preheated hydrogen-containing reducing agent.

[0077] Alternatively, pre-heated hydrogen-bearing reducing agent in the intermediate and / or lower interior is used to provide a semi-molten melt and / or to melt and / or sinter reduced iron ore material, the iron atoms of which are arranged in a body-centered cubic pattern.

[0078] Alternatively, the temperature of the preheated hydrogen-containing reducing agent introduced into the upper interior is controlled by the control circuit so that the waste reduction fluid produced by the reduction contains 100% water vapor or substantially 100% water vapor.

[0079] Alternatively, the direct reduction facility further comprises a waste reduction fluid outlet device configured to exhaust waste reduction fluids, such as water vapor and hydrogen gas, from the reduction facility.

[0080] Alternatively, the control circuit is adapted to control a waste reduced fluid outlet device for removing the waste reduced fluid from the reduction facility.

[0081] Alternatively, the control circuit is adapted to control the temperature of the chemical reaction by coarse adjustment of the thermal energy supplied by the metal oxide material supply unit and by fine adjustment of the temperature required for the chemical reaction and / or the heat treatment process by controlling the temperature of the introduced pre-heated hydrogen-containing reducing agent.

[0082] At least one of these or said objects is achieved by a metal material production configuration adapted for reducing a metal oxide material that retains thermal energy into a reduced metal material, the metal material production configuration comprising: a metal oxide material supply unit configured to supply a metal oxide material that retains thermal energy; a metal oxide material charging device configured to charge the metal oxide material into an upper interior of the reduction equipment; and a reductant inlet device configured to introduce a hydrogen-containing reducing agent into an intermediate interior and / or a lower interior of the reduction equipment, whereby the hydrogen-containing reducing agent is adapted to react with the metal oxide material that retains thermal energy for reducing the metal oxide material by utilizing the thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent to bring about a chemical reaction between the hydrogen-containing reducing agent and the metal oxide material. The metallic material production configuration is characterized in that a reduction equipment of the metallic material production configuration is configured to provide a heat treatment process for heat treatment of a metal oxide material and / or a reduced metallic material to be subjected to reduction, and a control circuit electrically connected to a reducing agent temperature regulating device configured to regulate the temperature of the hydrogen-containing reducing agent is adapted to control the temperature of the introduced hydrogen-containing reducing agent in order to reach at least one desired passivation parameter value of the reduced metallic material.

[0083] Alternatively, the reduction facility comprises a passivation parameter detector configured for detection of the actual passivation parameter value.

[0084] Alternatively, the passivation parameter detector may comprise a laser-based surface detector, a density detector, an X-ray detector, and / or other types of detectors.

[0085] Alternatively, the control circuit is electrically connected to the metal oxide material supply unit and adapted to control the temperature of the metal oxide material to be charged into the upper interior to effect a chemical reaction between the pre-heated hydrogen-containing reducing agent and the metal oxide material.

[0086] Alternatively, the metal oxide material supply unit is configured to supply a metal oxide material that retains thermal energy, the metal oxide material being formed as agglomerates that retain thermal energy resulting from a heating process provided by the metal oxide material supply unit.

[0087] Alternatively, the control circuitry controls the temperature of the introduced pre-heated hydrogen-containing reducing agent to effect sintering of the outer surfaces of the individual agglomerates and / or the entire agglomerate.

[0088] Alternatively, the middle interior and / or the lower interior are configured to accommodate the reduced metal material and are configured to provide a heat treatment process for hardening the reduced metal material using a hardening process for heat treatment of the reduced metal material using additional thermal energy provided by the introduced pre-heated hydrogen-containing reducing agent.

[0089] Alternatively, the control unit is adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent and is configured to adapt the temperature towards a predetermined temperature for causing sintering of the metal oxide material subjected to reduction and / or sintering and / or heat treatment of the reduced metal material during a predetermined period of time.

[0090] In that way, the tendency of the iron ore oxide material to revert to its oxide state when exposed to the natural environment is prevented, achieving a reduced risk of spontaneous combustion processes.

[0091] Alternatively, the control unit is adapted to control the amount of additional thermal energy by controlling the temperature of the introduced pre-heated hydrogen-containing reducing agent and / or by controlling the temperature of the metal oxide material charged in the upper interior by controlling the metal oxide material supply unit.

[0092] Alternatively, the middle interior and / or lower interior of the reduction equipment configured for the heat treatment process are separate units or a single unit connected to the reduction zone of the apparatus having a similar configuration as the upper interior adapted to accommodate the metal oxide material that retains thermal energy and the introduced pre-heated hydrogen-containing reducing agent.

[0093] Alternatively, the control circuit is adapted to control the temperature of the pre-heated hydrogen-containing reducing agent to control the heat treatment process in the reduction facility and / or in a separate or single unit heat treatment zone.

[0094] Alternatively, the control circuit is adapted to control the internal gas pressure in the upper interior and / or the middle interior and / or the lower interior of the reduction facility.

[0095] Alternatively, the heat treatment process includes thermally briquetting the metal oxide material and / or the reduced metal material by controlling the temperature of an introduced pre-heated hydrogen-containing reducing agent to produce at least one desired passivation parameter value of the reduced metal material.

[0096] Alternatively, the control circuitry is electrically connected to a passivation parameter value sensor device configured to detect at least one desired passivation parameter value of the reduced metallic material.

[0097] Alternatively, the control circuit is configured to control the temperature of the metal oxide material to be charged into the upper interior in order to control the heat treatment process toward a specific heat treatment temperature value determined from at least one desired passivation parameter value of the reduced metal material, and the control circuit takes into account the actual temperature of the metal oxide material to be charged in order to reach the specific heat treatment temperature value.

[0098] Alternatively, the control circuit is configured to control the temperature of the metal oxide material fed to the direct reduction plant.

[0099] Alternatively, the reduced and sintered agglomerates transferred to the intermediate interior and / or lower interior may comprise reduced metal particles that have bonded together to form pellets of reduced metal material.

[0100] In that way, it is achieved that the reduced iron ore material (illustratively, sponge iron, e.g., pellets, briquettes, balls, iron droplets, etc.) optionally has external structural features of higher density than the core of the pellet body, forming a dense reduced iron material body that facilitates cost-effective transportation and prevents spontaneous combustion of the reduced iron material.

[0101] The term "metal" may refer to metal ores or may be substituted with "iron ore", which may contain elements and / or minerals other than iron, such as naturally occurring alloying elements or lesser amounts of minerals that do not form an alloy.

[0102] The phrase "iron ore" may refer to iron ore with added additives such as quartzite, silica, lime, etc.

[0103] The phrase "reduction facility" may be changed to "direct reduction facility."

[0104] The term "heat treating" is sometimes changed to the term "heat curing."

[0105] The definition of "sintering" may refer to a heat treatment process in which an agglomerated reduced metal material is subjected to a sufficiently high temperature and / or pressure to result in reduced metal material pieces or pellets that are dense and solid.

[0106] Alternatively, a portion of the hydrogen-containing reductant is cooled before being introduced into the bottom section of the lower interior.

[0107] Alternatively, a cold hydrogen-containing reductant is introduced into the bottom section of the lower interior.

[0108] In that way, it is achieved that the reduced metal material is cooled by a cooling process directly in the reduction facility before being discharged from the reduction facility, while the hydrogen-containing reducing agent for cooling is heated, while the heat recovered from the reduced metal material can be reused for the reduction and heat treatment process.

[0109] Alternatively, heat recovered from the reduced metallic material by the cooling process may be raised upward in a direct reduction facility to add heat to the reduction and / or heat treatment process in a recirculating heat system.

[0110] Alternatively, the location at which the introduced pre-heated hydrogen-containing reductant is introduced into the direct reduction equipment can be adjusted vertically along the extension of the direct reduction equipment to achieve optimal sintering and to control the heat treatment process to produce reduced metal material pieces or pellets that are dense and solid.

[0111] Alternatively, the introduced hydrogen-containing reducing agent is introduced into the reduction arrangement via a reducing agent inlet device comprising at least one reducing agent inlet of the reduction arrangement.

[0112] Alternatively, the reductant inlet device comprises at least two reductant inlets, at least one of which is configured to introduce supplemental hydrogen-containing reductant into the reduction facility for effecting the heat treatment process.

[0113] Alternatively, the heat treatment comprises thermal hardening of a metal oxide material that has been subjected to reduction and / or a reduced metal material.

[0114] Alternatively, the heat treatment comprises a thermal hardening process which involves sintering of the reduced metallic material and / or shrinkage of the reduced metallic material and / or densification of the reduced metallic material.

[0115] Alternatively, the metal oxide material supply unit may comprise a metal oxide pelletising plant or a metal oxide preheating plant.

[0116] Alternatively, the reduction of a thermal energy bearing metal oxide material to a reduced metal material uses the thermal energy of the metal oxide material, which is utilized to heat or further heat an introduced hydrogen-containing reducing agent and / or the reduction process to effect a chemical reaction between the hydrogen-containing reducing agent and the metal oxide material.

[0117] Alternatively, the temperature of the chemical process for reduction is higher than 570°C or is in the range of 600-1500°C, preferably 750-1350°C.

[0118] Alternatively, the temperature of the chemical process for reduction is in the range of 700-1400°C, preferably 800-1300°C.

[0119] Alternatively, the temperature of the introduced hydrogen-containing reducing agent is controlled to effect regulation of the heat treatment process, the temperature being adapted to be a predetermined temperature value to effect the heat treatment process to reach at least one desired passivation parameter value of the reduced metallic material.

[0120] Alternatively, the predetermined temperature is adapted to be within the range of 200-600° C., preferably 300-500° C., to provide at least one desired passivation parameter value of the reduced metallic material.

[0121] Alternatively, the predetermined temperature is provided for a predetermined period of time long enough to enable a heat treatment process to provide at least one desired passivation parameter value of the reduced metallic material.

[0122] Alternatively, the at least one desired passivation parameter value may relate to a porosity parameter, and / or a dimensional parameter, and / or a weight parameter, and / or a metal grain structure parameter, and / or a sample cut evenness parameter, and / or a shrinkage parameter, and / or a sintering parameter, and / or a cold crush strength parameter, etc.

