Direct reduction equipment and method for metal oxides

Abstract

The present invention relates to a metallic material manufacturing system and a method for directly reducing a metal oxide material having a first thermal energy to a reduced metallic material. The method includes the steps of: feeding a metal oxide material having a first thermal energy into a direct reduction facility via a metal oxide material feeding device; and introducing a preheated hydrogen-containing reducing agent having a second thermal energy into the direct reduction facility via a reducing agent feeding device. The first thermal energy of the metal oxide material is used to heat or further heat the introduced preheated hydrogen-containing reducing agent, thereby inducing a chemical reaction between the introduced preheated hydrogen-containing reducing agent and the metal oxide material, thereby directly reducing the metal oxide material; exposing the reduced metallic material to a heat treatment temperature required to obtain a densified reduced metallic material by heat treatment of the reduced metallic material; and maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reducing agent using the heat treatment providing device.

Description

[Technical Field]

[0001] The present invention relates to a method for the direct reduction of metal oxide materials to reduced metal materials.

[0002] The present invention further relates to a direct reduction facility configured to reduce metal oxide material to produce reduced metal material (e.g., sponge iron).

[0003] The present invention further relates to a metal material manufacturing arrangement configured to produce reduced metal material that is resistant to reoxidation for cost-effective, safe, refractory transport of the reduced metal material to customers, such as metal manufacturers.

[0004] The present invention further relates to a data program adapted to control selected portions of a direct reduction facility and / or metallic materials production configuration to produce reduced metallic materials that are resistant to reoxidation.

[0005] The present disclosure may relate to a direct reduction facility configured to produce carbon-free reduced metallic materials that are resistant to reoxidation.

[0006] The invention further relates to a data program adapted to control the operation of a metallic material manufacturing arrangement.

[0007] The present invention relates primarily to the mining and reduced metal materials manufacturing industry and is relevant to manufacturers and suppliers of metal materials manufacturing equipment, metal oxide materials manufacturing units, direct reduction facilities, metal manufacturing industries, high temperature electrolysis units, data program providers, etc. [Background technology]

[0008] Current techniques for producing reduced metallic materials may utilize various strategies to prevent the reoxidation of the produced reduced metallic materials.

[0009] Current technology is aimed at energy-efficient production of reduced metal materials that are resistant to reoxidation.

[0010] Current technology targets the energy-efficient direct reduction of metal oxide materials using hydrogen, which is produced completely or partially by fossil-free and / or renewable energy-based water electrolysis.

[0011] Current technologies sometimes use hydrogen for the direct reduction of metal oxide materials, rather than using carbon-based reductants such as natural gas. One example is the HYBRIT™ concept, which proposes hydrogen direct reduction (H-DR) using hydrogen produced by electrolysis of water using renewable energy rather than fossil fuels.

[0012] Energy-saving and cost-effective production of reoxidation-resistant directly reduced metal materials is also found in the IronDrop™ concept. The IronDrop™ concept, developed by LKAB, aims to eliminate fossil fuels and / or utilize renewable energy in the energy-efficient production of reoxidation-resistant reduced metal materials. The IronDrop™ initiative also aims to advance current technology in the production of reoxidation-resistant sponge iron.

[0013] The direct reduction of metal oxide materials using introduced hydrogen-containing reducing agents requires high reaction temperatures to cause chemical reactions in the direct reduction process in the direct reduction equipment. Summary of the Invention

[0014] While the IronDrop™ concept works efficiently, the goal is to further develop IronDrop™ technology and provide a new approach to the current technology of using hydrogen for the direct reduction of metal oxide materials.

[0015] The present invention provides an energy-efficient production of reduced metallic materials that are treated to become reoxidation resistant prior to discharge from a direct reduction facility.

[0016] The objective is to establish efficient direct reduction of metal oxide materials and at the same time efficient control of the production of reduced metal materials that are resistant to reoxidation.

[0017] The objective is to efficiently use hydrogen in the production of reduced metal materials that are resistant to reoxidation, using hydrogen that is produced without using fossil fuels and / or by using renewable energy.

[0018] The objective is to provide a cost-effective transportation supply chain for transporting reduced metal materials to other industries, such as metal manufacturing.

[0019] The objective is to produce intermediate products that are resistant to reoxidation and are used in the cost-effective production of metallic materials such as steel.

[0020] The object is to provide a method for producing reduced metal materials that are resistant to reoxidation on an industrial scale in a CO2-neutral and / or low CO2-emission and / or CO2-free manner.

[0021] The objective is to provide reduced metal materials that are carbon-free and resistant to reoxidation through an energy-efficient direct reduction process.

[0022] The goal is to produce a substantially fully metallized reduced metal material that is greater than about 90%, preferably about 95-100%, reduced, thereby reducing the hydrogen content of the top gas in the hydrogen accumulation and / or direct reduction facility.

[0023] The goal is to produce a substantially fully metallized reduced metal material, which is greater than about 75% reduced.

[0024] The purpose of this project is to simplify the treatment of furnace top gas (produced by chemical reactions within the direct reduction equipment) removed from the direct reduction equipment, and to efficiently recycle the furnace top gas.

[0025] The objective is to establish efficient direct reduction of metal oxide materials and at the same time efficient control of reduced metal material production.

[0026] These or at least one of these objects can be achieved by a method for directly reducing a metal oxide material possessing a first thermal energy to a reduced metal material using a metal material production configuration, the metal oxide material possessing the first thermal energy being provided by a metal oxide material providing unit, the method comprising the steps of: inputting the metal oxide material possessing the first thermal energy into a direct reduction facility via a metal oxide material input device; introducing a preheated hydrogen-containing reducing agent possessing a second thermal energy into the direct reduction facility via a reducing agent input device; reducing the metal oxide material by utilizing the first thermal energy of the metal oxide material to heat or further heat the introduced preheated hydrogen-containing reducing agent and inducing a chemical reaction between the introduced preheated hydrogen-containing reducing agent and the metal oxide material; exposing the reduced metal material to a heat treatment temperature required to obtain a densified reduced metal material by heat treatment of the reduced metal material; maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reducing agent using a heat treatment providing device; and discharging the heat-treated reduced metal material.

[0027] Alternatively, the method further includes introducing a third thermal energy-carrying, preheated, hydrogen-containing heat treatment agent into the direct reduction equipment using a heat treatment agent supply device to maintain the required heat treatment temperature and expose the reduced metallic material to the required heat treatment temperature for heat treating the reduced metallic material to obtain a densified reduced metallic material.

[0028] Alternatively, the reducing agent inlet of the reducing agent introduction device configured to introduce the preheated hydrogen-containing reducing agent into the direct reduction equipment is positioned higher within the direct reduction equipment than the heat treatment agent inlet of the heat treatment agent supply device configured to introduce the preheated hydrogen-containing heat treatment agent.

[0029] In this way, the cooling rate of the reduced metallic material descending through the direct reduction facility is reduced, allowing for effective heat treatment of the reduced metallic material.

[0030] Alternatively, the heat treating agent supply device comprises a heat treating agent pre-heating unit configured to pre-heat the hydrogen-containing heat treating agent to reach the third thermal energy before introduction into the direct reduction facility.

[0031] Alternatively, the thermal treatment agent supply device is configured to introduce a third thermal energy-carrying, hydrogen-containing thermal treatment agent.

[0032] Alternatively, the reduced metallic material is heat-treated by introducing a preheated hydrogen-containing heat treatment agent into the direct reduction equipment, where a third thermal energy is increased using a heat treatment agent supply device to reduce the cooling rate of the reduced metallic material within the direct reduction equipment.

[0033] Alternatively, the control circuit is electrically coupled to the heat-treating agent thermal energy adjusting device of the heat-treating agent supply device to adjust the third thermal energy of the hydrogen-containing heat-treating agent to control the heat treatment of the reduced metallic material.

[0034] Alternatively, the reduced metal material is heat-treated using the third thermal energy of the hydrogen-containing heat treatment agent to shrink the metal particles of the reduced metal material.

[0035] The preheating hydrogen-containing heat treatment agent contains about 80 to 100% hydrogen, preferably about 100% hydrogen by volume, or about 60 to 80% hydrogen by volume, preferably about 65 to 75% hydrogen by volume.

[0036] Alternatively, direct reduction of the metal oxide material occurs through the introduction of preheated hydrogen, and a step is performed to maintain the required heat treatment temperature to an extent that the cooling rate of the reduced metal material descending through the direct reduction facility is slowed to maintain the required heat treatment temperature.

[0037] Alternatively, the metal oxide material includes an iron ore oxide material that is directly reduced to a reduced iron ore material, wherein the wustite material of the iron oxide material to be reduced is largely reduced to iron material due to the high hydrogen gas content of the introduced preheated hydrogen-containing reducing agent and / or hydrogen-containing heat treatment agent and the second thermal energy and / or third thermal energy preheated hydrogen-containing heat treatment agent.

[0038] Alternatively, the direct reduction facility is configured so that the reduced metallic material descends and contacts a preheated hydrogen-containing reducing agent and / or a preheated hydrogen-containing heat treatment agent for heat treatment.

[0039] Alternatively, the cooling rate of the reduced metallic material descending through the direct reduction facility is controlled using a control circuit by adjusting the temperature of the hydrogen-containing reducing agent and / or adjusting the mass flow rate of the hydrogen-containing reducing agent supplied to the direct reduction facility.

[0040] Alternatively, the cooling rate of the reduced metallic material descending through the direct reduction equipment is controlled using a control circuit by adjusting the temperature of the hydrogen-containing heat treatment agent and / or adjusting the mass flow rate of the hydrogen-containing heat treatment agent supplied to the direct reduction equipment.

[0041] In this way, the cooling rate is reduced to match the cooling rate of the reduced metallic material in the direct reduction equipment where the reduced metallic material is heat-treated, so that the reduced and heat-treated reduced metallic material forms compact, dense reduced metallic material (agglomerates), each having a compact, dense structure that is resistant to reoxidation.

[0042] In this way, the thermal energy of the reduced metallic material is maintained also in the lower part of the direct reduction equipment for carrying out the heat treatment.

[0043] Alternatively, the method includes preheating the hydrogen-containing reducing agent introduced into the direct reduction facility to the required heat treatment temperature using a reducing agent preheating device of the heat treatment providing device.

[0044] Alternatively, before introducing the hydrogen-containing reducing agent having a second thermal energy, a step of preheating the hydrogen-containing reducing agent is performed such that the second thermal energy of the introduced hydrogen-containing reducing agent does not exceed the first thermal energy of the metal oxide material introduced into the direct reduction equipment.

[0045] Alternatively, the step of maintaining the required thermal treatment temperature includes adjusting the second thermal energy using a reducing agent thermal energy adjustment device electrically coupled to a first control circuit configured to operate the reducing agent thermal energy adjustment device to control the required thermal treatment temperature.

[0046] Alternatively, the step of maintaining the required heat treatment temperature includes regulating the mass flow rate of the hydrogen-containing reductant introduced to the direct reduction equipment using a reductant mass flow regulating device electrically coupled to a second control circuit configured to operate the reductant mass flow regulating device to control the required heat treatment temperature.

[0047] Alternatively, the step of maintaining the required heat treatment temperature includes adjusting a residence time that maintains the reduced metallic material in the direct reduction equipment for a particular residence time using a residence time adjusting device electrically coupled to a third control circuit configured to operate the residence time adjusting device to achieve the particular residence time and control the required heat treatment temperature.

[0048] Alternatively, the step of providing the required heat treatment temperature includes adjusting the pressure inside the direct reduction equipment using a pressure adjusting device electrically coupled to a fourth control circuit configured to operate the pressure adjusting device to control the required heat treatment temperature.

[0049] Alternatively, the pressurization adjusting device may include a reducing agent introduction / pressurization device and / or a top gas removal device, and / or by adjusting the mass flow rate of top gas removed from the direct reduction facility.

[0050] Alternatively, the reducing agent introduction / pressurization device comprises a reducing agent pressurization gas pump.

[0051] Alternatively, the top gas removal device comprises a top gas suction pump.

[0052] Alternatively, pressurization within the direct reduction plant is achieved by introducing a hydrogen-containing reducing agent and / or adjusting the mass flow rate of the furnace gas removed from the direct reduction plant.

[0053] Alternatively, the direct reduction is carried out in a direct reduction facility at a pressure of from about 1 Bar to about 10 Bar, preferably from 3 Bar to about 8 Bar.

[0054] Alternatively, the direct reduction is carried out in a direct reduction facility at a pressure of from about 4 Bar to about 14 Bar, preferably from 6 Bar to about 12 Bar.

[0055] Alternatively, the direct reduction is carried out in a direct reduction facility at a pressure of less than 1 Bar.

[0056] Alternatively, the fifth control circuit is adapted to operate a heat treatment agent preheating unit that adjusts the third thermal energy of the preheated hydrogen-containing heat treatment agent to expose the reduced metal material to a heat treatment temperature required to obtain a densified reduced metal material by heat treatment of the reduced metal material and to maintain the required heat treatment temperature.

[0057] These or at least one of these objects is achieved by a metallic material production configuration adapted to directly reduce a metal oxide material possessing a first thermal energy to a reduced metallic material, the metallic material production configuration including: a metal oxide material providing unit configured to provide a metal oxide material possessing a first thermal energy; a direct reduction facility including a metal oxide material input device, a reducing agent input device (B) configured to introduce a hydrogen-containing reducing agent possessing a second thermal energy, a direct reduction zone of the direct reduction facility configured to reduce the metal oxide material by utilizing the first thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent and cause a chemical reaction between the introduced hydrogen-containing reducing agent and the metal oxide material, a heat treatment zone of the direct reduction facility configured to heat-treat the reduced metallic material by exposing the reduced metallic material to a heat treatment temperature required to obtain a densified reduced metallic material by heat-treating the reduced metallic material, a heat treatment providing device configured to maintain the required heat treatment temperature by introducing a preheated hydrogen-containing reducing agent, and a reduced metallic material discharge device configured to discharge the heat-treated reduced metallic material.

[0058] Alternatively, the reduced metallic material discharge device comprises a metallic material outlet configured to discharge the heat-treated reduced metallic material directly from the reduction facility.

[0059] Alternatively, the metallic material production configuration further comprises a reductant pre-heating device of the heat treatment providing device adapted to pre-heat a hydrogen-containing reductant introduced into the direct reduction facility.

[0060] Alternatively, the thermal treatment providing device includes a reducing agent thermal energy adjusting device configured to adjust the second thermal energy, and a first control circuit electrically coupled to the reducing agent thermal energy adjusting device and configured to control the reducing agent thermal energy adjusting device to achieve a required thermal treatment temperature.

[0061] Alternatively, the reductant thermal energy conditioning device comprises an electric preheater configured to preheat the hydrogen-containing reductant.

[0062] Alternatively, the heat treatment providing device includes a reducing agent mass flow rate adjusting device configured to adjust the mass flow rate of the hydrogen-containing reducing agent introduced into the direct reduction equipment, and a second control circuit electrically coupled to the reducing agent mass flow rate adjusting device and configured to operate the reducing agent mass flow rate adjusting device to adjust the mass flow rate of the hydrogen-containing reducing agent to achieve the required heat treatment temperature.

[0063] Alternatively, the heat treatment providing device includes a residence time adjusting device configured to adjust a residence time for maintaining the reduced metallic material in the direct reduction facility, and a third control circuit electrically coupled to the residence time adjusting device and configured to operate the residence time adjusting device to achieve a specific residence time and control a required heat treatment temperature.

[0064] Alternatively, the heat treatment providing device includes a pressure adjusting device configured to adjust the pressure inside the direct reduction equipment, and a fourth control circuit electrically coupled to the pressure adjusting device and configured to operate the pressure adjusting device to control the required heat treatment temperature.

[0065] Alternatively, the direct reduction facility includes a top gas removal device configured to remove top gas from the direct reduction facility.

[0066] Alternatively, the top gas contains up to about 100% by volume of high temperature steam.

[0067] Alternatively, the top gas contains a maximum of about 80-100% by volume, preferably about 85-95% by volume, of high temperature steam.

[0068] Alternatively, the top gas contains a maximum of about 60-90% by volume, preferably about 70-80% by volume, of high temperature steam.

[0069] Alternatively, the top gas contains a maximum of about 40-80% by volume, preferably about 50-70% by volume, of high temperature steam.

[0070] Alternatively, the top gas contains a maximum of about 20-60% by volume, preferably about 30-40% by volume, of high temperature steam.

[0071] Alternatively, the top gas contains a maximum of about 15-35% by volume, preferably about 20-30% by volume, of high temperature steam.

[0072] Alternatively, the top gas comprises high temperature steam and excess hydrogen gas.

[0073] Alternatively, excess hydrogen gas may be separated from the hot furnace gas and recycled to and introduced into the direct reduction system.

[0074] In this way, hydrogen gas can be utilized cost-effectively.

[0075] Alternatively, the temperature of the high-temperature steam is about 600°C to about 1200°C, preferably about 700°C to about 1100°C.

[0076] Alternatively, the temperature of the high-temperature steam is about 700°C to about 1450°C, preferably about 800°C to about 1350°C.

[0077] Alternatively, the reaction temperature required to sustain the direct reduction in the direct reduction equipment may be a temperature of about 800°C to about 1200°C, preferably about 900°C to about 1100°C.

[0078] Alternatively, the reaction temperature required to sustain direct reduction in the direct reduction equipment may be a temperature of about 600°C to about 1400°C, preferably about 850°C to about 1250°C.

[0079] Alternatively, the upper internal section is configured to allow for a required reaction temperature that is higher than that provided by the lower internal section.

[0080] Hydrogen-containing reducing agent temperature

[0081] Alternatively, the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment is about 200°C to about 700°C, preferably about 300°C to about 600°C.

[0082] Alternatively, the temperature of the hydrogen gas-containing reducing agent supplied to the direct reduction equipment may be about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0083] Alternatively, the temperature of the hydrogen gas-containing reducing agent introduced into the direct reduction equipment is about 400°C to about 950°C, preferably about 550°C to about 800°C.

[0084] Alternatively, the temperature of the hydrogen gas-containing reducing agent introduced into the direct reduction equipment is about 600°C to about 1200°C, preferably about 850°C to about 950°C.

[0085] Alternatively, the temperature of the supplemental hydrogen-containing reducing agent introduced into the direct reduction equipment is from about 200°C to about 700°C, preferably from about 300°C to about 600°C.

[0086] Alternatively, a supplemental hydrogen-containing reductant is introduced into the direct reduction facility at a level lower than the introduction of the hydrogen gas-containing reductant introduced into the direct reduction facility.

[0087] Alternatively, a cooling gas containing hydrogen may be introduced into a lower interior portion of the direct reduction plant to cost-effectively manage the cooled reduced metallic material exiting the plant.

[0088] metal oxide material temperature

[0089] Alternatively, the temperature of the metal oxide material that holds thermal energy and is input into the direct reduction equipment is 800°C to about 1200°C, preferably about 900°C to about 1100°C.

[0090] Alternatively, the temperature of the metal oxide material that holds the first thermal energy and is input into the direct reduction equipment is 900°C to about 1300°C, preferably about 1000°C to about 1200°C.

[0091] Alternatively, the temperature of the metal oxide material that holds thermal energy and is input into the direct reduction equipment is 1000°C to about 1450°C, preferably about 1100°C to about 1300°C.

[0092] In this way, efficient heat recovery is made available for the high temperature electrolysis unit.

[0093] Alternatively, the top gas contains water vapor produced by a chemical reaction between the metal oxide material and the hydrogen of the hydrogen-containing reducing agent.

[0094] Alternatively, the top gas contains hydrogen that was not consumed in the chemical reaction between the metal oxide material and the hydrogen of the hydrogen-containing reducing agent.

[0095] Alternatively, the hydrogen-containing reducing agent is continuously introduced in an amount such that the top gas removed from the direct reduction plant always contains hydrogen.

[0096] In this way, hydrogen is ensured to be available within the direct reduction facility to drive the chemical reaction.

[0097] Alternatively, the preheated hydrogen-containing reducing agent introduced contains about 80-100% hydrogen, preferably about 100% hydrogen by volume.

[0098] Alternatively, the preheated hydrogen-containing reducing agent introduced into the direct reduction facility comprises greater than about 70% by volume of hydrogen gas.

[0099] Alternatively, the preheated hydrogen-containing reducing agent introduced into the direct reduction equipment contains about 40% to about 80% by volume of hydrogen gas, preferably about 50% to about 70% by volume of hydrogen gas.

[0100] Alternatively, the preheated hydrogen gas-containing reducing agent introduced into the direct reduction equipment contains about 60% by volume to about 100% by volume of hydrogen gas, preferably about 70% by volume to about 90% by volume of hydrogen gas.

[0101] Alternatively, the preheated hydrogen-containing reducing agent contains about 60-80% hydrogen by volume, preferably about 65-75% hydrogen by volume.

[0102] These or at least one of these objects are achieved by a data program comprising a computer readable program code for a control circuit of a metal material manufacturing arrangement as set forth in any of the metal material manufacturing arrangement claims, the data program being programmed to enable a heat treatment providing device to maintain a required heat treatment temperature by introduction of a preheated hydrogen-containing reducing agent.

[0103] Alternatively, the control circuit includes a first control circuit, a second control circuit, a third control circuit, a fourth control circuit, and a fifth control circuit.

[0104] The or at least one of these objects is achieved by a product produced according to any of the method steps, wherein the reduced metal material comprises reduced iron ore particles bonded together to form a heat treated and / or heat hardened reduced metal material.

[0105] Alternatively, the lower interior portion of the direct reduction facility comprises a metallic material discharge port configured to discharge the heat-treated reduced metallic material from the direct reduction facility.

[0106] Alternatively, the control circuit is adapted to adjust the second thermal energy towards the reaction temperature required to complete the reduction.

[0107] In this manner, a densification process is achieved for densifying the directly reduced metallic material, which prevents reoxidation of the directly reduced metallic material and allows for safe and cost-effective transport of the reduced metallic material, e.g., intermediate products, to metal manufacturing industries and the like.

[0108] Alternatively, the separation unit is configured to separate excess hydrogen gas from the hot furnace top gas.

[0109] By utilizing the first thermal energy of the metal oxide material provided by the metal oxide material providing unit for direct reduction (complete, partial or substantial) within the reduction equipment, it is no longer necessary to heat the hydrogen-containing reducing agent to an extremely high temperature by performing exothermic partial oxidation of the hydrogen-containing reducing agent with oxygen or air to reach the required reaction temperature.

[0110] In this way, the chemical reactivity and / or high driving force of the hydrogen-containing reducing agent is maintained when introduced into a direct reduction facility, while the heat treatment produces a reduced metal material that is compact, dense, and resistant to reoxidation.

[0111] Chemical reactivity and / or high driving force are essential for the efficient direct reduction of metal oxide materials.

[0112] In this way, the reducing capacity of the hydrogen-containing reducing agent is maintained for efficient direct reduction and thermal treatment.

[0113] Alternatively, the relatively high temperature of the metal oxide material input to the direct reduction facility and the secondary thermal energy of the preheated hydrogen-containing reducing agent will allow the metal oxide material to be directly reduced to the reduced metal material in an energy-efficient manner at the required reaction temperature.

[0114] Alternatively, the reaction temperature required for efficient direct reduction in direct reduction equipment may be about 800°C to about 1200°C, preferably about 900°C to about 1100°C, or about 700°C to about 1400°C, preferably about 950°C to about 1200°C, or about 600°C to about 1500°C, preferably about 800°C to about 1200°C.

[0115] Alternatively, the required reaction temperature is maintained by preheating the hydrogen-containing reducing agent introduced into the direct reduction equipment and utilizing the high temperature of the first thermal energy-retaining metal oxide material.

[0116] Alternatively, the reducing agent pre-heating device of the heat treatment providing device comprises a reducing gas pre-heater, such as an electric reducing gas pre-heater.

[0117] Alternatively, the control circuit is adapted to operate the reductant mass flow rate adjustment device to increase the mass flow rate of the hydrogen-containing reductant (H) introduced into the direct reduction equipment, and is adapted to operate the reductant thermal energy adjustment device to decrease the second thermal energy of the hydrogen-containing reductant to the required heat treatment temperature.

[0118] Alternatively, the chemical reaction comprises a substantially or completely endothermic chemical reaction consuming thermal energy equivalent to about 475-525° C., preferably about 500° C. This energy is provided by the metal oxide material retaining the first thermal energy during reduction prior to heat treatment of the reduced metal material to obtain the densified reduced metal material.

[0119] Alternatively, the heat treatment temperature is adapted to be in the range of 200 to 600°C, preferably 300 to 500°C.

[0120] Alternatively, the heat treatment temperature is adapted to be in the range of 300 to 800°C, preferably 400 to 600°C.

[0121] Alternatively, the temperature of the metal oxide material retaining the first thermal energy is achieved using a metal oxide material providing unit, such as a metal oxide pelletizer, configured to produce a metal oxide material retaining the first thermal energy or substantially the first thermal energy.

[0122] Alternatively, the metal ore material is dried and then preheated in a preheating zone of the metal oxide pelletizer, the preheating zone being configured to preheat the metal ore material to a preheated metal ore material.

[0123] Alternatively, the metal ore material may be in the form of iron ore pellets (e.g., green pellets).

[0124] Alternatively, the preheated metal ore material is transferred to a hardening zone of the metal oxide pelletizer, the hardening zone being configured to harden the preheated metal ore material.

[0125] Alternatively, the hardening zone includes an oxidation zone configured to oxidize the preheated metal ore material and / or a sintering zone for sintering the oxidized preheated metal ore material.

[0126] Alternatively, the hydrogen in the hydrogen-containing reducing agent and / or the hydrogen in the hydrogen-containing heat treatment agent is produced using an electrolysis unit and / or a high-temperature electrolysis unit configured to split water into hydrogen and oxygen.

[0127] Alternatively, the electrolysis unit and / or the high temperature electrolysis unit are configured to split water into hydrogen and oxygen and are supplied with electricity by a renewable energy supplier.

[0128] Alternatively, oxygen produced by the electrolysis unit and / or high temperature electrolysis unit is transferred to the oxidation zone for oxidation of the preheated metal ore material.

[0129] Alternatively, the hardening zone is configured to harden the preheated metal ore material to a temperature of about 1000°C to about 1450°C, preferably about 1100°C to about 1300°C, to produce a metal oxide material possessing thermal energy substantially corresponding to the first thermal energy.

[0130] Alternatively, the metal oxide material may be discharged from the metal oxide pelletizer, in which case the metal oxide material retains the thermal energy provided by the metal oxide pelletizer and is discharged directly to the direct reduction facility, where the metal oxide material retains thermal energy substantially corresponding to the first thermal energy.

[0131] Alternatively, the temperature of the thermal energy-retaining metal oxide material is achieved using a metal oxide material providing unit, such as a metal oxide material preheating device, configured to preheat a pre-cooled thermal energy-retaining metal oxide material to produce a first thermal energy-retaining metal oxide material.

[0132] Alternatively, the first thermally energy-retaining metal oxide material temperature is achieved using a metal oxide material preheating device configured to preheat the metal oxide material to a temperature of about 1000°C to about 1450°C, preferably about 1100°C to about 1300°C, to produce the thermally energy-retaining metal oxide material.