[0123] Alternatively, the metal oxide material that retains thermal energy is transported by gravity from the upper interior to the middle and / or lower portion.

[0124] Alternatively, the reductant temperature regulation device may comprise an electrolysis unit or be part of an electrolysis unit adapted to regulate the temperature of an introduced hydrogen-containing reductant, the electrolysis unit being electrically connected to the control circuit.

[0125] Alternatively, the reductant temperature adjustment device may include a reductant pre-heating device adapted to adjust the temperature of the introduced hydrogen-containing reductant, the reductant pre-heating device being electrically connected to the control circuit.

[0126] Alternatively, the reductant temperature adjustment device is further configured to cool a hydrogen-containing reductant to be introduced into the middle portion and / or the lower interior of the reduction installation via the reductant inlet device.

[0127] Alternatively, the method includes utilizing thermal energy of the metal oxide material to reduce the metal oxide material in the upper interior by heating or further heating an introduced pre-heated hydrogen-containing reducing agent to effect a chemical reaction between the pre-heated hydrogen-containing reducing agent and the metal oxide material.

[0128] Alternatively, the reductant inlet device is configured to introduce a pre-heated hydrogen-containing reductant into the intermediate interior and / or lower interior of the reduction equipment, whereby the pre-heated hydrogen-containing reductant is adapted to react with a metal oxide material that holds thermal energy for reducing the metal oxide material by utilizing thermal energy of the metal oxide material to heat or further heat the introduced pre-heated hydrogen-containing reductant to effect a chemical reaction between the pre-heated hydrogen-containing reductant and the metal oxide material.

[0129] Alternatively, a control circuit electrically connected to the reductant pre-heating device configured to pre-heat the hydrogen-containing reductant is adapted to control the temperature of the introduced pre-heated hydrogen-containing reductant to reach at least one desired passivation parameter value of the reduced metallic material.

[0130] Alternatively, the introduced preheated hydrogen-containing reducing agent (preheated or cooled) contains, by volume, 80-100% hydrogen, preferably 90-95% hydrogen.

[0131] Alternatively, the introduced preheated hydrogen-containing reducing agent (preheated or cooled) contains, by volume, 70-95% hydrogen, preferably 80-90% hydrogen.

[0132] Alternatively, the substantially or completely endothermic chemical reactions may consume heat energy equivalent to about 475-525°C, preferably about 500°C, which is extracted from the heat energy retaining metal oxide material during the reduction and chemical reactions carried out in the direct reduction equipment.

[0133] Alternatively, the control circuitry is configured to control the time that the metal oxide material flows through the middle and / or lower interior of the reduction equipment by mechanical means, pressure application, reduction shaft and heat treatment shaft design.

[0134] At least one of these objects or the above objects has been achieved by a data program programmed to cause a metallic material manufacturing arrangement to carry out the method according to the enclosed claims.

[0135] The use of the present disclosure has been shown to be beneficial due to the fact that the chemical reactivity and / or high driving force of the hydrogen-containing reductant hydrogen H is maintained when introduced into a direct reduction facility.

[0136] Alternatively, the reduction facility is connected to a metal oxide preheat plant for preheating the metal oxide material.

[0137] Iron droplets may be defined as small, round, pear-shaped, droplet-like, globular, bead-like, spheroidal, or elliptical bodies of passivated reduced iron ore material and / or metal material having a compact and dense structure to produce an intermediate product that is resistant to reoxidation.

[0138] Alternatively, the reducing agent to be and / or introduced into the direct reduction facility has a gas temperature that is predetermined and / or controlled and / or selected by the control circuit to be any temperature in the range of about 600-1000°C, or about 500-900°C, or about 700-1200°C.

[0139] Alternatively, the introduced reductant rising upward in the direct reduction plant meets with the directly reduced iron ore material and / or the iron ore oxide material subjected to direct reduction falling in the direct reduction plant.

[0140] Alternatively, the reducing agent gas temperature is provided to slow the cooling rate of the directly reduced metal material descending through the direct reduction facility and / or the metal oxide material subjected to direct reduction.

[0141] Alternatively, because the reducing agent contains a higher degree of water vapor in the upper interior than in the middle section and / or lower interior, the reduction potential of the reducing agent rising in the upper interior may be lower than the reduction potential of the reducing agent introduced further down in the direct reduction system (i.e., in the middle section and / or lower interior).

[0142] Alternatively, the material temperature of the metal oxide material to be or being charged into the direct reduction equipment (eg, any temperature in the range of about 50° C. to about 350° C. or about 100° C. to about 400° C.) interacts with the reducing agent inside the upper side.

[0143] Alternatively, a portion of the hydrogen is used for chemical reactions in the middle section and / or inside the lower section.

[0144] Alternatively, the thermal energy retaining metal oxide material provides at least a portion of the thermal energy required for said chemical reaction between the metal oxide material and the reducing agent within the upper interior of the direct reduction equipment.

[0145] Alternatively, a metal oxide material that retains at least some of the thermal energy further heats the reducing agent within the upper portion.

[0146] Thereby, an energy saving process for the direct reduction of metal oxide materials with hydrogen and / or hydrogen-containing reductants is achieved, which hydrogen is preferably temporarily stored in gas storage tanks and / or in storage facilities in geological depositories and / or other buffer facilities so that the reductant hydrogen becomes available and can be used, for example to meet fluctuations in the production of renewable produced electrical energy, when the renewable energy is not sufficiently produced.

[0147] The present invention relates to a method for producing steel, comprising reducing a metal oxide material with a reducing agent, such as a hydrogen-containing reducing agent, in a direct reduction facility and metallurgically processing the thus obtained intermediate product of directly reduced metallic material and finally associated substances, wherein the reducing agent is produced by electrolysis of water by an electrolysis unit, such as a high-temperature electrolysis unit, and the electrical energy required for the electrolysis is renewable energy derived from hydroelectricity, and / or wind power, and / or solar power, and / or other renewable energy forms, and / or nuclear plants, such as plants including small modular reactors (SMR), and, if sufficient reducing agent is available, the resulting reduced metallic material, such as the so-called intermediate product sponge iron, is produced independently of current demand.

[0148] Alternatively, the metal oxide material may be transferred directly from a metal oxide material supply device, such as a pelletizing plant and / or a preheater, to the reduction facility, retaining the thermal energy originating from the metal oxide material supply device.

[0149] Alternatively, the direct reduction facility is configured for the introduction of a reducing agent adapted to react with the metal oxide material that retains thermal energy, thus utilizing the thermal energy of the metal oxide material to reduce the metal oxide material to an intermediate product by further heating the introduced reducing agent to effect a chemical reaction between the metal oxide material and the reducing agent, resulting in an energy-saving and time-saving process.

[0150] The hydrogen and / or hydrogen-containing reductant of the hydrogen-containing reductant may be stored in gas storage tanks, and / or in a geological repository storage facility, and / or in other buffer facilities.

[0151] A gas storage tank, or geological repository storage facility, may be located between the electrolysis unit and / or the high temperature electrolysis unit and the direct reduction facility.

[0152] Alternatively, the reducing agent may be preheated prior to being introduced into the direct reduction equipment so that the reducing agent not only effects the direct reduction and / or chemical reaction, but also reduces the cooling rate of the directly reduced metal material descending through the direct reduction equipment and / or the metal oxide material being subjected to direct reduction.

[0153] The temperature of the metal oxide material to be charged to the upper interior of the direct reduction equipment may be higher than the temperature of the reducing agent to be and / or be introduced into the direct reduction equipment.

[0154] The temperature of the metal oxide material to be charged to the upper interior of the direct reduction equipment may be lower than the temperature of the reducing agent to be and / or be introduced into the direct reduction equipment.

[0155] The temperature of the metal oxide material to be charged into the direct reduction equipment may be about 50°C to about 350°C, or about 100°C to about 400°C, or about 200°C to about 500°C, or about 300°C to about 600°C, or about 400°C to about 700°C, or about 500°C to about 800°C, or about 600°C to about 900°C, or about 700°C to about 1000°C, or about 800°C to about 1100°C, or about 900°C to about 1200°C or higher.

[0156] The reducing agent may be preheated to a gas temperature of about 200 to about 500°C, or about 300°C to about 600°C, or about 400°C to about 700°C, or about 500°C to about 800°C, or about 600°C to about 900°C, or about 700°C to about 1000°C, or about 800°C to about 1100°C, or about 900°C to about 1200°C or higher before and / or when it is introduced into the direct reduction equipment.

[0157] By introducing the reducing agent into the direct reduction equipment at a higher gas temperature (e.g., about 600°C to 900°C), it is possible to retain thermal energy and reduce the cooling rate of the directly reduced metal material and / or metal oxide material that reaches the intermediate portion and / or lower interior of the direct reduction equipment and is subjected to direct reduction and / or heat treatment in the intermediate portion and / or lower interior of the direct reduction equipment.

[0158] Thus, the heat treatment is carried out efficiently, providing an intermediate product in which the passivated reduced metal material has a dense and dense structure and is resistant to reoxidation.

[0159] The intermediate product may be defined as small, round, pear-shaped, droplet-shaped, globular, bead-shaped, spheroidal, or elliptical bodies of passivated reduced metal material having a dense and dense structure to produce an intermediate product that is resistant to reoxidation.

[0160] Alternatively, the direct reduction equipment is configured to allow the reduced metal material to descend into the lower interior and / or intermediate interior to provide a heat treatment process for efficient heat treatment of the reduced metal material using a reducing agent at a higher temperature that provides additional heat energy (additional heat energy in addition to the heat energy of the metal oxide material) to reduce the cooling rate of the metal material being directly reduced and / or heat treated.

[0161] The control circuit is connected to the metal oxide preheating plant and / or the heating device and is configured to control the material temperature of the metal oxide material to be charged, so that the metal oxide material to be subjected to reduction and / or heat treatment is maintained (controlled to increase / decrease) at a predetermined temperature of about 200-600°C, preferably about 300-500°C, for a predetermined period of time long enough to enable a heat treatment process resulting in said desired passivation parameter values ​​of the reduced metal material, thereby achieving an intermediate product that is resistant to reoxidation.