[0133] Alternatively, the temperature of the metal oxide material retaining the first thermal energy is achieved using a metal oxide material preheating device configured to preheat the metal oxide material to a temperature of about 900°C to about 1350°C, preferably about 1000°C to about 1200°C, to produce the metal oxide material retaining the first thermal energy.

[0134] Alternatively, the metal oxide material pre-heating device is configured to pre-heat the metal oxide material to a thermal energy that substantially corresponds to the first thermal energy.

[0135] Alternatively, the metal oxide material pre-heating device is connected to the metal oxide material input device via a metal oxide material transfer device.

[0136] Alternatively, the metal oxide material transfer device is configured to cool the pre-heated metal oxide material.

[0137] Alternatively, the metal oxide material transfer device comprises an input hopper mechanism associated with the upper interior portion of the direct reduction equipment.

[0138] Alternatively, the metal oxide material is discharged from the metal oxide material preheating device and directly input into the direct reduction equipment to obtain substantially the first thermal energy.

[0139] Alternatively, the metal oxide material retaining the thermal heat is discharged from the metal oxide material providing unit and directly input into the reduction equipment via the metal oxide material cooling unit to obtain the first thermal energy.

[0140] Alternatively, the input hopper mechanism is configured to introduce the first seal gas into the direct reduction equipment simultaneously with inputting the metal oxide material that retains thermal energy into the direct reduction equipment.

[0141] Alternatively, the first sealing gas and / or the second sealing gas includes an inert gas.

[0142] In this way, the formation of explosive air / process gas mixtures can be prevented when thermal energy-retaining metal oxide materials are introduced into the direct reduction plant.

[0143] Alternatively, the first sealing gas includes carbon dioxide gas to produce a carburized reduced metal material.

[0144] Alternatively, the metal oxide material retaining the thermal heat discharged from the metal oxide material providing unit is cooled using a metal oxide material cooling unit configured to cool the metal oxide material in accordance with the first thermal energy of the metal oxide material, the cooling being performed toward a temperature that effectively raises the temperature of the hydrogen-containing reducing agent to maintain the reaction temperature required for the direct reduction before being input into the direct reduction equipment.

[0145] Alternatively, the chemical reaction involves the direct reduction of a metal oxide material to a reduced metal material.

[0146] Alternatively, the direct reduction equipment is configured as a solid-gas countercurrent moving bed reactor. A first thermal energy-retaining metal oxide material is introduced into an upper internal portion of the direct reduction equipment through a metal oxide material introduction device and descends toward a lower internal portion of the direct reduction equipment by gravity, and a second thermal energy-retaining preheated hydrogen-containing reducing agent introduced into the direct reduction equipment (e.g., the upper internal portion, middle internal portion, and / or lower internal portion of the direct reduction equipment) reduces the metal oxide material.

[0147] Alternatively, the introduction of the preheated hydrogen-containing reducing agent occurs at a location lower than the metal oxide material input device.

[0148] Alternatively, the thermal energy of the introduced preheated hydrogen-containing reducing agent is adjusted toward the second thermal energy using a reducing agent thermal energy adjusting device.

[0149] Alternatively, the control circuit is adapted to control the chemical reaction between the hydrogen-containing reducing agent and the metal oxide material and / or to control the thermal treatment of the reduced metallic material by adjusting the second thermal energy of the hydrogen-containing reducing agent introduced to the direct reduction facility using a reducing agent thermal energy adjusting device, and / or adjusting the mass flow rate of the hydrogen-containing reducing agent to the direct reduction facility using a reducing agent mass flow adjusting device, and / or adjusting the residence time of the reduced metallic material in the direct reduction facility using a residence time adjusting device of the direct reduction facility, and / or adjusting the third thermal energy of the preheated hydrogen-containing heat treating agent using a heat treating agent supply device.

[0150] Alternatively, a hydrogen-containing reducing agent is used in the heat treatment of the reduced metal material and / or the metal oxide material to be reduced.

[0151] Alternatively, the hydrogen-containing reducing agent is introduced to such an extent that an excess of hydrogen is present within the direct reduction equipment, allowing a subsequent chemical reaction to completely and / or substantially completely reduce the first thermal energy-bearing metal oxide material.

[0152] Alternatively, the residence time adjusting device comprises a discharge feeder device, such as a vibratory discharge feeder, a screw discharge feeder, or a hopper discharge feeder, connected to the metal material discharge outlet in the lower interior portion of the direct reduction equipment.

[0153] Alternatively, a second seal gas is introduced into the direct reduction facility via a discharge feeder device simultaneously with the discharge of the reduced metallic material from the direct reduction facility.

[0154] In this way, the formation of explosive air / process gas mixtures can be prevented when the reduced metal material is discharged from the direct reduction installation.

[0155] Alternatively, the metal oxide material input to the direct reduction facility is in the form of metal oxide pellets structurally formed by metal oxide particles.

[0156] Alternatively, the metal oxide material to be reduced is in the form of metal oxide pellets structurally formed by the metal oxide particles to be reduced.

[0157] Alternatively, the reduced metal material is in the form of reduced metal pellets structurally formed by reduced metal particles.

[0158] Alternatively, the height-to-width ratio inside the direct reduction equipment is at least greater than 1:1 and at most 10:1, in order to obtain a residence time suitable for the heat treatment of the reduced metal material, while at the same time maintaining a high flow rate of the metal oxide material to be reduced and / or the reduced metal material passing through the direct reduction equipment so as to prevent metal particles of the reduced metal material from sticking together inside the equipment.

[0159] Alternatively, the direct reduction facility and / or the metal oxide material providing unit and / or the control circuit and / or the electrolysis unit and / or the high temperature electrolysis unit are part of a metallic material production configuration.

[0160] Alternatively, a second thermally energy-bearing hydrogen-containing reducing agent is introduced into an intermediate interior portion of the direct reduction equipment.

[0161] Alternatively, the metallic material production configuration includes a top gas recycling mechanism adapted to recycle a portion of the top gas and mix it with hydrogen produced in the electrolysis unit and / or the high-temperature electrolysis unit to form a hydrogen-containing reducing agent and / or a hydrogen-containing heat treatment agent.

[0162] Alternatively, the step of reducing the metal oxide material retaining the first thermal energy in the upper internal portion is carried out by utilizing the first thermal energy of the metal oxide material and utilizing the thermal energy of the reduced metal material that has been partially reduced in the upper internal portion to heat or further heat the introduced preheated hydrogen.

[0163] By directly inputting the metal oxide material retaining the first thermal energy from the metal oxide material providing unit into the reduction equipment from the metal oxide material providing unit, the reduction and the chemical reaction between the metal oxide material and the hydrogen-containing reducing agent will occur energy efficiently, and at the same time, the hydrogen in the hydrogen-containing reducing agent will maintain its reduction ability.

[0164] In this way, there is no need to further heat the hydrogen-containing reducing agent by exothermic partial oxidation of the hydrogen-containing reducing agent with oxygen or air, which would impair its reducing capacity.

[0165] Alternatively, the upper interior portion of the direct reduction facility is configured to directly reduce the first thermal energy-bearing metal oxide material.

[0166] Alternatively, the control circuit is electrically connected to the thermal treatment providing device and is connected to a reducing agent thermal energy adjusting device and / or a reducing agent mass flow rate adjusting device and / or a residence time adjusting device and / or a pressure adjusting device and / or a thermal treatment agent supplying device configured to introduce a hydrogen-containing thermal treatment agent carrying a third thermal energy adapted for thermal treatment.

[0167] Alternatively, the direct reduction equipment may be configured to allow the reduced metallic material to be lowered into a lower interior portion of the direct reduction equipment in order to expose the reduced metallic material to the heat treatment temperature required for heat treatment thereof and maintain the required heat treatment temperature by the introduction of a preheated hydrogen-containing reducing agent.

[0168] Alternatively, the direct reduction facility includes a heat treatment agent introduction device configured to introduce a hydrogen-containing heat treatment agent, the heat treatment agent introduction device being coupled to the control circuit.

[0169] Alternatively, the direct reduction facility includes a heat treatment agent supply device configured to introduce the preheated hydrogen-containing heat treatment agent, the heat treatment agent supply device being electrically coupled to the control circuit.

[0170] Alternatively, the heat treatment agent introduction device comprises a heat treatment agent preheater electrically coupled to a control circuit adapted to control the temperature of the heat of the hydrogen-containing heat treatment agent added to the reduced metallic material.

[0171] Alternatively, the metal oxide material bearing the first thermal energy can be continuously lowered through the direct reduction equipment so that it comes into contact with the continuously introduced preheated hydrogen-containing reducing agent bearing the second thermal energy, and the metal oxide material is reduced to the reduced metal material.

[0172] Alternatively, the metal oxide material and / or reduced metal material to be reduced can be passed down through the direct reduction equipment, where it is contacted with a hydrogen-containing heat treatment agent and heat treated in the direct reduction equipment.

[0173] Alternatively, exposing the reduced metallic material to the heat treatment temperature required for heat treating the reduced metallic material produces a densified reduced metallic material and / or a semi-molten reduced metallic material and / or a passivated reduced metallic material.

[0174] In this way, intermediate products that are resistant to reoxidation can be formed from reduced metallic materials discharged from a direct reduction facility.

[0175] In this way, cost-effective transportation is provided to metal manufacturing industries such as steel mills.

[0176] In this way, the intermediate products produced (eg sponge iron and IronDrop™) can be used in energy-efficient, "green" steel production.

[0177] Alternatively, the metal oxide material and / or reduced metal material to be reduced can descend and be contacted with a hydrogen-containing heat treatment agent to undergo heat treatment, wherein the control circuit is adapted to control the thermal energy of the hydrogen-containing heat treatment agent such that the temperature of the reduced metal material decreases as the reduced metal material descends in the direct reduction equipment.

[0178] In this way, by utilizing the first thermal energy to reach the required reaction temperature, the chemical reaction (which is essentially an endothermic reaction) becomes energy efficient, the reducing capacity of the preheated hydrogen-containing reducing agent is maintained, and further energy savings are ensured.

[0179] In this way, the amount of thermal energy used for reduction in the upper interior portion is high, making it possible to utilize a large portion of the first thermal energy of the metal oxide material, where the metal oxide material holding the first thermal energy is first contacted with a hydrogen-containing reducing agent, and the first thermal energy of the metal oxide material is utilized to heat or further heat the introduced hydrogen-containing reducing agent, causing a chemical reaction between the introduced hydrogen-containing reducing agent and the metal oxide material, thereby directly reducing the metal oxide material.

[0180] Alternatively, a semi-molten reduced metal material and / or a densified reduced metal material is produced by a preheated hydrogen-containing reducing agent and / or a preheated hydrogen-containing heat treatment agent introduced into a direct reduction facility.

[0181] In this way, degradation of the reduced metal material is prevented.

[0182] Alternatively, the direct reduction facility may include a heat treatment agent supply device located lower than the reducing agent input device, the heat treatment agent supply device configured to introduce a hydrogen-containing heat treatment agent carrying a third thermal energy, and the control circuit adapted to adjust the third thermal energy for performing the heat treatment to produce the semi-molten reduced metallic material and / or the densified reduced metallic material.

[0183] Alternatively, the control circuit is adapted to operate a reductant temperature regulator to adjust the second thermal energy of the hydrogen-containing reductant to a required reaction temperature for direct reduction and / or to a required heat treatment temperature.

[0184] Alternatively, the direct reduction facility comprises a metallic material outlet configured to discharge the heat-treated reduced metallic material from the direct reduction facility.

[0185] Alternatively, the direct reduction facility includes a top gas removal device configured to remove top gas from the direct reduction facility.

[0186] Alternatively, the metal ore material comprises an iron ore material.

[0187] Alternatively, the iron ore material includes a hematite material and a magnetite material.

[0188] Alternatively, the preheated metal ore material comprises preheated iron ore material.

[0189] Alternatively, the metal oxide material comprises an iron ore oxide material.

[0190] Alternatively, the reduced and heat treated metallic material comprises a reduced and heat treated iron ore material.

[0191] Alternatively, the metal oxide material is formed as metal oxide aggregates.

[0192] Alternatively, the reduced and heat treated metallic material is formed as reduced metal aggregates.

[0193] Alternatively, the reduced and heat treated metal aggregates have a densified surface area.

[0194] Alternatively, the reduced metal aggregates are formed from reduced metal particles.

[0195] Alternatively, the reduced and heat treated metal aggregates have a densified surface area of ​​fused reduced metal particles covering a porous core of reduced metal particles.

[0196] Alternatively, the reduced and heat treated metal aggregates consist of fused reduced metal particles.

[0197] The terms "reducing" or "reduction" are interchangeable with "direct reducing" or "direct reduction."

[0198] Alternatively, the method further includes the steps of decomposing water into electrolytic hydrogen and oxygen using an electrolysis unit, producing methanol by reacting the electrolytic hydrogen with carbon dioxide, storing the methanol, reforming the methanol with water and / or oxygen to provide carbon dioxide and released hydrogen, providing the released hydrogen as a component of a preheated hydrogen-containing reducing agent to a direct reduction facility, and introducing the preheated hydrogen-containing reducing agent that retains second thermal energy into the direct reduction facility via a reducing agent input device.

[0199] In this way, when this method is applied, a means of buffering energy in the form of methanol used in the reforming step is achieved, which means that hydrogen can be produced by the reforming step during times of high electricity prices and / or low renewable electricity supplies.

[0200] Alternatively, the method may further include a step of simultaneously introducing the first thermal energy-retaining metal oxide material into the reduction equipment via a metal oxide material input device and / or simultaneously introducing the second seal gas and discharging the reduced metal material.

[0201] In this way, the dosing of metal oxide materials into a direct reduction facility can be carried out safely without forming an explosive air / process gas mixture during dosing.