[0162] Alternatively, the control circuit is further connected to a reducing agent pre-heating device configured to pre-heat the reducing agent prior to introduction into the direct reduction equipment and configured to control the gas temperature of the reducing agent so that the metal oxide material subjected to reduction and / or heat treatment is maintained (controlled to increase / decrease) towards a predetermined temperature of about 200-600°C, preferably about 300-500°C, for a predetermined period of time long enough to enable a heat treatment process resulting in said desired passivation parameter value of the reduced metal material, thereby reaching an intermediate product that is resistant to re-oxidation.

[0163] Alternatively, the predetermined temperature is about 400 to 800°C, preferably about 500 to 700°C.

[0164] Alternatively, the predetermined temperature is about 600 to 1000°C, preferably about 700 to 900°C.

[0165] Alternatively, the desired passivation parameter value may be defined as a rate and / or degree and / or grade and / or amount and / or percentage value of reoxidation of the intermediate product (sponge iron and / or reduced iron ore material).

[0166] Alternatively, the control circuit may be adapted to control the temperature of the metal oxide material retaining thermal energy towards a predetermined temperature for effecting a heat treatment process in the direct reduction facility for heat treatment of the metal oxide material subjected to reduction during a predetermined period of time, thereby reaching desired passivation parameter values ​​in terms of porosity, and / or sponge iron dimensions, and / or weight per volume of the produced sponge iron, and / or metal grain structure, and / or sample cut uniformity, and / or shrinkage, and / or sintering, and / or cold crush strength, etc.

[0167] The definition of the desired passivation parameter value for porosity can be expressed as the ratio of the pore volume of the produced sponge iron to its total volume. The size of the sponge iron can generally be expressed as the average diameter of the produced sponge iron agglomerates. Weight per volume can generally be defined as a measure of the iron concentration of the produced sponge iron agglomerates. Metal grain structure can be defined as the final microstructure and distribution of dense and porous regions of the produced sponge iron agglomerates. Sample cut uniformity can determine the density of the produced sponge iron agglomerates.

[0168] The heat treatment process effected by the control circuit for a predetermined period of time, thereby reaching the desired passivation parameters of the resulting sponge iron, results in a reoxidation resistant sponge iron or intermediate product having a dense structure in certain regions (such as the central region of the sponge iron aggregates) and / or high uniformity of final porosity, and / or a highly uniform chemical composition for cost-effective and energy-saving production in subsequent steel production in the steel plant.

[0169] Alternatively, the high material temperature (e.g., any temperature in the range of about 600°C to about 900°C, or about 700°C to about 1000°C, or about 800°C to about 1100°C, or about 900°C to about 1200°C or higher) of the metal oxide material to be and / or being charged into the direct reduction equipment interacts with the reducing agent.

[0170] Alternatively, a portion of the hydrogen is used for chemical reactions in the middle section and / or inside the lower section.

[0171] Alternatively, the high material temperature of the metal oxide material charged inside the upper part of the reduction equipment provides part of the thermal energy for the chemical reaction, producing a high temperature top gas containing high temperature steam to be used in the high temperature electrolysis unit.

[0172] Alternatively, the metal oxide material and / or directly reduced metal material in the middle portion and / or the lower interior are subjected to said heat treatment process.

[0173] In that way, an efficient processing and energy-saving recirculation of the high-temperature steam in the top gas produced by the chemical reaction assisted by the high-temperature charged metal oxide material is achieved, and this high-temperature steam is supplied to the high-temperature electrolysis unit, thus enabling the high-temperature electrolysis unit to operate energy-efficiently due to the efficient heat recovery of the high-temperature steam and due to the high content of high-temperature steam in the top gas discharged from the direct reduction facility.

[0174] Alternatively, the high temperature electrolysis unit is configured to produce hydrogen and the metal oxide material supply unit is configured to supply a metal oxide material that retains thermal energy.

[0175] Alternatively, the direct reduction facility comprises a metal oxide material charge inlet device, a reductant inlet device configured to introduce a hydrogen-containing reductant carrying additional thermal energy.

[0176] Alternatively, the control circuit is configured to control the direct reduction of the metal oxide material by regulating the temperature of the charged metal oxide material and the introduced hydrogen-containing reducing agent.

[0177] Alternatively, the metal material producing configuration is adapted to reduce the metal oxide material by using at least a portion of the thermal energy of the metal oxide material charged to the direct reduction facility to further heat the introduced hydrogen-containing reducing agent towards a required reaction temperature of a chemical reaction to effect a chemical reaction between the hydrogen-containing reducing agent and the metal oxide material.

[0178] Alternatively, the direct reduction equipment comprises a gas outlet device configured to remove hot outlet gas (top gas) from an upper interior of the direct reduction equipment.

[0179] Alternatively, the metallic material manufacturing arrangement includes a first fluid line arrangement configured for fluid communication and adapted to supply high temperature water vapor of the hot outlet gas to the high temperature electrolysis unit.

[0180] Alternatively, the second fluid line arrangement is configured for fluid communication and adapted to supply hydrogen (produced by the high temperature electrolysis unit) directly from the high temperature electrolysis unit to the reduction facility.

[0181] In that way, a high content of high temperature steam in the hot outlet gas is achieved, which promotes efficient utilization of the high temperature steam injected into the high temperature electrolysis unit.

[0182] Alternatively, the upper interior is configured to allow for a required reaction temperature that is higher than the required reaction temperature provided by the lower interior.

[0183] Alternatively, the thermal energy retaining metal oxide material charged to the direct reduction facility exhibits a temperature of from 1000°C to about 1450°C, preferably from about 1100°C to about 1300°C.

[0184] Alternatively, the method includes the step of supplying hot outlet gas (top gas) to the upper interior by charging a metal oxide material that retains thermal energy into the upper interior to effect a chemical reaction between the metal oxide material and a hydrogen-containing reducing agent.

[0185] In that way, endothermic chemical reactions can occur within the upper interior between the metal oxide material and the hydrogen-bearing reducing agent, despite the fact that the hydrogen-bearing reducing agent may contain a high content of water vapor produced by the chemical reaction.

[0186] Due to the high temperature of the charged metal oxide material which retains thermal energy, it is achieved that the hot outlet gas (top gas) generated in the upper interior contains high temperature water vapor due to the high temperature transport from the charged metal oxide material which further heats the hydrogen-containing reducing agent which has risen to the upper interior resulting in said (endothermic) chemical reaction.

[0187] Alternatively, the hot outlet gas contains up to about 80-100% by volume, preferably about 85-95% by volume, of hot water vapor.

[0188] Alternatively, the hot outlet gas contains a maximum of about 60-90% by volume, preferably about 70-80% by volume, of hot water vapor.

[0189] Alternatively, the hot outlet gas contains a maximum of about 40-80% by volume, preferably about 50-70% by volume, of hot water vapor.

[0190] Alternatively, the hot outlet gas contains a maximum of about 20-60% by volume, preferably about 30-40% by volume, of hot water vapor.

[0191] Alternatively, the hot outlet gas contains a maximum of about 10-30% by volume, preferably about 15-20% by volume, of hot water vapor.

[0192] Alternatively, the hot exit gas (top gas) comprises hot water vapor and excess hydrogen gas.

[0193] Alternatively, the excess hydrogen gas may be separated from the hot outlet gas, recycled to the direct reduction facility, and introduced into the direct reduction facility to effect direct reduction within the direct reduction facility.

[0194] Alternatively, the metallic materials production configuration includes a top gas recirculation arrangement adapted to recirculate excess hydrogen gas of the hot outlet gas and add it to the hydrogen produced by the high temperature electrolysis unit.

[0195] Alternatively, a carbon-containing gas is added to the reducing agent to incorporate carbon into the intermediate product.

[0196] Alternatively, at least a significant amount of a carbon-containing gas is added to the reducing agent so that the intermediate product contains carbon.

[0197] Alternatively, the carbon-containing gas includes methane and / or other carbon-containing gases from biogas production, and / or carbon-containing gases from pyrolysis of renewable feedstocks, and / or synthesis gas from biomass.

[0198] Alternatively, the reducing agent configured for direct reduction has at least a sufficient amount of a carbon-containing gas added thereto to provide an intermediate product that includes carbon.

[0199] Alternatively, the reducing agent comprises hydrogen configured for the direct reduction of the metal oxide material and for effecting a chemical conversion of the metal oxide material to a carbon-free intermediate product.

[0200] Alternatively, the reducing agent (e.g., comprised of hydrogen and, optionally, including a carbon-containing gas) is introduced into the reduction process at a temperature lower and / or higher than the temperature of the metal oxide material charged to the direct reduction facility.

[0201] Alternatively, the reducing agent may be preheated to some extent before being introduced into the direct reduction equipment, and the reducing agent introduced may have a temperature of about 300°C to about 700°C, preferably about 400°C to about 650°C.

[0202] Alternatively, carbon-containing material extracted from the carbon source is added to the directly reduced metal material in a separate carburization zone of the direct reduction equipment and / or in a separate carburization reactor configured to introduce carbon to the metal oxide material to provide an intermediate product that is discharged from the direct reduction equipment or the separate carburization reactor.

[0203] Alternatively, the carbon-containing material may comprise pure carbon or may be a component of a molecule such as methane, propane or other hydrocarbons or other molecules.

[0204] Alternatively, the carbon production unit comprises a Sabatier reactor which produces methane CH4 from the reaction between hydrogen H2 and carbon dioxide CO2, this methane CH4 being a carbon-containing or hydrogen-containing gas which is transferred to a separate carburization zone and / or a separate carburization reactor.

[0205] Alternatively, the carbon production unit, and / or the carbon capture and utilization unit, and / or the biogas production unit, and / or the syngas production unit are incorporated as an integrated unit with the preheater, and / or the metal production unit, and / or the direct reduction facility, and / or the electrolysis unit.

[0206] Alternatively, the carbon production unit may comprise a Fischer-Tropsch apparatus configured to produce a carbon-containing product by reducing methane CH4 produced by the Sabatier reactor, and this carbon-containing product is transferred to a separate carburization zone and / or a separate carburization reactor.