[0202] This is achieved by ensuring that only a seal gas, and not air, is introduced into the direct reduction equipment during loading of the metal oxide material, and that no process gas and / or hydrogen-containing reducing gas escapes from the direct reduction equipment during loading.

[0203] Alternatively, the input mechanism of the metal oxide material input device is configured to transfer the metal oxide material holding the first thermal energy directly from the metal oxide material providing unit to the reduction facility.

[0204] Alternatively, the injection mechanism includes a seal gas introduction device configured to introduce the seal gas directly into the reduction equipment.

[0205] Alternatively, the direct reduction facility is provided as a gas-solid countercurrent moving bed reactor.

[0206] Alternatively, the direct reduction is conducted in a direct reduction facility at a first pressure, wherein the seal gas introduction device is configured to introduce a seal gas into the direct reduction facility at a second pressure higher than the first pressure.

[0207] Alternatively, there is provided a method for directly reducing a metal oxide material retaining a first thermal energy to a reduced metal material using a metal material production configuration, wherein the metal oxide material retaining a first thermal energy is provided by a metal oxide material providing unit.

[0208] Alternatively, the method includes the step of directly inputting the first thermal energy-bearing metal oxide material into the reduction facility via a metal oxide material input device.

[0209] Alternatively, the reduction facility may have an upper internal portion, a lower internal portion, and an intermediate internal portion located between the upper and lower internal portions.

[0210] Alternatively, a step of introducing a preheated hydrogen-containing reducing agent that retains second thermal energy directly into the reduction equipment via a reducing agent input device is provided.

[0211] Alternatively, the reduction equipment is configured to utilize the first thermal energy of the metal oxide material to further heat the introduced preheated hydrogen-containing reducing agent and cause a chemical reaction between the hydrogen in the introduced preheated hydrogen-containing reducing agent and the metal oxide material, thereby directly reducing the metal oxide material in the upper internal portion.

[0212] Alternatively, the direct reduction facility is configured to allow the reduced metallic material and / or metal oxides to be directly reduced to descend into a lower interior portion that includes the heat treatment zone.

[0213] Alternatively, the direct reduction facility is configured to allow the preheated hydrogen gas-containing reducing agent to ascend through the direct reduction facility and contact the descending metal oxide material.

[0214] Alternatively, the heat treatment zone is configured to expose the reduced metallic material and / or the metal oxide material to be directly reduced to a predetermined heat treatment temperature, which results in a reduced metallic material comprising reduced iron ore particles bonded together to form a heat-treated and / or heat-hardened and / or densified reduced metallic material.

[0215] Alternatively, the heat treatment zone is configured to maintain a predetermined heat treatment temperature through the introduction of a preheated hydrogen-containing reducing agent.

[0216] Alternatively, the method includes the step of discharging the heat-treated reduced metallic material.

[0217] Alternatively, the first thermal energy is utilized in the upper interior portion to further heat the remaining hydrogen (and formed water vapor) of the preheated hydrogen-containing reducing agent, which has not yet been consumed and rises toward the upper interior portion within the direct reduction facility.

[0218] Alternatively, the remaining hydrogen can cause a chemical reaction that effectively reduces the metal oxide material directly in the upper interior portion.

[0219] This is achieved even though the preheated hydrogen-containing reducing agent has a higher water vapor content and a lower hydrogen content as it rises in the direct reduction facility.

[0220] Alternatively, a first thermal energy is utilized in the upper interior portion to further heat a portion of the preheated hydrogen-containing reducing agent to induce a chemical reaction between hydrogen in the preheated hydrogen-containing reducing agent and oxygen in the metal oxide material.

[0221] Alternatively, the first thermal energy is utilized in the upper internal portion to further heat the remaining hydrogen (and the formed water vapor) of the preheated hydrogen-containing reducing agent, which has not yet been consumed and rises within the direct reduction equipment toward the top of the upper internal portion (the furnace top interior of the direct reduction equipment).

[0222] Alternatively, as the preheated hydrogen-containing reducing agent rises in the direct reduction equipment, the water vapor content of the preheated hydrogen-containing reducing agent increases and the hydrogen content decreases, but the remaining hydrogen allows chemical reaction and efficient direct reduction of the metal oxide material (iron ore oxide material) to occur at the top.

[0223] Alternatively, the first thermal energy may be utilized in this top portion to further heat the remaining hydrogen and induce a chemical reaction between at least a portion of the remaining hydrogen and oxygen in the metal oxide material (iron ore oxide material) to effect reduction, where oxygen is removed from the iron ore oxide material.

[0224] Alternatively, the excess preheated hydrogen-containing reducing agent at the top is part of the top gas containing hot steam, and the top gas is removed from the direct reduction facility via a top gas removal device.

[0225] Alternatively, the first thermal energy may be utilized in this manner to further heat the remaining hydrogen for efficient direct reduction at the top and / or to prevent undesired / unnecessary cooling of the remaining hydrogen of the hydrogen-containing reducing agent not yet consumed at the top for efficient direct reduction.

[0226] In this way, the iron ore oxide material entering the direct reduction plant is prevented from quenching the remaining hydrogen in the top hydrogen-containing reductant.

[0227] Alternatively, the first thermal energy of the iron ore oxide material is utilized in the upper interior portion UP and / or at the top to further heat the remaining hydrogen and / or water vapor of the preheated hydrogen-containing reducing agent.

[0228] Alternatively, the top gas contains water vapor produced by a chemical reaction between oxygen in the iron oxide material and hydrogen in the hydrogen-containing reducing agent.

[0229] Alternatively, the top gas contains up to about 100% by volume of high temperature steam.

[0230] Alternatively, the top gas contains a maximum of about 80-100% by volume, preferably about 85-95% by volume, of high temperature steam.

[0231] Alternatively, the top gas contains a maximum of about 60-90% by volume, preferably about 70-80% by volume, of high temperature steam.

[0232] Alternatively, the top gas contains a maximum of about 30-60% by volume, preferably about 40-50% by volume, of high temperature steam.

[0233] Alternatively, the top gas contains a maximum of about 10-40% by volume, preferably about 20-30% by volume, of high temperature steam.

[0234] Alternatively, the top gas contains a maximum of about 0-20% by volume, preferably about 5-15% by volume, of high temperature steam.

[0235] Alternatively, the top gas contains a maximum of about 0-15% by volume, preferably about 1-10% by volume, of high temperature steam.

[0236] Alternatively, there is provided a method for directly reducing iron ore oxide material bearing a first thermal energy into densified reduced iron material using a sponge iron production configuration, wherein the iron ore oxide material bearing a first thermal energy is provided by an iron ore oxide material providing unit, such as an iron ore oxide pelletizer and / or an iron ore oxide preheating device.

[0237] Alternatively, the temperature of the iron ore oxide material retaining the first thermal energy is achieved using an iron ore oxide material providing unit configured to produce and / or preheat the iron ore oxide material retaining the first thermal energy or substantially the first thermal energy.

[0238] Alternatively, the iron ore oxide material providing unit is electrically coupled to a control circuit adapted to control the first thermal energy of the iron ore oxide material input to the direct reduction facility.

[0239] Alternatively, the temperature of the first thermal energy-carrying iron ore oxide material provided by the iron ore oxide material providing unit corresponds to a predetermined temperature determined to avoid "sticking" (sticking of iron ore oxide material particles to each other) in the upper interior portion of the direct reduction equipment.

[0240] Such "sticking" can prevent subsequent direct reduction of the iron ore oxide material in the upper interior portion UP of the direct reduction installation.

[0241] Alternatively, the predetermined temperature of the iron ore oxide material, which is important to avoid "sticking", is controlled by a control circuit, typically to about 800°C to about 1000°C, preferably about 875°C to about 925°C.

[0242] Alternatively, the control circuit is adapted to adjust the first thermal energy of the iron ore oxide material to a predetermined temperature to avoid "sticking."

[0243] During charging and direct reduction, it may be essential to avoid "sticking" of iron ore oxide material particles and / or pellets, as such "sticking" would prevent the direct reduction plant from continuing to operate. Avoidance of "sticking" or reduction of the Sticking Index SI can be achieved by avoiding very high temperatures (greater than 1200°C) in the upper interior parts of the direct reduction plant.

[0244] Alternatively, the predetermined temperature of the iron ore oxide material may be adjusted by the control circuit based on specific characteristics of the direct reduction and / or specific characteristics of the iron ore oxide material input to the direct reduction facility and / or specific process parameters of the iron ore oxide pelletizer and / or specific process parameters of the iron ore oxide preheating device, wherein the specific characteristics and / or specific process parameters are: the external shape of the iron ore oxide pellets, and / or the porosity and / or density of the iron ore oxide material, and / or the mineralogical characteristics of the iron ore material, and / or the composition of the iron ore oxide material, and / or Cohesion, and / or the iron oxide material pellet size of the iron ore oxide material, and / or the direct reduction rate of the iron ore oxide material, and / or the hydrogen content of the hydrogen-containing reducing agent, and / or the desired temperature of the furnace gas, and / or The output temperature of the iron ore oxide material provided by the iron ore oxide pelletizer and / or the iron ore oxide preheating device may be an output temperature of the iron ore oxide material. Taking into consideration the temperature of the first thermal energy, the composition of the preheated hydrogen-containing reducing agent, and the degree of direct reduction at a particular level in the direct reduction facility, an efficient heat treatment is performed to obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0245] Alternatively, the predetermined temperature of the iron ore oxide material is adjusted by the control circuit based on the residence time during which the iron ore oxide material is directly reduced and / or exposed to the hydrogen-containing reducing agent in the direct reduction facility.

[0246] Alternatively, residence time is defined as the time during which the iron ore oxide material is subjected to direct reduction and heat treatment to complete the direct reduction process. X is directly reduced to iron Fe to form densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0247] Alternatively, the residence time within the direct reduction facility is determined by the height to width ratio within the facility.

[0248] Alternatively, the residence time in the direct reduction equipment is about 0.5 to 5.0 hours, preferably 1 to 4 hours.

[0249] Alternatively, the residence time in the direct reduction equipment is about 2 to 6 hours, preferably 3 to 4 hours.

[0250] Alternatively, the residence time in the direct reduction equipment is about 0.25 to 1.5 hours, preferably 0.5 to 1.25 hours.

[0251] Alternatively, the temperature and / or mass flow rate of the hydrogen-containing reducing agent may be controlled by a control circuit. The specific process parameters of the direct reduction, and / or The specific characteristics of the iron ore oxide material and / or the specific process parameters may be adjusted based on: the external shape of the iron ore oxide pellets, and / or the porosity and / or density of the iron ore oxide material, and / or the mineralogical characteristics of the iron ore material, and / or the composition of the iron ore oxide material, and / or Cohesion, and / or the iron oxide material pellet size of the iron ore oxide material, and / or the direct reduction rate of the iron ore oxide material, and / or the hydrogen content of the hydrogen-containing reducing agent, and / or the desired temperature of the furnace gas, and / or The output temperature of the iron ore oxide material provided by the iron ore oxide pelletizer and / or the iron ore oxide preheating device may be an output temperature of the iron ore oxide material. Taking into consideration the temperature of the first thermal energy, the composition of the preheated hydrogen-containing reducing agent, and the degree of direct reduction at a particular level in the direct reduction facility, an efficient heat treatment is performed to obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0252] Alternatively, the control of the temperature of the iron ore oxide material (first thermal energy) input at the top and the temperature of the hydrogen-containing reducing agent (second thermal energy) introduced into the direct reduction equipment is determined / controlled by a control circuit based on the mass flow rate of the iron ore oxide material input and / or the mass flow rate of the hydrogen-containing reducing agent introduced.

[0253] Alternatively, the control of the mass flow rate of the hydrogen-containing reducing agent introduced into the direct reduction equipment is determined / controlled by a control circuit based on the temperature of the iron ore oxide material introduced at the top (first thermal energy) and / or the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy), to optimize the chemical reduction reaction and / or limit the high temperature steam content in the direct reduction equipment and / or maintain a required ratio of high temperature steam to hydrogen to efficiently carry out the chemical reduction reaction.

[0254] Alternatively, the method includes the step of injecting a first thermal energy-bearing iron ore oxide material into an upper interior portion of the direct reduction equipment via a metal oxide material injection device.

[0255] Alternatively, the direct reduction facility has an upper internal portion, a lower internal portion, and an intermediate internal portion located between the upper and lower internal portions.

[0256] Alternatively, there is provided a step of introducing a preheated hydrogen-containing reducing agent carrying a second thermal energy directly into the reduction equipment via a reducing agent input device.

[0257] Alternatively, the direct reduction equipment is configured to utilize the first thermal energy of the iron ore oxide material to further heat the introduced preheated hydrogen-containing reducing agent and cause a chemical reaction between hydrogen in the introduced preheated hydrogen-containing reducing agent and the iron ore oxide material, thereby enabling direct reduction of the iron ore oxide material in the upper internal portion.

[0258] Alternatively, the direct reduction facility is configured to allow reduced iron material and / or iron ore oxide material to be directly reduced to descend into a lower interior portion that includes a heat treatment zone.

[0259] Alternatively, the direct reduction facility is configured to allow the preheated hydrogen gas-containing reducing agent to rise through the direct reduction facility and contact the descending iron ore oxide material.

[0260] Alternatively, the heat treatment zone is configured to expose the reduced iron material and / or iron ore oxide material to be directly reduced to a predetermined heat treatment temperature, which results in a reduced iron ore material comprising reduced iron ore particles bonded together to form a heat-treated and / or heat-hardened and / or densified reduced iron ore material.

[0261] Alternatively, the heat treatment zone is configured to maintain a predetermined heat treatment temperature by the introduction of a preheated hydrogen-containing reducing agent.