[0207] Alternatively, the carbon capture and utilization unit (CCU) may comprise a CO2 capture device CCD configured to capture CO2 from the atmosphere, and this captured CO2 may be transferred to said Sabatier reactor configured for the production of carbon or methane CH4.

[0208] Alternatively, a carbon production unit configured for the production of carbon derived from non-fossil fuels may be used by a cement industry plant to manufacture cement from mined calcium minerals.

[0209] Alternatively, the method includes the steps of directly reducing a metal oxide material with a reducing agent having a hydrogen content of at least 80% by volume, then increasing the carbon content in the directly reduced metal material with a carburizing gas, and then at least partially removing the used carburizing gas while substantially avoiding mixing of the carburizing gas with the reducing agent.

[0210] Alternatively, the reducing agent comprises a hydrogen content of at least about 40-60% by volume, or about 50-70% by volume, or about 60-80% by volume, or about 70-90% by volume.

[0211] Alternatively, the carburization zone corresponds to a separate (insulated) carburization zone configured to avoid mixing of the carbon-containing material with the reducing agent.

[0212] Alternatively, the carburizing zone may comprise a carburizing volume within a direct reduction installation, the carburizing volume being configured for the reduction of metal oxide material and configured to carburize the metal oxide material subjected to reduction by mixing a carbon-containing material with a reducing agent.

[0213] Alternatively, the carburizing zone may comprise a carburizing volume (not shown) within a direct reduction installation, which is configured for the reduction of metal oxide material and configured to carburize the metal oxide material subjected to reduction and to mix the carbon-containing material with a reducing agent.

[0214] By utilizing the thermal energy of the metal oxide material to further heat the introduced reducing agent, the chemical reaction between the metal oxide material and the reducing agent is accomplished in an energy-efficient manner.

[0215] Alternatively, the control circuit is adapted to control the metal oxide material temperature of the metal oxide material transferred to the direct reduction equipment, and / or to control the internal gas pressure within the direct reduction equipment, and / or the reductant temperature and / or the reductant gas pressure of the introduced reductant, in order to reach a predetermined temperature of the metal oxide material to be subjected to reduction and / or heat treatment.

[0216] Alternatively, the direct reduction facility is configured to be charged with a metal oxide material having a temperature in the range of about 600-1500°C.

[0217] Alternatively, the direct reduction facility is configured to be charged with metal oxide material having a temperature within the range of about 500°C to 1600°C, preferably within the range of about 800°C to 1300°C.

[0218] Alternatively, the reduced metal material consists of reduced iron particles which bond together to form pellets of heat treated and / or heat hardened and / or passivated reduced iron material in the form of iron droplets.

[0219] Thereby an intermediate product (reduced iron material) suitable for steel production ("iron drip") is achieved, whereby an environmentally friendly (carbon-free / low carbon) production is achieved and at the same time a safe transport to the steel plant is achieved (durable against reoxidation).

[0220] The intermediate product produced is advantageous because it allows for more precise addition of the optimum amount of carbon in the EAF to achieve the desired steel quality.

[0221] The present disclosure may not be limited to the above examples, and yet many possibilities for modification or combination of the above examples should be apparent to those skilled in the art without departing from the basic idea as defined in the appended claims.

[0222] The present invention will now be described with reference to the embodiments and accompanying schematic drawings, in which some unimportant details may be omitted for clarity and understanding of the present invention. [Brief description of the drawings]

[0223] [Figure 1] 1 shows a metallic material production setup adapted for the reduction of metallic oxide materials according to a first example. [Diagram 2] 13 shows a flow diagram resulting from a metal material manufacturing configuration according to a second example. [Diagram 3] 13 shows a metallic material production setup adapted for the reduction of metallic oxide materials according to a third example. [Figure 4] 1 shows a phase diagram of iron phase domains as a function of the oxidizing power of hydrogen gas and temperature. [Diagram 5] 4 shows the mole / mole phase diagram of hydrogen / hydrogen+iron versus temperature. [Figure 6a] 1 illustrates the transition stages of iron ore aggregate structure associated with the heat treatment process. [Figure 6b] 1 illustrates the transition stages of iron ore aggregate structure associated with the heat treatment process. [Figure 6c] 1 illustrates the transition stages of iron ore aggregate structure associated with the heat treatment process. [Figure 7a] 4 shows a metallic material production setup adapted for the reduction of metallic oxide materials according to a fourth example. [Figure 7b] 4 shows a metallic material production setup adapted for the reduction of metallic oxide materials according to a fourth example. [Figure 8] 13 shows a closed loop diagram used by a metal material manufacturing configuration according to a fifth example. [Figure 9a] 1 shows a flow chart illustrating an exemplary method for reducing a thermal energy retaining metal oxide material to a reduced metal material. [Figure 9b] 1 shows a flow chart illustrating an exemplary method for reducing a thermal energy retaining metal oxide material to a reduced metal material. [Figure 10] 13 shows a control circuit for a metal material manufacturing configuration according to a sixth example. [Figure 11] 5 shows a metallic material production setup adapted for the reduction of iron ore oxide material according to a fifth example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0224] Figure 1 shows a metallic material production setup adapted for the reduction of a metal oxide material according to a first example. Figure 1 shows a metallic material production setup 1 adapted for the reduction of a thermal energy-retaining metal oxide material 5 into a reduced metallic material 16.

[0225] The metallic material production arrangement 1 comprises a metal oxide material supplier unit 3, such as a metal oxide pelletizing plant or a metal oxide preheating plant, configured to supply a thermal energy-holding metal oxide material 5. The metallic material production arrangement 1 comprises a reduction facility 7 configured to reduce the thermal energy-holding metal oxide material 5. A metal oxide material charging and transferring unit (not shown) of the metallic material production arrangement 1 is configured to charge the metal oxide material 5 into an upper interior UP of the reduction facility 7.

[0226] The reduction apparatus 7 comprises a reducing agent inlet (not shown) configured to introduce the hydrogen-containing reducing agent 6 into the lower interior of the reduction apparatus 7, whereby the hydrogen-containing reducing agent 6 is adapted to react with the metal oxide material 5, which holds thermal energy for reducing the metal oxide material 5, by utilizing thermal energy of the metal oxide material 5 to heat or further heat the introduced hydrogen-containing reducing agent 6 to effect a chemical reaction between the hydrogen-containing reducing agent 6 and the metal oxide material 5.

[0227] The hydrogen of the hydrogen-containing reductant 6 may be produced by an electrolysis unit 17 comprising a reductant temperature regulator 18 configured to regulate (pre-heat or cool) the temperature of the hydrogen-containing reductant 6 .

[0228] The reduction facility 7 is configured to provide a heat treatment process for the heat treatment of the metal oxide material 5 and / or reduced metal material 16 to be reduced. The metal material production arrangement 1 comprises a control circuit 50 electrically connected to a reducing agent temperature regulator 18 for pre-heating the hydrogen-containing reducing agent 6.

[0229] The control circuit 50 is adapted to control the temperature of the introduced preheated hydrogen-containing reducing agent 6 in order to bring about at least one desired passivation parameter value of the reduced metallic material 16. The control circuit 50 is electrically connected to the metal oxide material supply unit 3 and adapted to control the temperature of the metal oxide material to be charged in the upper interior UP. The reduced metallic material 16 exhibiting at least one desired passivation parameter value is discharged from the reduction facility 7 and transported to a steel manufacturer (not shown), while the reduced metallic material is resistant to reoxidation due to the passivation of the reduced metallic material 16.

[0230] The reduction facility 7 is further configured for the reduced metallic material 16 to descend into the lower interior LP to provide a heat treatment process for heat treatment of the reduced metallic material using additional thermal energy provided by the hydrogen-containing reducing agent. It is shown that the chemical reactivity and / or high driving force of the hydrogen of the hydrogen-containing reducing agent 6 is maintained.

[0231] Chemical reactivity and / or high driving force are essential to bring about an efficient reduction of the metal oxide material. The introduced hydrogen-containing reducing agent 6 comprises 80-100% hydrogen, preferably 100% hydrogen. The control circuit 50 is adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent 6 towards a predetermined temperature for bringing about sintering and / or heat treatment of the metal oxide material 5 subjected to reduction, during a predetermined period of time.

[0232] Alternatively, the temperature of the metal oxide material to be charged into the upper interior is controlled by a control circuit so as to be within the range of 900 to 1500°C, preferably 1000 to 1300°C.

[0233] Alternatively, the temperature of the hydrogen-containing reducing agent is controlled by a control circuit so as to be within a range of 100 to 400°C, preferably 200 to 300°C, or 0 to 300°C, preferably 100 to 200°C.

[0234] 2 shows a flow diagram provided by the metal material production configuration 1 according to the second example. A metal oxide material 5 that retains thermal energy is charged into a reduction facility 7. The reduction facility 7 can be defined as having an upper interior UP, a middle interior IP, and a lower interior LP. A hydrogen-containing reducing agent 6 is introduced into the middle interior IP and flows upward to intersect with the downwardly transferred metal oxide material 5 that retains thermal energy, whereby the upper interior UP serves as a countercurrent heat exchange zone for effecting a chemical reaction between the metal oxide material and the hydrogen-containing reducing agent 6.

[0235] Alternatively, the hydrogen-containing reducing agent 6 is pre-heated.

[0236] Alternatively, the metal oxide material that retains thermal energy is transported by gravity from the upper interior to the middle interior and / or the lower interior.

[0237] Alternatively, the temperature of the hydrogen-containing reducing agent 6 introduced into the upper interior UP is controlled by a control circuit (not shown) so that the waste reduction fluid 4 produced by the reduction contains 100% water vapor or substantially 100% water vapor.

[0238] Alternatively, the temperature of the hydrogen-containing reducing agent 6 introduced into the upper interior UP is controlled by a control circuit (not shown) so that the waste reduction fluid 4 produced by the reduction contains more than 90% water vapor and the remaining hydrogen-containing reducing agent, so that an excess volume of the hydrogen-containing reducing agent is achieved to ensure the complete reduction of the metal oxide material.