[0262] Alternatively, the method includes the step of discharging the reduced iron material that has been heat treated in the heat treatment zone.

[0263] The preheated hydrogen-containing reducing agent contains about 80-100% hydrogen, preferably up to 100% hydrogen by volume.

[0264] Alternatively, the temperature of the hydrogen gas-containing reducing agent supplied to the direct reduction equipment can be about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0265] Alternatively, the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment is about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0266] Alternatively, the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment is about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0267] Alternatively, the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment is about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0268] Alternatively, the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment is about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0269] Alternatively, the hydrogen-containing reducing agent is introduced into the upper and / or lower and / or middle internal portion.

[0270] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 200°C to about 500°C, preferably about 300°C to about 400°C.

[0271] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 300°C to about 600°C, preferably about 400°C to about 500°C.

[0272] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 400°C to about 700°C, preferably about 500°C to about 600°C.

[0273] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 500°C to about 800°C, preferably about 600°C to about 700°C.

[0274] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 600°C to about 900°C, preferably about 700°C to about 800°C.

[0275] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 700°C to about 1000°C, preferably about 800°C to about 900°C.

[0276] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 800°C to about 1100°C, preferably about 900°C to about 1000°C.

[0277] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 900°C to about 1200°C, preferably about 1000°C to about 1100°C.

[0278] Alternatively, the temperature of the iron ore oxide material fed into the direct reduction facility is maintained at 1000°C to about 1300°C, preferably about 1100°C to about 1200°C.

[0279] Alternatively, the chemical reaction comprises a substantially or completely endothermic chemical reaction.

[0280] Alternatively, the thermal energy consumed by direct reduction in the upper interior portion includes the first thermal energy and / or the second thermal energy.

[0281] Alternatively, the thermal energy consumed by direct reduction in the intermediate internal portion includes the first and / or second thermal energy.

[0282] Alternatively, the thermal energy consumed by direct reduction in the lower interior portion includes the second thermal energy.

[0283] Alternatively, heat treatment is defined as the densification (passivation) of the iron ore oxide material and / or reduced iron ore material to be directly reduced.

[0284] Alternatively, the iron ore oxide material and / or reduced iron material to be directly reduced by heat treatment is controlled by a first control circuit (not shown) and / or a control circuit adapted to adjust the second thermal energy of the hydrogen-containing reducing agent using a reducing agent thermal energy adjusting device (not shown) to control the required heat treatment temperature determined to achieve the desired quality of the produced sponge iron and / or densified reduced metal material and / or semi-molten reduced metal material and / or passivated reduced metal material.

[0285] Alternatively, the heat treatment temperature is controlled within the range of 150 to 550°C, preferably 250 to 450°C.

[0286] Alternatively, the heat treatment temperature is controlled within the range of 200 to 600°C, preferably 300 to 500°C.

[0287] Alternatively, the heat treatment temperature is controlled within the range of 250 to 650°C, preferably 350 to 550°C.

[0288] Alternatively, the heat treatment temperature is controlled within the range of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0289] Alternatively, the heat treatment temperature is controlled within the range of about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0290] Alternatively, the heat treatment temperature is controlled within the range of about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0291] Alternatively, the heat treatment temperature is controlled within the range of about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0292] Alternatively, the heat treatment temperature is controlled within the range of about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0293] Alternatively, the heat treatment temperature is controlled by a control circuit that controls the temperature of the hydrogen gas-containing reducing agent H.

[0294] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 100 to 500°C, preferably 200 to 400°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 600 to 1100°C, preferably 700 to 1000°C.

[0295] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 200 to 600°C, preferably 300 to 500°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 700 to 1200°C, preferably 800 to 1100°C.

[0296] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 300 to 700°C, preferably 400 to 600°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 700 to 1100°C, preferably 750 to 950°C.

[0297] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 400 to 800°C, preferably 500 to 700°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 800 to 1300°C, preferably 900 to 1200°C.

[0298] Alternatively, the first thermal energy of the iron ore oxide material is utilized in the upper interior portion UP and / or at the top to further heat the remaining hydrogen and / or water vapor of the preheated hydrogen-containing reducing agent.

[0299] Alternatively, the top gas contains water vapor produced by a chemical reaction between oxygen in the iron oxide material and hydrogen in the hydrogen-containing reducing agent.

[0300] Alternatively, the remaining hydrogen in the hydrogen-containing reducing agent can be defined as the hydrogen-containing reducing agent that has not yet been consumed in the direct reduction in the main part of the upper internal part and has risen within the direct reduction equipment to the top of the upper internal part (inside the furnace top of the direct reduction equipment).

[0301] Alternatively, as the preheated hydrogen-containing reducing agent rises in the direct reduction equipment, the water vapor content of the preheated hydrogen-containing reducing agent increases and the hydrogen content decreases, but the remaining hydrogen allows chemical reaction and efficient direct reduction of the metal oxide material (iron ore oxide material) to occur at the top.

[0302] Alternatively, the first thermal energy may be utilized in this manner at the top to further heat the remaining hydrogen and induce a chemical reaction between at least a portion of the remaining hydrogen and oxygen in the metal oxide material (iron ore oxide material), resulting in a direct reduction that efficiently removes oxygen from the iron ore oxide material.

[0303] Alternatively, the excess preheated hydrogen-containing reducing agent, which includes excess hydrogen gas and hot steam, forms a top gas at the top, which is removed from the reduction facility directly via a top gas removal device.

[0304] Alternatively, the first thermal energy may be utilized in this manner to further heat the remaining hydrogen to effect an efficient direct reduction at the top and / or to prevent cooling of the remaining hydrogen of the hydrogen-containing reducing agent not yet consumed at the top to effect an efficient direct reduction.

[0305] Therefore, any accidental low / ambient temperature iron ore oxide material (if unheated iron ore oxide material is added) introduced into the direct reduction plant will prevent the cooling of the remaining hydrogen in the top hydrogen-containing reductant.

[0306] This has the effect of producing energy-efficient passivated reduced iron materials such as sponge iron while at the same time producing a top gas containing hot steam that can be used in the high-temperature electrolysis unit.

[0307] In this manner, a densification process is achieved to produce densified reduced iron material, which prevents reoxidation and allows for safe, cost-effective transport of the reduced iron material, such as sponge iron, to metal manufacturers.

[0308] In this manner, customers, such as metal manufacturers, are provided with a metal material production setup configured to produce reduced iron material (carbon-free) that is resistant to reoxidation for cost-effective, safe, and refractory transport of the reduced metal material.

[0309] The term "metal oxide material" can be replaced with the term "iron ore oxide material."

[0310] The expression "metal oxide material providing unit" can be replaced with the expression "iron ore oxide material providing unit".

[0311] The term "reduced metal material" may be replaced with the term "reduced iron ore material."

[0312] The term "reduced iron ore material" can be replaced with the term "reduced iron material."

[0313] The expression "metallic material manufacturing composition" can be replaced with the expression "sponge iron manufacturing composition."

[0314] The term "metal oxide material" may be substituted with the terms "zinc sulphite oxide raw material" and / or "zinc sulphite oxide raw material".

[0315] Prior to input of metal oxide materials and direct reduction / thermal treatment, the sphalerite and sphalerite concentrates are converted to oxides and agglomerated, respectively.

[0316] The term "consume" may be substituted with the terms "use" or "utilize."

[0317] The present disclosure is not limited to the above examples, and it will be apparent to those skilled in the art that there are many possibilities for modifying or combining the described examples without departing from the basic idea defined in the appended claims. [Brief explanation of the drawings]

[0318] The present invention will now be described with reference to the examples and the accompanying schematic drawings, in which some unimportant details may have been omitted for clarity and understanding of the invention.

[0319] [Figure 1] 1 shows a metallic material production setup adapted for the reduction of metal oxide materials according to a first embodiment; [Figure 2a-2b] A second example is presented that applies different designs within the direct reduction facility to affect residence time when directly reducing metal oxide materials. [Figure 3] 10 shows a metallic material production setup adapted for the reduction of metal oxide materials according to a third embodiment. [Figure 4] FIG. 10 is a flow diagram showing a metal material manufacturing configuration according to a fourth embodiment. [Figure 5] 10 shows a metallic material production setup adapted for the reduction of metal oxide materials according to a fifth embodiment. [Figure 6a] 1 shows a phase diagram of iron phase domains as a function of the oxidizing power of hydrogen gas and temperature. [Figure 6b] The mole / mole phase diagram of hydrogen / hydrogen + iron versus temperature is shown. [Figures 7a-7c] 1 shows an example of a phase-transition aggregate structure upon heat treatment of reduced metal materials. [Figures 8a-8c] 1 shows an example of a phase-transition aggregate structure upon heat treatment of reduced metal materials. [Figure 9a-9b] 10 shows a metallic material production setup adapted for the reduction of metal oxide materials according to a sixth embodiment. [Figure 10]1 is a flow chart illustrating an exemplary method for directly reducing a metal oxide material to a reduced metal material. [Figure 11] 1 is a flow chart illustrating an exemplary method for directly reducing a metal oxide material to a reduced metal material. [Figure 12] 10 shows a control circuit for a metallic material production arrangement according to a further embodiment; [Figure 13] 10 shows a sponge iron production setup for producing densified reduced iron material according to a further embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0320] 1 shows a metallic material production arrangement 1 according to a first embodiment for reducing a metal oxide material to a reduced iron ore material 16 using a hydrogen-containing reducing agent H. The metallic material production arrangement 1 is adapted for reducing a metal oxide material 5 having a first thermal energy. The metallic material production arrangement 1 comprises a metal oxide material providing unit 3, such as a metal oxide pelletizing plant (not shown) or a metal oxide material preheating plant (not shown), which is configured to produce a metal oxide material having a relatively high first thermal energy, such as a temperature of about 900°C to about 1500°C, preferably about 1000°C to about 1400°C.

[0321] A metal oxide material carrying a first thermal energy is introduced into the upper interior portion UP of the direct reduction arrangement 7 via a metal oxide material introduction device A. A hydrogen-containing reducing agent H is adapted to carry a second thermal energy before being introduced into the direct reduction arrangement 7 via a reducing agent introduction device B.

[0322] The control circuit 50 of the metallic material manufacturing configuration 1 is electrically coupled to the heat treatment providing device 17 and configured to operate the heat treatment providing device 17 to supply and / or adjust second thermal energy. The heat treatment providing device 17 may include an electric preheater (not shown) configured to preheat the hydrogen-containing reducing agent H. The control circuit 50 is adapted to control the heat treatment by adjusting the second thermal energy of the hydrogen-containing reducing agent H using the heat treatment providing device 17. The heat treatment providing device 17 is configured to adjust the second thermal energy in order to maintain a required heat treatment temperature in the direct reduction facility 7 by introducing preheated hydrogen-containing reducing agent H carrying the adjusted second thermal energy. The preheated hydrogen-containing reducing agent is supplied from a hydrogen-containing reducing agent supplier SP.

[0323] The direct reduction zone RZ of the direct reduction equipment 7 is configured to reduce the metal oxide material 5, and this reduction is carried out by utilizing the first thermal energy of the metal oxide material 5 to heat or further heat the introduced hydrogen-containing reducing agent H, causing a chemical reaction (e.g., a substantially endothermic chemical reaction for the direct reduction) between the introduced hydrogen-containing reducing agent H and the metal oxide material 5.

[0324] The heat treatment zone HZ of the direct reduction facility 7 is configured to heat treat the reduced metallic material 16 by exposing the reduced metallic material to a heat treatment temperature required to obtain a densified reduced metallic material by heat treatment of the reduced metallic material.

[0325] The dashed boxes of the directly reduced zone RZ and the heat treatment zone HZ shown in the schematic diagram are for illustrative purposes only; for example, the dashed boxes may overlap, or one dashed box may cover both the directly reduced zone RZ and the heat treatment zone HZ.

[0326] Alternatively, an electrolysis unit (not shown) configured to split water into hydrogen and oxygen is used to produce the hydrogen-containing reducing agent.

[0327] The direct reduction equipment may be designed as a solid-gas countercurrent moving bed reactor, in which the first thermal energy-retaining metal oxide material 5 is introduced into an upper internal part UP of the direct reduction equipment 7 via a metal oxide material introduction device A and flows downward by gravity toward a lower internal part LP of the direct reduction equipment 7.

[0328] A second thermal energy-carrying preheated hydrogen-containing reducing agent H is introduced into the lower internal portion LP and / or the upper internal portion UP.

[0329] The metallic material production arrangement 1 further comprises a reducing agent pre-heating device 20 of the heat treatment providing device 17, which reducing agent pre-heating device 20 is adapted to pre-heat the hydrogen-containing reducing agent H introduced into the direct reduction facility 7.

[0330] The control circuit 50 is electrically coupled to the reductant pre-heating device 20 and adapted to control the reductant pre-heating device to provide secondary thermal energy for the hydrogen-containing reductant to achieve the reaction temperature required for the direct reduction of the metal oxide material 5.

[0331] The control circuit 50 is further electrically coupled to the first heat treatment agent supply device 30 of the heat treatment providing device 17 and adapted to control the heat treatment agent supply device to provide heat treatment of the reduced metallic material.

[0332] The metal material production system 1 is configured to reduce a metal oxide material 5 to a reduced metal material 16. This reduction is performed by utilizing a first thermal energy of the metal oxide material 5 input into the direct reduction equipment 7 to heat or further heat an introduced hydrogen-containing reducing agent H, which holds a second thermal energy, and causing a chemical reaction between the introduced hydrogen-containing reducing agent H and the metal oxide material 5.