[0239] Due to the high temperature of the charged metal oxide material 5, efficient reduction of the metal oxide material 5 is achieved despite the fact that the hydrogen-containing reducing agent 6 contains a large amount of water vapor.

[0240] A preheated hydrogen-containing reductant 6' is additionally introduced into the middle inner part IP and / or the lower inner part LP. The temperature of the additionally introduced preheated hydrogen-containing reductant 6' is controlled by a control circuit for adapting the temperature towards a predetermined temperature for achieving sintering and / or heat treatment of the reduced metal material 16 during a predetermined period of time in order to bring about at least one desired passivation parameter value of the reduced metal material 16.

[0241] Alternatively, the location of introduction of the introduced pre-heated hydrogen-containing reducing agent 6' can be adjusted vertically VD along the extension of the direct reduction facility 7 to achieve optimal sintering and to control the heat treatment process to produce dense and solid reduced metal material pieces or pellets.

[0242] 3 shows a metallic material production arrangement 1 adapted for the reduction of a thermal energy retaining metal oxide material 5 to a reduced metallic material 16 according to a third example. The metallic material production arrangement 1 comprises a metal oxide material supplier unit 3, such as a metal oxide pelletizing plant or a metal oxide preheating plant, configured to supply a thermal energy retaining metal oxide material 5. The metallic material production arrangement 1 comprises a reduction facility 7 configured to reduce the thermal energy retaining metal oxide material 5.

[0243] The metal oxide material loading and transport unit 12 of the metal material production configuration 1 is configured to load metal oxide material 5 into the upper interior UP of the reduction equipment 7 via a metal oxide material loading device a configured to load the metal oxide material 5 retaining thermal energy into the top section of the upper interior UP, for example comprising a fire-resistant steel band for transportation (not shown).

[0244] The reduction facility 7 comprises a reducing agent inlet b adapted to introduce a preheated hydrogen-containing reducing agent 6 into an intermediate interior IP of the reduction facility 7, whereby the preheated hydrogen-containing reducing agent 6 reacts with the metal oxide material 5, which holds thermal energy for reducing the metal oxide material 5, by utilizing thermal energy of the metal oxide material 5 to heat or further heat the introduced preheated hydrogen-containing reducing agent 6 to effect a chemical reaction between the preheated hydrogen-containing reducing agent 6 and the metal oxide material 5. Hydrogen of the preheated hydrogen-containing reducing agent 6 can be produced by an electrolysis unit (not shown).

[0245] The metal oxide material 5 that retains thermal energy descends through the upper interior UP and is sequentially reduced to reduced metal material 16 in the upper interior UP. The temperature of the introduced preheated hydrogen-containing reducing agent 6 increases as the introduced preheated hydrogen-containing reducing agent 6 rises in the upper interior UP, and the metal oxide material 5 that retains thermal energy interacts with the introduced preheated hydrogen-containing reducing agent 6, and the metal oxide material 5 that retains thermal energy is cooled. The upper interior UP functions as a countercurrent heat exchange zone, promoting the chemical reaction between the metal oxide material and the preheated hydrogen-containing reducing agent 6.

[0246] Further, the middle interior portion IP is configured to provide a heat treatment process for heat treatment of the reduced metal material 16 in the middle interior portion IP. The reduced metal material 16 descends from the upper interior portion UP to the middle interior portion IP.

[0247] The control circuit 50 is electrically connected to a reductant preheater 18 configured to preheat the hydrogen-containing reductant 6 to be introduced into the intermediate interior IP via the reductant inlet b.

[0248] The control circuit 50 controls the temperature of the reduced metal material 16 towards a predetermined temperature, for example set in the range of 200-600°C, preferably 300-500°C, for a predetermined period of time long enough to enable a heat treatment process to result in at least one desired passivation parameter value of the reduced metal material.

[0249] As such, the temperature of the introduced pre-heated hydrogen-containing reducing agent 6 is controlled by the control circuit 50 to maintain the temperature of the reduced metallic material 16 in the intermediate inner IP at an elevated predetermined temperature for an extended period of time to accomplish the heat treatment process.

[0250] In that way, it is achieved that the heat treatment process for heat treating the reduced metal material uses additional thermal energy provided by the pre-heated hydrogen-containing reducing agent 6, and the heat treatment process is controlled by the control circuit 50.

[0251] The control circuit 50 is configured to control the additional thermal energy by adjusting the temperature of the introduced pre-heated hydrogen-containing reducing agent in such a manner that at least one desired passivation parameter value of the reduced metallic material is achieved.

[0252] The control circuit 50 may be electrically connected to an additional reducing agent pre-heater 18 ′ configured to pre-heat the hydrogen-containing reducing agent 6 introduced into the lower interior LP of the reduction arrangement 7 .

[0253] The introduced pre-heated hydrogen-containing reducing agent 6 supplied to the lower interior LP may contain 80-100% hydrogen, preferably 100% hydrogen. The control circuit 50 is adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent 6 supplied to the lower interior LP towards a predetermined temperature for effecting sintering and / or heat treatment of the reduced metallic material 16 during a predetermined period of time.

[0254] Alternatively, the volume of hydrogen-containing reducing agent introduced is such that complete reduction of the metal oxide material is achieved, and an excess volume of hydrogen-containing reducing agent is provided to the reduction facility to effect said reduction of the metal oxide material.

[0255] Figure 4 shows a phase diagram of the iron phase domains as a function of the oxidizing power of hydrogen gas and temperature for the gas mixture H2-H2O. As shown in the figure, the reduction of iron ore oxide material in the form of hematite, and / or magnetite, and / or wustite to reduced iron ore material is carried out in two or three stages, depending on whether the temperature is above or below 570°C. In this case, hematite Fe2O3 is reduced first to magnetite Fe3O4 and then to wustite Fe 1-Y O and finally to iron Fe.

[0256] The preheated hydrogen-bearing reducing agent 6 introduced into the reduction facility rises through the upper interior and contacts the iron ore oxide material descending under reduction, while the preheated hydrogen-bearing reducing agent 6 contains an increasing amount of water the higher the introduced preheated hydrogen-bearing reducing agent 6 rises in the upper interior UP. As shown in the figure, hematite is reduced to magnetite at high temperature (e.g., 1200°C) and reduction to magnetite is still achievable despite the high water content (e.g., 90%) of the preheated hydrogen-bearing reducing agent 6. The present solution to at least one of the targeted problems retains thermal energy and uses the high temperature of the iron ore oxide material charged into the upper interior from the iron ore oxide material feeder unit. This high temperature of the iron ore oxide material facilitates that reduction is possible despite the fact that the preheated hydrogen-bearing reducing agent contains an increased amount of water when it reaches the upper region of the upper interior.

[0257] Figure 5 shows the mole / mole phase diagram of hydrogen / hydrogen+iron in terms of different temperatures. Reference O represents the liquid phase, reference P represents the Bcc / liquid phase, reference Q represents the Bcc phase and reference R represents the Fcc phase. In the figure, it is shown that iron Fe is subjected to sintering in the Bcc+liquid phase P, i.e. the iron of the reduced iron ore material hardens at a relatively low temperature (e.g. 200-600°C) due to the fact that the introduced hydrogen maintains its chemical reactivity and / or high driving force.

[0258] As shown in the prior art, it is not necessary to "burn" the hydrogen or to heat it intensely, for example to 1200° C., to provide heat for the reduction.

[0259] Conversely, by using the thermal energy of the iron ore oxide material charged to the reduction installation to effect the reduction, it is possible to control and / or adjust and / or fine-tune the temperature of the introduced hydrogen-containing reducing agent in order to reach at least one desired passivation parameter value.

[0260] Thus, by controlling the temperature of the introduced hydrogen while maintaining a high chemical reactivity and / or a high driving force, the control circuitry can efficiently control the heat treatment process.

[0261] Alternatively, therefore, the control circuit is adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent to effect sintering of the reduced iron ore material agglomerates by such relatively low temperature for an extended period of time to achieve reduced iron ore material that is resistant to reoxidation.

[0262] In that way, the tendency of the intermediate products (illustratively sponge iron, e.g. pellets, briquettes, etc.) to revert to the oxidized state when exposed to the natural environment is prevented, achieving a reduced risk of spontaneous combustion processes.

[0263] Alternatively, the control circuit is adapted to control the internal gas pressure within the reduction equipment and / or the hydrogen temperature and / or hydrogen pressure of the pre-heated hydrogen-containing reducing agent.

[0264] The control circuit 50 is adapted to effect sintering of the reduced iron ore agglomerates subjected to sintering with Bcc+liquid phase P, or preferably to expose the reduced metal material to temperatures, for example in the range of 200-600°C, and high hydrogen / hydrogen+iron molar / molar ratios, for example 0.75-1.0 (shaded region S). Such relatively low temperatures provide reduced iron ore material that is resistant to reoxidation for long periods of time and by hydrogen with high chemical reactivity and / or high driving force.

[0265] Figures 6a-c show transition stages of iron ore aggregate structure related to the heat treatment process. Figure 6a shows the aggregate structure of iron ore oxide material 5 that holds the thermal energy to be subjected to reduction in the upper interior of the reduction equipment (not shown). It is shown that the iron ore oxide particles 10 are bonded together to form a porous aggregate 20, the porosity of which facilitates contact of the iron ore oxide with the introduced preheated hydrogen-bearing reducing agent during reduction. Figure 6b shows the aggregate 20 with reduced iron ore oxide material ready for heat treatment. Alternatively, the particles 10 have been sintered in the upper interior. Some iron ore oxide material (FeO) may be bound and / or remain in the pores of the aggregate 20. To provide a reduced iron ore material that is resistant to reoxidation, a heat treatment process is provided for the heat treatment of the reduced iron ore material and / or the iron ore oxide material to be subjected to reduction. This is achieved by the control circuit 50 being adapted to control the temperature of the introduced pre-heated hydrogen-containing reducing agent 6 towards a predetermined temperature for effecting sintering and / or heat treatment of the iron ore oxide material during a predetermined period of time. Figure 6c shows a fully or substantially fully reduced iron ore material, where the particles 10 of the agglomerates 20 form a denser structure, thereby preventing the eventual FeO from coming into contact with the ambient atmosphere outside the agglomerates 20 when discharged from the reduction facility. Figure 6c shows that the particles 10 of the agglomerates 20 of the reduced iron ore material 16 form a denser structure, which is achieved by sintering, as shown and described in conjunction with Figure 5.