[0333] Due to the high temperature of the metal oxide material 5 introduced into the direct reduction equipment 7 and the additional heat from the preheated hydrogen-containing reducing agent, the metal oxide material is reduced to a reduced metal material at the required reaction temperature in an energy-efficient manner, while the second thermal energy slows down the cooling rate of the reduced metal material, exposing the reduced metal material to the heat treatment temperature required for heat treatment to obtain a densified reduced metal material. Meanwhile, the required heat treatment temperature due to the introduction of the preheated hydrogen-containing reducing agent H can be maintained by the heat treatment providing device 17 and the additional heat from the preheated hydrogen-containing reducing agent.

[0334] Alternatively, the reaction temperature required to maintain direct reduction in the direct reduction equipment may be from about 800°C to about 1200°C, preferably from about 900°C to about 1100°C.

[0335] The temperature of the hydrogen-containing reducing agent H continuously supplied to the direct reduction equipment 7 can be about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0336] Preferably, after the reduction of the metal oxide material 5 to the reduced metal material 16, a heat treatment is carried out before the reduced metal material 16 is discharged from the direct reduction facility 7.

[0337] The heat treatment densifies the reduced metal material and / or the metal oxide material being reduced, producing a compact, dense reduced metal material that is resistant to reoxidation.

[0338] The compact and high-density reduced metal material is discharged through a metal material discharge port C at the bottom of the direct reduction equipment 7, and the discharged reduced metal material is resistant to reoxidation and fire resistance during subsequent transportation and storage.

[0339] The direct reduction facility 7 further comprises a top gas removal device D configured to remove the top gas TG from the direct reduction facility 7.

[0340] 2a and 2b show a second example of a direct reduction equipment interior design that affects the residence time during the direct reduction of metal oxide material. FIG. 2a shows an example in which the height-to-width ratio Hi / Wi within the direct reduction equipment 7 is approximately 1:2. This relatively small height-to-width ratio Hi / Wi of the direct reduction equipment 7 can result in a relatively high heat treatment temperature being required for the heat treatment, since the residence time for the heat treatment of the reduced metal material can be relatively short.

[0341] Therefore, a step is provided to maintain the required heat treatment temperature, to the extent that the introduction of preheated hydrogen reduces the metal oxide material directly and slows the cooling rate of the reduced metal material descending through the direct reduction facility 7, allowing the reduced metal material to be exposed to the heat treatment temperature required to obtain a densified reduced metal material by heat treatment.

[0342] 2b shows an example of a direct reduction apparatus 7 having an internal height-to-width ratio Hi / Wi of about 3:1. Such a relatively slender, narrow-to-height direct reduction apparatus 7 is believed to be suitable when it is desirable to increase the velocity of reduced metal material that may have a tendency to "stick," and further when exposing the reduced metal material to the heat treatment temperatures required to obtain a densified reduced metal material by heat treatment of the reduced metal material.

[0343] Alternatively, the height to width ratio is at least greater than 1:1 and at most 10:1, in order to achieve a residence time suitable for the heat treatment of the reduced metallic material, while at the same time maintaining a high flow rate of the metal oxide material to be reduced and / or the reduced metallic material passing through the direct reduction equipment to an extent that metal particles of the reduced metallic material do not stick together within the equipment, and further to expose the reduced metallic material to a heat treatment temperature required for obtaining a densified reduced metallic material by heat treatment of the reduced metallic material.

[0344] 3 shows a metallic material production setup 1 according to a third embodiment, adapted for the direct reduction of a metal oxide material 5 that retains a first thermal energy to a reduced metallic material 16. The direct reduction facility 7 is configured to perform a heat treatment in the direct reduction facility 7 of the metal oxide material 5 and / or the reduced metallic material 16 to be reduced.

[0345] The metal material manufacturing arrangement 1 comprises a metal oxide material providing unit 3, such as a metal oxide material pelletizing plant (not shown) or a metal oxide material preheating plant (not shown), configured to provide a metal oxide material 5 that retains a first thermal energy.

[0346] Alternatively, the temperature of the metal oxide material retaining the first thermal energy discharged from the metal oxide material providing unit is 1000°C to about 1450°C, preferably about 1100°C to about 1300°C, in order to produce a metal oxide material retaining the first thermal energy.

[0347] The metal material production configuration 1 further comprises a direct reduction facility 7 configured to reduce the metal oxide material 5 to a reduced metal material 16. The input hopper mechanism 6 of the metal oxide material input device A is configured to input the metal oxide material 5 into an upper interior portion UP of the reduction facility 7.

[0348] The hydrogen-containing reducing agent H, which retains the second thermal energy, is introduced into the direct reduction equipment 7 via the reducing agent input device b. The hydrogen-containing reducing agent H is adapted to react with the metal oxide material 5, which retains the first thermal energy, to reduce the metal oxide material 5. This is achieved by using the first thermal energy of the metal oxide material 5 to heat or further heat the introduced hydrogen-containing reducing agent H, causing a chemical reaction (substantially direct reduction) between the hydrogen-containing reducing agent H and the metal oxide material 5. The hydrogen-containing reducing agent H, which retains the second thermal energy, is introduced into the direct reduction equipment 7 via the reducing agent input device b.

[0349] The hydrogen of the hydrogen-containing reducing agent H may be produced by an electrolysis unit (not shown). The reducing agent temperature regulator 18 of the heat treatment providing device 17 is configured to adjust (preheat and / or cool) the second thermal energy of the hydrogen-containing reducing agent H.

[0350] The preheated hydrogen-containing reducing agent is supplied from a hydrogen-containing reducing agent supplier SP.

[0351] The heat treatment results in densification of the reduced metal material, providing a compact, dense reduced metal material (intermediate product IM) that is resistant to reoxidation.

[0352] The compact, dense reduced metal material is discharged through a metal material discharge device C, which includes a metal material discharge port (not shown), at the bottom 60 of the direct reduction facility 7. The intermediate product IM can be transported to a metal manufacturer (not shown) for metal production such as steel.

[0353] The metallic material production configuration 1 includes a control circuit 50 electrically coupled to a reducing agent temperature regulator 18 of the heat treatment providing device 17 configured to regulate the second thermal energy of the hydrogen-containing reducing agent H before introduction into the direct reduction facility 7.

[0354] The control circuit 50 is adapted to operate the reductant temperature regulator 18 to adjust the second thermal energy of the hydrogen-containing reductant H to a required reaction temperature for direct reduction and / or to a required heat treatment temperature.

[0355] The control circuit 50 is adapted to control and monitor the second thermal energy of the preheated hydrogen-containing reducing agent H introduced into the direct reduction facility 7 using the heat treatment providing device 17 .

[0356] Alternatively, the control circuit 50 is electrically connected to the metal oxide material providing unit 3 and adapted to control and monitor the first thermal energy of the metal oxide material 5 input into the upper internal portion UP.

[0357] The thermal treatment providing device 17 includes a reducing agent thermal energy adjusting device 17 ′, a reducing agent mass flow adjusting device 17 ″, a residence time adjusting device 17 ′″, a pressure adjusting device 17 ″″, and a thermal treatment agent supply device 30 .

[0358] The heat treatment agent supply device 30 is electrically coupled to the control circuit 50 and configured to operate the heat treatment agent supply device 30 to introduce the preheated hydrogen-containing heat treatment agent HT carrying third thermal energy into the direct reduction equipment, in order to expose the reduced metal material to a required heat treatment temperature and maintain the required heat treatment temperature to heat treat the reduced metal material 16 in the direct reduction equipment and obtain a densified reduced metal material.

[0359] The preheated hydrogen-containing heat treatment agent is supplied from the hydrogen-containing reducing agent supplier SP to the heat treatment agent supply device 30 .

[0360] The preheated hydrogen-containing heat treatment agent HT is introduced into the direct reduction equipment 7 via the heat treatment agent input device 30 of the direct reduction equipment 7 .

[0361] The preheated hydrogen-containing reducing agent H is introduced at a position lower than the metal oxide material input device A. The heat treatment agent supply device 30 includes a heat treatment agent preheating unit (not shown) configured to preheat the hydrogen-containing heat treatment agent HT to reach a third thermal energy before introduction into the direct reduction equipment.

[0362] The reducing agent input device B is located at a higher level than the heat treatment agent input device 30 .

[0363] The control circuit 50 is electrically coupled to the thermal treatment providing device 17 configured to provide a hydrogen-containing thermal treatment agent HT carrying a third thermal energy adapted for thermal treatment.

[0364] The reducing agent thermal energy adjusting device 17′ is configured to adjust the second thermal energy and is electrically coupled to the first control circuit 50′, which is configured to control the reducing agent thermal energy adjusting device 17′ to introduce the heat treatment agent HT at a specific temperature to achieve the required heat treatment temperature.

[0365] The reductant thermal energy conditioning device may comprise an electric preheater configured to preheat the hydrogen-containing reductant.

[0366] The reducing agent mass flow regulating device 17'' is configured to regulate the mass flow rate of the hydrogen-containing reducing agent H introduced into the direct reduction equipment 7, and is electrically coupled to the second control circuit 50''. The second control circuit is configured to operate the reducing agent mass flow regulating device 17'' to regulate the mass flow rate of the hydrogen-containing reducing agent H to achieve the required heat treatment temperature.

[0367] The residence time adjusting device 17''' is configured to adjust the residence time for maintaining the reduced metallic material 16 within the direct reduction facility 7 and is electrically coupled to the third control circuit 50'''. The third control circuit is configured to operate the residence time adjusting device 17''' to achieve a particular residence time for maintaining the reduced metallic material within the direct reduction facility 7 and to control the required heat treatment temperature.

[0368] The pressure adjusting device (17'''') is configured to adjust the pressure inside the direct reduction equipment 7 and is electrically coupled to the fourth control circuit 50''''. The fourth control circuit is configured to operate the pressure adjusting device 17'''' toward a specific pressure inside the direct reduction equipment 7 to control the required heat treatment temperature.

[0369] The direct reduction facility 7 further comprises a top gas outlet of a top gas removal device D configured to remove top gas from the direct reduction facility 7, the top gas being preferably reused and / or recycled.

[0370] Alternatively, the top gas contains up to about 100% by volume of high temperature steam.

[0371] Alternatively, the top gas contains a maximum of about 80-100% by volume, preferably about 85-95% by volume, of high temperature steam.

[0372] Alternatively, the top gas contains a maximum of about 60-90% by volume, preferably about 70-80% by volume, of high temperature steam.

[0373] Alternatively, the top gas contains a maximum of about 30-60% by volume, preferably about 40-50% by volume, of high temperature steam.

[0374] Alternatively, the top gas contains a maximum of about 10-40% by volume, preferably about 20-30% by volume, of high temperature steam.

[0375] Alternatively, the top gas contains a maximum of about 0-20% by volume, preferably about 5-15% by volume, of high temperature steam.

[0376] Alternatively, the top gas contains a maximum of about 0-15% by volume, preferably about 1-10% by volume, of high temperature steam.

[0377] The reduction facility 7 is configured so that the reduced metal material 16 can be directly lowered through the reduction facility 7 for heat treatment of the reduced metal material 16 .

[0378] The chemical reactivity and / or high driving force of the preheated hydrogen-containing reducing agent H is not impaired after introduction into the direct reduction equipment 7. This is because the desired reaction temperature is achieved by utilizing the primary thermal energy of the input metal oxide material. Therefore, it is not necessary to "burn" the reducing agent using, for example, a combustion heater, to achieve the desired reaction temperature.

[0379] The thermal treatment agent supply device 30 is electrically coupled to the control circuit 50 and configured to operate the thermal treatment agent supply device 30 to introduce preheated hydrogen.

[0380] Alternatively, the heat treatment of the reduced metallic material 16 is carried out by introducing a preheated hydrogen-containing heat treatment agent HT into the direct reduction equipment 7. Here, the third thermal energy is increased using the heat treatment agent supply device 30 to reduce the cooling rate of the reduced metallic material 16 in the direct reduction equipment 7.

[0381] Alternatively, the control circuit is electrically coupled to a heat treatment agent thermal energy adjusting device of the heat treatment agent supply device 30, which adjusts the third thermal energy of the hydrogen-containing heat treatment agent HT to control the heat treatment of the reduced metal material 16.

[0382] The metal oxide material 5 that has been reduced to reduced metallic material and / or the metal oxide material 5 that has not yet been fully reduced is exposed to a heat treatment temperature required for heat treatment of the reduced metallic material 16 to obtain a densified reduced metallic material (e.g., a produced intermediate product with limited reoxidation or sponge iron) that is discharged via a metallic material discharge device C configured to discharge the reduced and heat-treated metallic material 16.

[0383] FIG. 4 shows a flow diagram of a metal material production configuration 1 according to a fourth embodiment. A thermally energy-retaining metal oxide material 5 is input into a reduction facility 7. The reduction facility 7 can be defined as having an upper internal portion UP, a middle internal portion IP, and a lower internal portion LP. A hydrogen-containing reducing agent H is introduced into the middle internal portion IP and flows upward to contact the thermally energy-retaining metal oxide material 5 transported downward. Thus, the upper internal portion UP functions as a countercurrent heat exchange zone for carrying out a chemical reaction (direct reduction) between the metal oxide material and the hydrogen-containing reducing agent 6, producing a reduced metal material 16.

[0384] The hydrogen-containing reducing agent H is preheated using the heat treatment providing device 17 to become the hydrogen-containing reducing agent H that retains second thermal energy.

[0385] Alternatively, the metal oxide material 5 retaining the first thermal energy is moved downward from the upper internal portion UP to the middle internal portion IP and / or the lower internal portion LP by gravity.

[0386] A control circuit (not shown) is electrically coupled to the heat treatment providing device 17 and adapted to operate the heat treatment providing device 17 to preheat the hydrogen-containing reagent to retain second thermal energy for exposing the reduced metallic material 16 to a heat treatment temperature required for obtaining a densified reduced metallic material by heat treatment of the reduced metallic material, and for maintaining the required heat treatment temperature by introduction of the preheated hydrogen-containing reducing agent H.