[0266] Figures 7a-b show a metallic material production arrangement 1 according to a fourth example adapted for the reduction of a thermal energy retaining metal oxide material 5 to a reduced metallic material 16. The metallic material production arrangement 1 comprises a metal oxide material supplier unit 3, such as a metal oxide pelletising plant or a metal oxide pre-heating plant, arranged to supply a thermal energy retaining metal oxide material 5.

[0267] The metallic material production arrangement 1 comprises a reduction facility 7 configured to reduce a thermal energy-holding metal oxide material 5. The thermal energy-holding metal oxide material 5 is charged into an upper interior UP of the reduction facility 7.

[0268] The reductant preheater 18 configured to preheat the hydrogen-containing reductant is electrically connected to the control unit 50. The preheated hydrogen-containing reductant 6 is introduced into an intermediate interior IP of the reduction equipment 7, whereby the preheated hydrogen-containing reductant 6 is adapted to react with the metal oxide material 5 that retains thermal energy for reducing the metal oxide material 5 by utilizing thermal energy of the metal oxide material 5 to heat or further heat the introduced preheated hydrogen-containing reductant 6 and effect a chemical reaction between the preheated hydrogen-containing reductant 6 and the metal oxide material 5 that retains thermal energy.

[0269] The metal oxide material supply unit 3 is electrically connected to a control circuit 50 adapted for coarse setting of the thermal energy of the metal oxide material 5. The control circuit 50 controlling the reductant preheater 18 is adapted for fine setting of the temperature of the introduced preheated hydrogen-containing reductant 6 in order to achieve at least one desired passivation parameter value.

[0270] The control circuit 50 in FIG. 7a is adapted to control the temperature of the chemical reaction by coarse regulation of the thermal energy supplied by the metal oxide material supply unit 3 and by fine regulation of the temperature required for the chemical reaction and / or heat treatment process by controlling the temperature of the introduced pre-heated hydrogen-containing reducing agent 6.

[0271] Additionally, the pre-heated hydrogen-containing reducing agent may be introduced into the reduction equipment at different levels, and may be introduced at different temperatures, pressures, flow rates, and the like.

[0272] For example, the control circuit 50 may be electrically connected to an additional reducing agent pre-heater 18 ′ configured to pre-heat the hydrogen-containing reducing agent 6 introduced into the lower interior LP of the reduction equipment 7 .

[0273] In that way, efficient regulation of the temperature for the reduction of the metal oxide material is achieved and at the same time efficient regulation of the temperature for the heat treatment of the reduced metal material is achieved.

[0274] The introduced pre-heated hydrogen-containing reductant 6 supplied to the lower and / or inner LP may contain 80-100% hydrogen, preferably 100% hydrogen.

[0275] Alternatively, the temperature of the preheated hydrogen-containing reducing agent 6 introduced into the intermediate interior IP is controlled by the control circuit 50 so that the waste reduction fluid 4 produced by the reduction contains 100% water vapor or substantially 100% water vapor and is discharged. Due to the high temperature of the charged metal oxide material 5, efficient reduction of the metal oxide material 5 is achieved despite the fact that the preheated hydrogen-containing reducing agent 6 contains a large amount of water vapor.

[0276] Figure 7b shows the reduction facility 7 in a cross-sectional view. Preheated hydrogen-containing reducing agent 6 is introduced circumferentially around the middle interior. Waste reduction fluid 4 is discharged circumferentially from the reduction facility 7.

[0277] FIG. 8 shows a closed-loop diagram for a closed-loop algorithm used by a metallic material manufacturing arrangement according to a fifth example.

[0278] The control circuit 50 is electrically connected to the metal oxide material supplier unit 3, such as a metal oxide pelletizing plant or a metal oxide preheating plant, and is adapted to regulate the temperature of the metal oxide material bearing thermal energy to be charged to the reduction facility. The control circuit 50 may be adapted to control the temperature of the metal oxide material bearing thermal energy towards a predetermined temperature value PDTV for effecting a heat treatment process in the reduction facility for the heat treatment of the metal oxide material subjected to reduction and / or the reduced metal material during a predetermined period of time, thereby reaching at least one desired passivation parameter value DPPV of the reduced metal material.

[0279] The at least one desired passivation parameter value DPPV may relate to a porosity parameter, and / or a dimensional parameter, and / or a weight parameter, and / or a metal grain structure parameter, and / or a sample cut uniformity parameter, and / or a shrinkage parameter, and / or a sintering parameter, etc.

[0280] A passivation parameter detector PPD is associated with the reduction facility for detecting the actual passivation parameter value APPV. The control circuit 50 is capable of carrying out calculation and comparison procedures for regulating the temperature of the metal oxide material retaining thermal energy by the metal oxide material supply unit 3.

[0281] Alternatively, the control circuit 50 may be adapted to control the temperature of the charged metal oxide material in such a manner that a predetermined temperature value PDTV for effecting a heat treatment process indicates a temperature value of the heat treatment process for reaching at least one desired passivation parameter value DPPV.

[0282] The control circuit 50 repeats the closed loop algorithm until at least one desired passivation parameter value DPPV is reached.

[0283] The control circuit 50 is electrically connected to a reductant temperature adjustment device 18 configured for adjusting the temperature of the hydrogen-containing reductant to be introduced into the reduction facility of the metallic material production arrangement in order to achieve at least one desired passivation parameter value DPPV of the reduced metallic material. In a closed loop diagram, a start process may be used in which an input temperature value IN of the preheated hydrogen-containing reductant is used.

[0284] The control circuit 50 is adapted to control the reducing agent temperature adjustment device 18 in such a way that the temperature of the introduced preheated hydrogen-containing reducing agent is adapted towards a predetermined temperature value PDTV for effecting a heat treatment process in the reduction facility for the heat treatment of the metal oxide material and / or reduced metallic material to be reduced during a predetermined period of time, thereby reaching at least one desired passivation parameter value DPPV of the reduced metallic material. The control circuit 50 takes into account the at least one desired passivation parameter value DPPV when determining the predetermined temperature value PDTV. The at least one desired passivation parameter value DPPV of the reduced metallic material is determined with a view to reaching an efficient passivation of the reduced metallic material.

[0285] The at least one desired passivation parameter value DPPV may relate to a porosity parameter, and / or a dimensional parameter, and / or a weight parameter, and / or a metal grain structure parameter, and / or a sample cut uniformity parameter, and / or a shrinkage parameter, and / or a sintering parameter, etc.

[0286] The passivation parameter detector PPD is associated with a reduction facility for detecting an actual passivation parameter value APPV.

[0287] The actual passivation parameter value APPV of the reduced metallic material is detected by a passivation parameter detector PPD electrically connected to the control circuit 50. The control circuit 50 executes a calculation and comparison procedure for adjusting the reductant temperature adjustment device 18 in a manner that adapts the temperature of the introduced pre-heated hydrogen-containing reductant towards a predetermined temperature value PDTV for reaching at least one desired passivation parameter value DPPV.

[0288] The control circuit 50 repeats the closed loop algorithm until at least one desired passivation parameter value DPPV is reached.

[0289] The control circuit 50 is configured to compare the actual passivation parameter value APPV with at least one desired passivation parameter value DPPV, and controls the reductant temperature adjustment device 18 to adjust the temperature of the hydrogen-containing reductant until the at least one desired passivation parameter value DPPV is reached.

[0290] The thermal energy retaining metal oxide material may be metal oxide pellets that have been preheated to contain thermal energy. The metal oxide pellets may be produced by a pelletizing plant that processes the metal mixture and are transported to the reduction facility by a shipping steel band.

[0291] The upper interior of the reduction equipment is configured for reduction of the metal oxide pellets, the reduction equipment being configured to effect a chemical reaction between a hydrogen-containing reducing agent and the metal oxide pellets.

[0292] The lower portion and / or the middle portion are configured for a heat treatment process for heat treatment of the metal oxide material.

[0293] The reduced and heat-hardened metal material is discharged from the lower interior by a discharge transport unit connected to an opening in the lower interior.

[0294] The product produced by this process is a reduced metal material (16) comprised of reduced iron ore particles that have bonded together to form pellets of heat treated and / or heat hardened and / or passivated reduced iron ore material in the form of iron droplets.

[0295] Alternatively, the control circuit computer is electrically connected to the metal oxide material charging device to control the charging rate to the reduction facility.

[0296] The computer may be electrically connected to a metal oxide material supply unit for controlling the temperature of the metal oxide pellets to be charged, and / or may be electrically connected to a reductant temperature regulating device for controlling the temperature of the hydrogen-containing reductant introduced, and / or may be electrically connected to an exhaust transport unit.

[0297] 9a is a flow chart showing an exemplary method of reduction of a metal oxide material that retains thermal energy to a reduced metal material by a metal material production arrangement. The metal material production arrangement comprises a metal oxide material supply unit configured to supply a metal oxide material that retains thermal energy, a metal oxide material charging device configured to charge the metal oxide material into an upper interior of the reduction facility, and a reducing agent inlet device configured to introduce a hydrogen-containing reducing agent into an intermediate interior and / or a lower interior of the reduction facility, whereby the hydrogen-containing reducing agent is adapted to react with the metal oxide material that retains thermal energy for reducing the metal oxide material by utilizing the thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent to bring about a chemical reaction between the hydrogen-containing reducing agent and the metal oxide material. The metal material production arrangement is configured to bring about a heat treatment process for the heat treatment of the metal oxide material and / or the reduced metal material that is subjected to reduction, and a control circuit electrically connected to a reducing agent temperature adjustment device configured to adjust the temperature of the hydrogen-containing reducing agent is adapted to control the temperature of the introduced hydrogen-containing reducing agent to reach at least one desired passivation parameter value of the reduced metal material.

[0298] The method of Fig. 9a starts at step 901. Step 902 includes adapting the method. Step 903 includes stopping the method. Step 902 may include reducing the metal oxide material in the upper interior by utilizing thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent to effect a chemical reaction between the hydrogen-containing reducing agent and the metal oxide material, effecting a heat treatment process for heat treatment of the metal oxide material subjected to reduction and / or the reduced metal material before being discharged from the lower interior, and controlling the temperature of the introduced hydrogen-containing reducing agent for adjustment of the chemical reaction and / or the heat treatment process to reach at least one desired passivation parameter value of the reduced metal material.

[0299] FIG. 9b is a flow chart showing an exemplary method of reducing a metal oxide material that retains thermal energy by a metal material manufacturing configuration disclosed herein. The method starts at step 1001. Step 1002 includes preheating the metal oxide material. Step 1003 includes loading the metal oxide material that retains thermal energy into a reduction facility. Step 1004 includes introducing preheated hydrogen into the reduction facility. Step 1005 includes reducing the metal oxide material in the upper interior by utilizing the thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent to effect a chemical reaction between the hydrogen-containing reducing agent and the metal oxide material. Step 1006 includes effecting a heat treatment process for heat treatment of the reduced metal material in the middle interior and / or the lower interior. Step 1007 includes controlling the temperature of the introduced hydrogen-containing reducing agent for adjustment of the chemical reaction and / or heat treatment process to reach at least one desired passivation parameter value of the reduced metal material. Step 1008 includes discharging the reduced metal material from the reduction facility, the reduced metal material having at least one desired passivation parameter value and being resistant to reoxidation. Step 1009 includes stopping the method.

[0300] Alternatively, the reductant pre-heating device is adapted to adjust the temperature of the pre-heated introduced hydrogen-containing reductant.

[0301] 10 shows a metal material manufacturing configuration 1 with a control circuit 50 including a computer (not shown) according to a sixth example. The control circuit 50 is configured to control any of the example 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 further includes a processing unit 1010 and a read / write memory 1050.

[0302] The NVM 1020 comprises a first memory unit 1030. A computer program (which may be of any type suitable for any operational database) is stored in the first memory unit 1030 for use in controlling the functionality of the control circuit 50.

[0303] Furthermore, the control circuit 50 comprises a bus controller (not shown) and a serial communication port (not shown) providing a physical interface through which information is transferred separately in two directions. The control circuit 50 also comprises an I / O module (not shown) of any suitable type providing input / output signal transfer, an A / D converter (not shown) for converting continuously changing signals from the passivation parameter detector PPD and / or from a temperature sensor device for detecting the temperature of the metal oxide material retaining thermal energy and / or the temperature of the hydrogen-containing reducing agent introduced into the reduction facility and / or from various monitoring units (not shown) into a binary code suitable for processing by the computer of the control circuit 50.

[0304] The control circuit 50 further comprises an input / output unit (not shown) for adapting the time and date. The control circuit 50 may also comprise an event counter (not shown) for counting the number of event multiples occurring during the adjustment of the chemical reaction and / or heat treatment process to reach at least one desired passivation parameter value of the reduced metallic material.

[0305] Additionally, the control circuit 50 includes an interrupt unit (not shown) for providing multitasking capabilities and real-time computing. The NVM 1020 also includes a second memory unit 1040 for external control operations.

[0306] A data medium adapted to store a data program P includes a driver routine adapted to command the operation of the metallic material manufacturing arrangement 1 .

[0307] The data program P is adapted to operate the control circuit 50 in performing any of the exemplary methods described herein. The data program P includes routines for executing instructions during operation of the metallic material manufacturing configuration 1. The data program P includes computer readable program code for causing a computer to perform the exemplary methods described herein.

[0308] The data program P may further be stored in a separate memory 1060 and / or in the read / write memory 1050. In this embodiment, the data program P is stored in an executable or compressed data format.

[0309] When the processing unit 1010 is described as performing a particular function, this should be understood to involve the processing unit 1010 executing a particular portion of a program stored in separate memory 1060 or a particular portion of a program stored in read / write memory 1050.

[0310] The processing unit 1010 is associated with a signal (data) port 1099 for communication via a first data bus 1015, which may be adapted to be electrically connected to electronic control circuitry of an operator station (not shown).

[0311] In that way it is achieved that an operator is able to control and monitor the metal material production arrangement 1 via the display of the electronic control circuitry.

[0312] The non-volatile memory NVM 1020 is adapted for communication with the processing unit 1010 via a second data bus 1012. The separate memory 1060 is adapted for communication with the processing unit 1010 via a third data bus 1011. The read / write memory 1050 is adapted to communicate with the processing unit 1010 via a fourth data bus 1014. The signal (data) port 1099 may be connectable to a data link, such as a network, connected to the control circuit 50.

[0313] When data is received by the signal port 1099, the data is temporarily stored in the second memory unit 1040. After the received data is temporarily stored, the processing unit 1010 is ready to execute program code according to the exemplary method.

[0314] Preferably, the signal (received by signal (data) port 1099) contains information about the operating state of the metallic material manufacturing arrangement 1.

[0315] Signals received at a signal port 1099, such as a serial bus, may be used by the control circuit 50 to control and monitor the reduction and heat treatment process.

[0316] The signal received by the signal (data) port 1099 can be used as historical data and data regarding the operation of the metal material manufacturing configuration 1.

[0317] The metal material manufacturing arrangement 1 may be configured to be connected to a data network via a signal bus configured for an electrical interface expressly providing electrical compatibility and associated data transfer, and this data may include information about the status of the metal material manufacturing arrangement 1 and the sensor devices. The data may also be manually sent to or displayed from the computer via a suitable communication device such as a display (not shown).

[0318] The separate sequences of this method may be carried out by a computer running a data program P stored in a separate memory 1060 or in the read / write memory 1050. When the computer runs the data program P, the method steps according to any of the examples disclosed herein are performed.

[0319] A data program product may be provided that includes program code stored on a suitable computer-readable data medium for performing the exemplary method steps of the present specification when the data program P is run on a computer.

[0320] FIG. 11 shows a metal material production arrangement 1 adapted for reducing an iron ore oxide material 5 bearing thermal energy into a reduced iron ore material 16. The metal material production arrangement 1 comprises an iron ore oxide material feeder unit 3 configured for feeding an iron ore oxide material 5 bearing thermal energy. An iron ore oxide material charging device a configured for charging the iron ore oxide material 5 into an upper interior UP of a reduction facility 7. A reducing agent inlet device b configured for introducing a hydrogen-bearing reducing agent 6 into an intermediate interior IP and / or a lower interior LP of the reduction facility 7. The hydrogen-bearing reducing agent 6 is preheated and adapted to react with the iron ore oxide material 5 bearing thermal energy for reducing the iron ore oxide material 5 by utilizing thermal energy of the iron ore oxide material 5 to further heat the introduced hydrogen-bearing reducing agent 6 to bring about a chemical reaction between the hydrogen-bearing reducing agent 6 and the iron ore oxide material 5.

[0321] The reducing agent 6 is preheated and introduced into the direct reduction plant 7 so that the reducing agent 6 not only effects the direct reduction and / or chemical reaction, but also reduces the cooling rate of the directly reduced iron ore material RT descending through the direct reduction plant 7 and / or the iron ore oxide material 5 subjected to direct reduction. The temperature of the iron ore oxide material 5 charged into the upper interior UP of the direct reduction plant 7 is lower than the temperature of the preheated reducing agent 6 introduced into the direct reduction plant 7.

[0322] The reduction potential of the hydrogen of the reducing agent (reference numeral 6 a ) moving through the upper interior is lower than the reduction potential of the hydrogen of the reducing agent introduced further below in the reduction unit 7 .

[0323] The reduction facility 7 is configured to provide a heat treatment process for the thermal treatment of the iron ore oxide material 5 and / or reduced iron ore material 16 subjected to reduction.

[0324] The direct reduction facility 7 comprises a heat treatment zone HZ configured for a heat treatment process for heat treating the reduced iron ore material by exposing the reduced iron ore material to a required heat treatment temperature to effect heat treatment of the reduced iron ore material to obtain a densified reduced iron ore material.

[0325] The metallic material production arrangement 1 comprises a control circuit 50 electrically connected to a reducing agent temperature regulating device 18 configured to regulate a temperature of the reducing agent 6. The control circuit 50 is adapted to control the temperature of the introduced reducing agent 6 in order to reach at least one desired passivation parameter value of the reduced iron ore material 16.

[0326] The upper interior UP is configured to effect at least some of the chemical reaction by further heating the reducing agent (reference numeral 6a) moving through the upper interior UP in order to achieve a chemical reaction between the iron ore oxide material 5 moving through the upper interior and the reducing agent 6a.

[0327] By introducing the reducing agent 6 into the direct reduction equipment at a higher temperature, it is achieved that the thermal energy is preserved and the iron ore oxide material 5 which reaches the intermediate part IP and / or the lower interior LP and is subjected to direct reduction and / or heat treatment does not cool down rapidly in the direct reduction equipment 7, i.e. the cooling rate of the iron ore oxide material 5 which is subjected to direct reduction and / or heat treatment is reduced.

[0328] Alternatively, the direct reduction facility 7 is configured such that the reduced iron ore material can descend into the lower interior LP and / or the intermediate interior IP to effect the heat treatment process.

[0329] Alternatively, thermal treatment of the reduced iron ore material is achieved by the introduction of a pre-heated reducing agent 6 , with the reduced iron ore material 16 being contacted with the pre-heated reducing agent 6 .

[0330] The reducing agent temperature regulation device 18 is configured to maintain the required heat treatment temperature by the introduction of preheated reducing agent 6 .

[0331] Alternatively, the step of maintaining the required heat treatment temperature may be provided by the introduction of preheated (hydrogen-containing) reducing agent to the extent that the cooling rate of the reduced iron ore material 16 is slowed to maintain the required heat treatment temperature.

[0332] The direct reduction equipment 7 is equipped with a metal material discharge device c that discharges the reduced metal material 16 that has been subjected to the heat treatment.