[0387] Alternatively, the temperature of the hydrogen-containing reducing agent H introduced into the intermediate internal portion IP is controlled by a direct command control circuit to produce a top gas TG containing or substantially containing high temperature steam by direct reduction.

[0388] Alternatively, the temperature of the hydrogen-containing reducing agent H introduced into the middle internal portion LP is controlled by a control circuit to produce a top gas TG containing more than about 80.90% high temperature steam.

[0389] The removed top gas TG may also contain residual hydrogen that was not consumed by the direct reduction.

[0390] In this way, the metal oxide material is completely reduced.

[0391] Since the introduced metal oxide material 5 is at a high temperature, the metal oxide material 5 is efficiently reduced in the upper part of the upper interior portion UP, even though the hydrogen-containing reducing agent H contains a large amount of water.

[0392] The metallic material production configuration 1 is adapted to introduce a preheated hydrogen-containing heat treatment agent HT carrying a third thermal energy into the direct reduction facility 7 using the heat treatment agent supply device 30 in order to expose the reduced metallic material 16 to a required heat treatment temperature, maintain the required heat treatment temperature, and heat treat the reduced metallic material 16 to obtain a densified reduced metallic material.

[0393] The preheating hydrogen-containing heat-treating agent HT carrying the third thermal energy is preferably introduced into the middle internal portion IP and / or the lower internal portion LP. The temperature of the preheating hydrogen-containing heat-treating agent HT carrying the third thermal energy is controlled by a heat-treating agent supply device 30 electrically connected to a control circuit adapted to adjust the temperature of the preheating hydrogen-containing heat-treating agent HT to a heat-treating temperature required for the heat treatment.

[0394] 4 also shows a residence time adjusting device 17''' configured to adjust the residence time for which the reduced metallic material 16 remains within the direct reduction facility 7 for a particular residence time. The residence time adjusting device 17''' is electrically coupled to a control circuit, which is configured to operate the residence time adjusting device 17''' to maintain and control the required heat treatment temperature of the reduced metallic material within the direct reduction facility 7 to achieve the particular residence time.

[0395] The residence time adjusting device 17''' comprises choking mechanisms CM', CM'' adapted to regulate the discharge of the heat-treated reduced metallic material from the lower internal portion LP. The choking mechanisms CM', CM'' are connected to the metallic material flow rate reduction member MM. The operation of the choking mechanisms CM', CM'' is synchronized with the operation of a dosing mechanism (not shown) configured to regulate the amount of metal oxide material 5 to the reduction facility 7.

[0396] Alternatively, the heat treatment agent supply device 30 is configured to regulate a third thermal energy for controlling the heat treatment to produce the semi-molten reduced metal material and / or the densified reduced metal material.

[0397] Figure 5 shows a metallic material production arrangement 1 adapted for the direct reduction of metal oxide material 5 to reduced iron ore material 16 and for heat treatment of the reduced iron ore material with a hydrogen-containing reducing agent H according to a fifth embodiment. The metallic material production arrangement 1 comprises a direct reduction facility 7 arranged to input metal oxide material 5 carrying first thermal energy, the first thermal energy being provided by a metal oxide material providing unit 3, such as a metal oxide pelletizing plant PP and / or a metal oxide material preheating unit PHU, configured to preheat metal oxide material transferred from a metal oxide material storage 8.

[0398] The metal oxide material fed into the direct reduction equipment can be kept at a temperature of about 900°C to about 1500°C, preferably about 1000°C to about 1400°C.

[0399] A metal oxide material carrying a first thermal energy is introduced into the upper interior portion UP of the direct reduction equipment 7 via a metal oxide material introduction device A. A hydrogen-containing reducing agent H carries a second thermal energy before being introduced into the direct reduction equipment 7 via a reducing agent introduction device B.

[0400] Alternatively, the reducing agent inlet E of the reducing agent input device 30 configured to directly introduce the preheated hydrogen-containing reducing agent HT into the reduction equipment 7 may be located below the reducing agent input device B configured to introduce the preheated hydrogen-containing reducing agent H.

[0401] The input hopper mechanism 6 of the metal oxide material input device A is configured to input the metal oxide material 5 into the upper interior portion UP of the reduction equipment 7. The metal oxide material that substantially retains the second thermal energy is transferred from the metal oxide material providing unit 3 directly to the reduction equipment 7 via the input hopper mechanism 6.

[0402] The metal material production configuration 1 includes a first seal gas introduction device 61 configured to introduce a seal gas into the direct reduction equipment 7 simultaneously with the step of inputting a metal oxide material that retains a first thermal energy into the direct reduction equipment 7. The material production configuration 1 includes a second seal gas introduction device (not shown) configured to introduce a second seal gas into the direct reduction equipment 7 via a metal material discharge device C configured to discharge the heat-treated reduced metal material 16.

[0403] In this way, the dosing of metal oxide materials into a direct reduction facility can be carried out safely without forming an explosive air / process gas mixture during dosing.

[0404] This is achieved by ensuring that only a seal gas, and not air, is introduced into the direct reduction equipment during the introduction of the metal oxide material, so that no process gas and / or hydrogen-containing reducing gas escapes from the direct reduction equipment during the introduction of the metal oxide material.

[0405] The control circuit 50 of the metallic material manufacturing configuration 1 is electrically coupled to the heat treatment providing device 17 and configured to operate the heat treatment providing device 17 to supply and / or adjust the second thermal energy of the preheated hydrogen-containing reducing agent H. The heat treatment providing device 17 may include an electric preheater (not shown) configured to preheat the hydrogen-containing reducing agent H.

[0406] The control circuit 50 is adapted to control the thermal treatment of the reduced metallic material 16 by adjusting the second thermal energy of the hydrogen-containing reducing agent H using the heat treatment providing device 17. The heat treatment providing device 17 is configured to adjust the second thermal energy so as to maintain a required thermal treatment temperature in the direct reduction facility 7 by introducing preheated hydrogen-containing reducing agent H carrying the adjusted second thermal energy. The preheated hydrogen-containing reducing agent is supplied from a hydrogen-containing reducing agent supplier SP, such as an electrolysis unit 62. The electrolysis unit 62 is configured to decompose water W into hydrogen and oxygen gas O, which is contained in the hydrogen-containing reducing agent H. The oxygen gas O produced by the electrolysis unit 62 may be transported to an oxidation zone (not shown) of the metal oxide pelletization plant PP for oxidation of the preheated metallic ore material.

[0407] The direct reduction facility 7 is configured to reduce the metal oxide material 5 by utilizing a first thermal energy of the metal oxide material 5 to heat or further heat the introduced hydrogen-containing reducing agent H to cause a chemical reaction between the introduced hydrogen-containing reducing agent H and the metal oxide material 5 (e.g., a substantially endothermic chemical reaction for the direct reduction).

[0408] The direct reduction facility 7 is configured to heat treat the reduced metallic material 16 by exposing the reduced metallic material 16 to a heat treatment temperature required to heat treat the reduced metallic material 16 to obtain a densified reduced metallic material with limited reoxidation.

[0409] The direct reduction equipment may be designed as a solid-gas countercurrent moving bed reactor, in which the first thermal energy-retaining metal oxide material 5 is introduced into an upper internal part UP of the direct reduction equipment 7 via a metal oxide material introduction device A and flows downward by gravity toward a lower internal part LP of the direct reduction equipment 7.

[0410] The second thermal energy-carrying preheated hydrogen-containing reducing agent H may be introduced into the lower internal portion LP and / or the upper internal portion UP and introduced into the direct reduction facility 7 at a level higher than each other.

[0411] The control circuit 50 is further electrically coupled to the heat treatment agent supply device 30 of the heat treatment providing device 17 and adapted to control the heat treatment agent supply device, thereby performing heat treatment of the reduced metallic material 16. The heat treatment agent supply device 30 is adapted to introduce and adjust the third thermal energy of the preheated hydrogen-containing heat treatment agent HT introduced into the direct reduction equipment 7, in order to expose the reduced metallic material to a heat treatment temperature required for heat treating the reduced metallic material to obtain a densified reduced metallic material, i.e., an intermediate product with limited reoxidation.

[0412] The high temperature of the metal oxide material 5 fed into the direct reduction equipment 7, the additional heat of the preheated hydrogen-containing reducing agent carrying the second thermal energy, and the added preheated hydrogen-containing heat treatment agent HT are controlled by a control circuit to energy-efficiently reduce the metal oxide material to a reduced metal material at the required reaction temperature, while simultaneously utilizing the second and third thermal energies to slow the cooling rate of the reduced metal material and expose it to the heat treatment temperature required to obtain a densified reduced metal material by heat treatment of the reduced metal material.

[0413] The required heat treatment temperature is controlled by the control circuit by adjusting the third thermal energy to maintain the required heat treatment temperature and to obtain a densified reduced metal material by heat treatment of the reduced metal material 16, and the control circuit is also controlled to adjust the second thermal energy of the preheated hydrogen-containing reducing agent H using the heat treatment providing device 17.

[0414] The direct reduction facility 7 includes a top gas discharge device D configured to remove a top gas TG containing excess hydrogen and high-temperature steam from the direct reduction facility 7. The high-temperature steam is generated by a chemical reaction between metal oxide materials and hydrogen in the hydrogen-containing reducing agent. The top gas TG is supplied to a filter unit 63 adapted to separate high-temperature steam from excess hydrogen gas (not shown), which is recycled to the hydrogen-containing reducing agent H. The filter unit 63 is further configured to filter the high-temperature steam WS from impurities. The high-temperature steam WS is supplied to a heat exchange device 64 for preparing water W to be supplied to the electrolysis unit 62. The heat exchange device 64 is adapted to cool the high-temperature steam WS to water W and transfer the recovered heat, for example, to the heat treatment providing device 17, for preheating the hydrogen-containing reducing agent H and / or the hydrogen-containing heat treatment agent HT. The electrolysis unit 62, configured to decompose the water W, is supplied with electricity from a renewable energy supplier RGE and water from an external water supplier 65.

[0415] Figure 6a shows the 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 to reduced iron ore material in the form of hematite and / or magnetite and / or wustite occurs in two or three stages, depending on whether the temperature is above or below 570°C. In this case, hematite Fe2O3 first converts to magnetite Fe3O4, and then to wustite FeO. X and finally reduced to iron, Fe. The figure shows that as the water vapor content inside the direct reduction plant increases, higher temperatures are required to reduce the iron ore oxide material.

[0416] The preheated hydrogen gas-containing reducing agent carrying the second thermal energy introduced into the direct reduction equipment contacts the iron ore oxide material carrying the first thermal energy ascending and descending within the direct reduction equipment.

[0417] Since the iron ore oxide material, which holds the first thermal energy, is directly input into the reduction equipment, reduction of the iron ore oxide material is possible even if the water content in the hydrogen-containing reducing agent is high (see position Q in the phase diagram of FIG. 6a, for example, the HO / (HO+H) ratio is about 0.9).

[0418] Preferably, the further down the direct reduction plant, the less water vapor there is in the reduction plant, since less hydrogen is used for reduction and the hydrogen content can be twice the water content (see position R in the phase diagram of FIG. 5, e.g., HO / (HO+H) ratio of about 0.3).

[0419] Alternatively, a control circuit (not shown) is adapted to control the direct reduction in the direct reduction facility so that the reduced metallic material is not reoxidized.

[0420] Alternatively, the control circuit is electrically coupled to a reducing agent thermal energy regulating device (not shown) and / or a pressure regulating device (not shown) and / or a reducing agent mass flow rate regulating device (not shown) and / or a residence time regulating device (not shown) adapted to hold the iron oxide material in the direct reduction facility for a particular residence time and / or a reducing agent introduction / pressurization device and / or a top gas removal device to control the required reaction temperature and / or the required heat treatment temperature.

[0421] Thus, the required reaction temperature is maintained using a control circuit by adjusting the temperature of the hydrogen-containing reductant and / or adjusting the mass flow rate of the preheated hydrogen-containing reductant supplied to the direct reduction facility.

[0422] In this way, reduced iron material is obtained that has not been reoxidized in the direct reduction plant.

[0423] Alternatively, the control circuit is adapted to control the reductant mass flow regulating device to supply the preheated hydrogen-containing reductant to the direct reduction facility at a relatively high flow rate, thereby reducing the steam load in the direct reduction facility and performing efficient direct reduction to provide a completely directly reduced ferrous material.

[0424] By utilizing the secondary thermal energy of the preheated hydrogen-containing reducing agent, direct reduction becomes possible despite the relatively high water content at the bottom of the direct reduction unit (see position R in the phase diagram in Figure 5).

[0425] Alternatively, the preheated hydrogen gas-containing reducing agent introduced into the direct reduction equipment may have a higher thermal heat as the preheated hydrogen gas-containing reducing agent rises within the direct reduction equipment because the hotter iron ore oxide material heats or further heats the preheated hydrogen gas-containing reducing agent to bring it to the required reaction temperature.

[0426] Alternatively, the preheating of the hydrogen gas containing reducing agent reduces the cooling rate of the iron ore oxide material moving down the direct reduction facility.

[0427] Alternatively, the higher the preheated hydrogen gas-containing reducing agent temperature in the direct reduction equipment, the greater the amount of high-temperature steam contained in the preheated hydrogen gas-containing reducing agent. However, efficient direct reduction of iron ore oxide materials is possible (see position Q in the phase diagram in Figure 5).

[0428] As shown in the figure, despite the high water content of the preheated hydrogen gas-containing reducing agent (position Q), hematite is reduced to magnetite at high temperatures (e.g., 1200 °C), and direct reduction to magnetite is still possible.