[0333] The control circuit of the metal material production arrangement 1 is connected to the iron ore oxide material supplier unit 3 and is configured to control the temperature of the iron ore oxide material 5 to be charged, so that the iron ore oxide material 5 subjected to reduction and / or heat treatment tends to a predetermined temperature for a predetermined period of time long enough to enable a heat treatment process resulting in the desired passivation parameter values ​​of the reduced iron ore material, and then providing an intermediate product resistant to re-oxidation.

[0334] Alternatively, the control circuit 50 is connected to a reductant temperature adjustment device 18 configured to pre-heat the reductant prior to introduction into the direct reduction plant 7 and is configured to control the temperature of the reductant, thereby directing the iron ore oxide material subjected to reduction and / or heat treatment towards a predetermined temperature.

[0335] Alternatively, the control circuit 50 is electrically connected to a reducing agent temperature adjustment device 18 configured for adjusting the temperature of a hydrogen-containing reducing agent introduced into a reduction facility of a metal material manufacturing configuration to achieve at least one desired passivation parameter value.

[0336] Alternatively, the control circuit 50 is electrically connected to a reducing agent temperature adjustment device 18 configured for adjusting the temperature of the hydrogen-containing reducing agent introduced into the reduction equipment for chemical reactions and / or heat treatment processes by controlling the temperature of the introduced pre-heated hydrogen-containing reducing agent 6.

[0337] The control circuit 50 is connected to a material temperature regulating device 98 adapted to control the temperature of the chemical reaction by regulating the thermal energy supplied by the iron ore oxide material supply unit 3 .

[0338] In that way, efficient processing and energy-saving recirculation of the high-temperature steam in the top gas produced by the chemical reaction assisted by the hot charge iron ore oxide material is achieved, and this high-temperature steam is supplied to the high-temperature electrolysis unit 17, thus enabling the high-temperature electrolysis unit to operate energy-efficiently due to the efficient heat recovery of the high-temperature steam and due to the high content of high-temperature steam in the top gas discharged from the direct reduction facility.

[0339] Alternatively, the high temperature electrolysis unit is configured to produce hydrogen and the iron ore oxide material supplier unit is configured to supply iron ore oxide material that retains thermal energy.

[0340] Alternatively, the direct reduction facility comprises an iron ore oxide material charge inlet device, a reductant inlet device configured to introduce a hydrogen-containing reductant carrying additional thermal energy.

[0341] Alternatively, the control circuit is configured to control the direct reduction of the iron ore oxide material by regulating the temperature of the charged iron ore oxide material and the introduced hydrogen-containing reductant.

[0342] Alternatively, due to the high temperature of the charged iron ore oxide material which retains thermal energy, it is achieved that the hot outlet gas (top gas) generated in the upper interior contains hot water vapor due to the high temperature transport from the charged iron ore oxide material which further heats the hydrogen-containing reducing agent which has risen to the upper interior resulting in said (endothermic) chemical reaction.

[0343] Alternatively, the high temperature steam is transferred to a high temperature electrolysis unit 17 .

[0344] Alternatively, a carbon-containing gas is added to the reducing agent to incorporate carbon into the intermediate product in a carburization zone (not shown).

[0345] Alternatively, the carburization zone corresponds to a separate (insulated) carburization zone configured to avoid mixing of the carbon-containing material with the reducing agent.

[0346] Alternatively, the carburizing zone may comprise a carburizing volume within a direct reduction installation, the carburizing volume being configured for the reduction of iron ore oxide material and configured to carburize the iron ore oxide material subjected to reduction by mixing a carbon-containing material with a reducing agent.

[0347] Naturally, the present invention is in no way limited to the above-described preferred examples, but many possibilities for modification or combination of the above examples should be apparent to those skilled in the art, without departing from the basic idea of ​​the invention as defined in the appended claims.

Claims

1. A method for the reduction of a thermal energy retaining metal oxide material (5) to a reduced metal material (16), comprising the steps of: said metal oxide material (5) carrying thermal energy is supplied by a metal oxide material supply unit (3) and is charged into the upper interior (UP) of a reduction facility (7) of the metal material production arrangement (1) via a metal oxide material charging device (a), a control circuit (50) electrically connected to a reducing agent temperature regulation device (17) configured to regulate the temperature of a hydrogen-containing reducing agent (6, 6') to be introduced into the intermediate interior (IP) and / or the lower interior (LP) of said reduction installation (7) via a reducing agent inlet device (b), The method further comprising: - reducing said metal oxide material (5) in the upper interior (UP) by utilizing the thermal energy of said metal oxide material (5) to heat or further heat the introduced hydrogen-containing reducing agent (6, 6') in order to bring about a chemical reaction between said hydrogen-containing reducing agent (6, 6') and said metal oxide material (5); - providing a heat treatment process for the heat treatment of said metal oxide material (5) subjected to reduction and / or said reduced metal material (16) before being discharged from said lower interior (LP); - controlling the temperature of the introduced hydrogen-containing reducing agent (6, 6') for regulation of the chemical reactions and / or the heat treatment process to reach at least one desired passivation parameter value (DPPV) of the reduced metallic material (16); A method comprising:

2. 2. The method according to claim 1, wherein the reductant temperature adjustment device (17) comprises a reductant pre-heating device (18) adapted to adjust the temperature of a pre-heated introduced hydrogen-containing reductant (6, 6'), the reductant pre-heating device (18) being electrically connected to the control circuit (50).

3. 3. The method according to claim 1 or 2, wherein the step of controlling the temperature of the introduced hydrogen-containing reducing agent (6, 6') comprises adapting the temperature towards a predetermined temperature for effecting sintering of the metal oxide material (5) subjected to reduction and / or heat treatment of the reduced metal material (16) during a predetermined period of time in order to reach the at least one desired passivation parameter value (DPPV).

4. The method according to any one of claims 1 to 3, wherein the introduced hydrogen-containing reducing agent (6) comprises, by volume, 90 to 100% hydrogen, preferably 100% hydrogen.

5. 5. The method according to claim 1, wherein the control circuit (50) is adapted for coarse setting of the temperature of the metal oxide material retaining thermal energy by the metal oxide material supply unit (3) and for fine setting of the temperature of the introduced hydrogen-containing reducing agent (6) in order to achieve the at least one desired passivation parameter value (DPPV).

6. 6. The method according to any one of claims 1 to 5, wherein the introduced volume of hydrogen-containing reducing agent (6, 6') is such that complete reduction of the metal oxide material (5) is achieved, and an excess volume of hydrogen-containing reducing agent (6, 6') is supplied to the reduction facility (7) to effect the reduction of the metal oxide material (5).

7. The method according to any one of claims 1 to 6, wherein the introduced hydrogen-containing reducing agent (6, 6') is introduced into the reduction facility (7) via a reducing agent inlet device (b) comprising at least one reducing agent inlet of the reduction facility (7).

8. A metallic material production arrangement (1) adapted for reducing a thermal energy-retaining metal oxide material (5) into a reduced metallic material (16), said metallic material production arrangement (1) comprising: a metal oxide material supply unit (3) configured to supply said metal oxide material (5) that holds thermal energy; a metal oxide material charging device (a) configured to charge said metal oxide material (5) into an upper interior (UP) of a reduction installation (7); a reducing agent inlet device (b) configured to introduce a hydrogen-containing reducing agent (6) into the intermediate interior (IP) and / or the lower interior (LP) of the reduction equipment (7), whereby the hydrogen-containing reducing agent (6, 6') is adapted to react with the metal oxide material (5) that holds thermal energy for reducing the metal oxide material (5) by utilizing the thermal energy of the metal oxide material (5) to heat or further heat the introduced hydrogen-containing reducing agent (6, 6') to effect a chemical reaction between the hydrogen-containing reducing agent (6, 6') and the metal oxide material (5); In a metal material manufacturing configuration (1), the reduction facility (7) of the metallic material production arrangement (1) is configured to provide a heat treatment process for the heat treatment of the metal oxide material (5) and / or the reduced metallic material (16) subjected to reduction, A control circuit (50) electrically connected to a reducing agent temperature regulating device (17) configured to regulate the temperature of the hydrogen-containing reducing agent (6, 6') is adapted to control the temperature of the introduced hydrogen-containing reducing agent (6, 6') to reach at least one desired passivation parameter value (DPPV) of the reduced metallic material (16). A metal material manufacturing configuration (1).

9. 9. The metallic material production arrangement (1) according to claim 8, wherein the reduction facility (7) comprises a passivation parameter detector (PPD) connected to the control circuit (50) configured for detection of an actual passivation parameter value (APPV).

10. The metallic material production arrangement (1) according to claim 8 or 9, wherein the introduced hydrogen-containing reducing agent (6, 6') comprises, by volume, 90-100% hydrogen, preferably 100% hydrogen.

11. The metallic material production arrangement (1) according to any one of claims 8 to 10, wherein the control circuit (50) is configured to control the temperature of the metal oxide material (5) to be charged to the direct reduction facility (7).

12. A data program (P) programmed to cause a metallic material manufacturing configuration (1) according to any one of claims 8 to 11 to carry out the method according to any one of claims 1 to 7, the data program (P) comprising: - reducing said metal oxide material (5) in the upper interior (UP) by utilizing the thermal energy of said metal oxide material (5) to heat or further heat the introduced hydrogen-containing reducing agent (6, 6') in order to bring about a chemical reaction between said hydrogen-containing reducing agent (6, 6') and said metal oxide material (5); - providing a heat treatment process for the heat treatment of said metal oxide material (5) subjected to reduction and / or said reduced metal material (16) before being discharged from said lower interior (LP); - controlling the temperature of the introduced hydrogen-containing reducing agent (6, 6') for regulation of the chemical reactions and / or the heat treatment process to reach at least one desired passivation parameter value (DPPV) of the reduced metallic material (16); A data program (P) comprising a computer readable program code for said control circuit (50) to provide said

13. A data medium arranged to store a data program (P) according to claim 12, said data medium comprising computer readable program code for carrying out the method according to any one of claims 1 to 7.

14. 8. A product produced by the method of any one of claims 1 to 7, wherein the reduced metallic material (16) consists of reduced iron ore particles bonded together to form pellets of heat treated and / or heat hardened and / or passivated reduced iron ore material in the form of iron droplets.

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