[0429] In this way, the thermal energy of the first thermal energy generated by the metal oxide material providing unit, together with the thermal energy of the hydrogen gas-containing reducing agent 8 and / or hydrogen gas H, is utilized to achieve the required reaction temperature.

[0430] In this way, the high temperature of the iron ore oxide material promotes efficient direct reduction, even though the preheated hydrogen gas-containing reducing agent contains a high content of water vapor (see position Q in the phase diagram of Figure 5).

[0431] Alternatively, excess hydrogen gas may be separated from the top gas removed from the direct reduction plant and recycled to and introduced into the direct reduction plant.

[0432] In this way, hydrogen gas can be used cost-effectively.

[0433] The preheated hydrogen-containing reducing agent introduced into the reduction equipment and carrying the second thermal energy therefore rises in the upper internal portion and comes into contact with the iron ore oxide material carrying the first thermal energy that is moving downward, whereby reduction occurs. However, the further the introduced preheated hydrogen-containing reducing agent rises within the direct reduction equipment, the greater the water content of the preheated hydrogen-containing reducing agent.

[0434] As shown in the figure, despite the high water content of the preheated hydrogen-containing reducing agent H, hematite is reduced to magnetite at high temperatures (e.g., 1200 °C), and reduction to magnetite is still possible.

[0435] The present disclosure utilizes the high temperature of iron ore oxide material, which contains a first thermal energy, and which is introduced into the upper interior portion UP from an iron ore oxide material providing unit, and upon reaching the top of the upper interior portion UP, the high temperature of the iron ore oxide material allows reduction despite the high water content of the preheated hydrogen-containing reducing agent.

[0436] By introducing the second energy-retaining preheated hydrogen-containing reducing agent H, the required heat treatment temperature is maintained to such an extent that the cooling rate of the reduced iron material descending the direct reduction facility (see, for example, reference numeral 7 in FIG. 5 ) is reduced.

[0437] This reduces the cooling rate of the reduced iron material descending through the direct reduction facility, allowing for effective heat treatment of the reduced iron material, allowing the reduced iron material to be exposed to the heat treatment temperature required to obtain densified reduced iron material, and the required heat treatment temperature to be maintained by the introduction of a preheated hydrogen-containing reducing agent H using a heat treatment providing device (not shown).

[0438] Figure 6b shows a mole / mole phase diagram of hydrogen / hydrogen + iron versus temperature, from different temperature perspectives. Reference symbol O represents the liquid phase, reference symbol P represents the Bcc / liquid phase, reference symbol Q represents the Bcc phase, and reference symbol R represents the Fcc phase. The diagram shows that iron (Fe) sinters in the Bcc + liquid phase (P), i.e., the iron in the reduced iron ore material hardens at relatively low temperatures (e.g., 200-600°C). This is because the introduced hydrogen maintains its chemical reactivity and / or high driving force. This, along with exposing the reduced iron material to the heat treatment temperatures required for the heat treatment, also facilitates the production of densified reduced metal material.

[0439] Furthermore, there is no need to "burn" or ignite the reducing agent to, for example, 1200° C. to provide thermal energy to effect direct reduction as shown in the prior art.

[0440] On the contrary, by utilizing the first thermal energy of the iron ore oxide material introduced into the reduction facility to supply heat for the direct reduction, it is now possible to control the second thermal energy of the hydrogen-containing reducing agent introduced at the bottom of the direct reduction facility to slow down the cooling rate of the reduced iron material as it descends through the direct reduction facility.

[0441] Therefore, the secondary thermal energy of the hydrogen-containing reducing agent and the maintained high chemical reactivity and / or high driving force enable efficient heat treatment.

[0442] Alternatively, the reduced iron material is heat treated for an extended period of time at the heat treatment temperature required to obtain a densified reduced iron material, wherein the wustite is largely reduced to sponge iron and / or the surface of the sponge iron agglomerates produced is densified.

[0443] In this way, the intermediate product (such as sponge iron) is prevented from having a tendency to revert to an oxidized state when exposed to natural atmosphere.

[0444] In this way, there is no risk of the sponge iron spontaneously combusting.

[0445] In this way, the transport of sponge iron to steel mills becomes safe.

[0446] In this way, steelmakers save energy in steel production by using sponge iron in electric arc furnaces.

[0447] Alternatively, the control circuit 50 is adapted to control a heat treatment providing device that provides heat treatment of, or preferably exposes, the reduced iron ore material in the Bcc+ liquid phase P. Exposing the reduced iron material and / or iron ore oxide material during reduction, maintaining the required heat treatment temperature for an extended period of time, and using a hydrogen-containing reducing agent with high chemical reactivity and / or high driving force provides reduced iron material that is resistant to reoxidation.

[0448] Figures 7a to 7c show the phase transition of the aggregate structure for the heat treatment disclosed herein. Figure 7a shows the aggregate structure of iron ore oxide material 5 that retains first thermal energy. This iron ore oxide material 5 is directly reduced in the upper interior portion of the reduction equipment (not shown).

[0449] Porous agglomerates PA containing iron ore oxide particles OP are fed into the direct reduction equipment. The iron ore oxide particles bond together to form porous agglomerates PA, whose porosity facilitates the chemical reaction between the iron ore oxide and the preheated hydrogen-containing reducing agent introduced, resulting in the initial direct reduction. Figure 7b shows the porous agglomerates PA containing the reduced iron material before heat treatment. Eventually, some of the wüstite material may reside in the spaces between the reduced iron particles RIP. Here, the high hydrogen content of the introduced hydrogen-containing gas and the required heat treatment temperature ultimately decompose the FeO compound into Fe and oxygen, which then combine to form water molecules.

[0450] Alternatively, to provide a reduced iron material that is resistant to reoxidation, the reduced iron material and / or iron ore oxide material (mainly wüstite material) is exposed to a heat treatment temperature required to provide a densified reduced iron material by heat treatment, as shown in Figure 7c. This is done by maintaining the required heat treatment temperature by introducing a preheated hydrogen-containing reducing agent using a heat treatment providing device and / or by introducing a preheated hydrogen-containing heat treatment agent to heat treat the reduced iron material and / or iron ore oxide material to be reduced.

[0451] Alternatively, the reduced iron particles are spheroidized by heat treatment.

[0452] Alternatively, the produced sponge iron SI shown in Figure 7c has voids V. Heat treatment results in sponge iron SI that is resistant to reoxidation.

[0453] Figure 7c shows a portion of sponge iron SI that has been densified by heat treatment.

[0454] Figures 8a to 8c show the phase transition of the aggregate structure for the heat treatment disclosed herein. Figure 8a shows the aggregate structure of iron ore oxide material 5 that retains first thermal energy. This iron ore oxide material 5 is directly reduced in the upper interior portion of the reduction equipment (not shown).

[0455] Porous agglomerates PA containing iron ore oxide particles OP are fed into the direct reduction equipment. The iron ore oxide particles bond together to form porous agglomerates PA, whose porosity facilitates the chemical reaction between the iron ore oxide and the preheated hydrogen-containing reducing agent introduced, resulting in the initial direct reduction. Figure 8b shows the porous agglomerates PA containing the reduced iron material before heat treatment. Eventually, some of the wüstite material may reside in the spaces between the reduced iron particles RIP. Here, the high hydrogen content of the introduced hydrogen-containing gas and the required heat treatment temperature ultimately decompose the FeO compound into Fe and oxygen, which then combine to form water molecules.

[0456] Alternatively, to provide reduced iron material that is resistant to reoxidation, the reduced iron material and / or iron ore oxide material (mainly wüstite material) is exposed to a heat treatment temperature required to obtain a densified reduced iron material by heat treatment, as shown in Figure 8c. This is accomplished by maintaining the required heat treatment temperature by introducing a preheated hydrogen-containing reducing agent using a heat treatment providing device and / or by introducing a preheated hydrogen-containing heat treatment agent to heat treat the reduced iron material and / or iron ore oxide material to be reduced. Figure 8c schematically illustrates a portion of sponge iron SI that has been densified by heat treatment.

[0457] Figures 9a-9b show a metallic material production setup 1 adapted for the reduction of a first thermal energy-carrying iron ore oxide material 5. This material is fed into a reduced iron ore material 16 according to a sixth embodiment.

[0458] The metallic material production arrangement 1 comprises an iron ore oxide material providing unit 3, such as an iron ore oxide pelletizing plant or an iron ore oxide preheating plant, configured to provide a first thermal energy-bearing iron ore oxide material 5.

[0459] The metallic material production arrangement 1 comprises a reduction facility 7 configured to reduce an iron ore oxide material 5. The iron ore oxide material 5 carrying a first thermal energy is introduced into an upper interior portion UP of the reduction facility 7.

[0460] The metallic material production arrangement 1 comprises a reducing agent pre-heating device 20 of a heat treatment providing device 17. The reducing agent pre-heating device 20 and / or the heat treatment providing device 17 are configured to operate the direct reduction installation 7 to the required heat treatment temperature.

[0461] The reductant pre-heating device 20 is configured to pre-heat the hydrogen-containing reductant H introduced into the direct reduction facility 7 and is electrically coupled to the control circuit 50 of the metallic material production configuration 1.

[0462] The heat treatment agent supply device 30 of the heat treatment providing device 17 is adapted to introduce and adjust the third thermal energy of the preheated hydrogen-containing heat treatment agent HT introduced into the direct reduction facility 7. This is to expose the reduced iron material to a heat treatment temperature required for obtaining a densified reduced metallic material by heat treatment of the reduced metallic material.

[0463] Additionally, the preheated hydrogen-containing reducing agent H may be introduced into the reduction equipment 7 at different levels, at different temperatures, at different pressures, flow rates, and the like.

[0464] The direct reduction installation 7 may have an upper internal portion UP and / or an intermediate internal portion IP and / or a lower internal portion.

[0465] The preheated hydrogen-containing reducing agent H supplied and introduced into the direct reduction facility may contain about 80-100% hydrogen, preferably about 85-95% hydrogen, or pure hydrogen.

[0466] 9b shows a cross section of the reduction equipment 7. A preheated hydrogen-containing reducing agent H and a preheated hydrogen-containing heat treatment agent (not shown) that is introduced as needed are directly introduced from the periphery of the reduction equipment 7. The top gas TG is discharged from the reduction equipment 7 to the periphery.

[0467] Alternatively, the reaction temperature required to sustain direct reduction in a direct reduction facility may be from about 800°C to about 1200°C, preferably from about 900°C to about 1100°C.

[0468] The temperature of the hydrogen-containing reducing agent H continuously supplied to the direct reduction equipment 7 can be about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0469] Preferably, after the reduction of the iron ore oxide material 5 to the reduced iron material, and before the discharge of the reduced iron material 16 from the direct reduction facility 7, a heat treatment is carried out.

[0470] Alternatively, the heat treatment may densify the reduced iron material and / or the iron ore oxide material being reduced to produce a compact, dense reduced metallic material that is resistant to reoxidation.

[0471] The compact, high-density reduced iron material is discharged from a bottom outlet (not shown) at the bottom (not shown) of the direct reduction facility 7. The discharged reduced iron material is resistant to reoxidation and is refractory for subsequent transportation in the atmosphere.

[0472] 10 is a flowchart illustrating an exemplary method for directly reducing a metal oxide material to a reduced metallic material using a metallic material production configuration (not shown). The metallic material production configuration includes a metal oxide material providing unit (not shown) configured to provide a metal oxide material having a first thermal energy, a direct reduction facility (not shown) including a metal oxide material input device, a reducing agent input device configured to introduce a hydrogen-containing reducing agent having a second thermal energy, a direct reduction zone of the direct reduction facility configured to reduce the metal oxide material by utilizing the first thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent and cause a chemical reaction between the introduced hydrogen-containing reducing agent and the metal oxide material, a heat treatment zone of the direct reduction facility configured to heat-treat the reduced metallic material by exposing the reduced metallic material to a heat treatment temperature required to obtain a densified reduced metallic material by heat-treating the reduced metallic material, a heat treatment providing device configured to maintain the required heat treatment temperature by introducing a preheated hydrogen-containing reducing agent, and a metallic material discharge device configured to discharge the heat-treated reduced metallic material.

[0473] 10 starts at step 801. Step 802 includes adapting the method. Step 803 includes stopping the method. Step 802 may include the steps of: inputting a metal oxide material having a first thermal energy into a direct reduction facility via a metal oxide material input device; introducing a preheated hydrogen-containing reducing agent having a second thermal energy into the direct reduction facility via a reducing agent input device; utilizing the first thermal energy of the metal oxide material to heat or further heat the introduced preheated hydrogen-containing reducing agent to cause a chemical reaction between the introduced preheated hydrogen-containing reducing agent and the metal oxide material, thereby reducing the metal oxide material; exposing the reduced metal material to a heat treatment temperature required to obtain a densified reduced metal material by heat treatment of the reduced metal material; maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reducing agent using a heat treatment providing device; and discharging the heat-treated reduced metal material.

[0474] FIG. 11 is a flowchart illustrating an exemplary method for directly reducing a metal oxide material to a reduced metal material using the metal material production configuration disclosed herein. The method begins at step 900. Step 901 includes introducing a metal oxide material having a first thermal energy into the direct reduction facility via a metal oxide material input device. Step 902 includes introducing a preheated hydrogen-containing reducing agent having a second thermal energy into the direct reduction facility via a reducing agent input device. Step 903 includes utilizing the first thermal energy of the metal oxide material to heat or further heat the introduced preheated hydrogen-containing reducing agent, thereby reducing the metal oxide material by inducing a chemical reaction between the introduced preheated hydrogen-containing reducing agent and the metal oxide material. Step 904 includes exposing the reduced metal material to a heat treatment temperature required to obtain a densified reduced metal material by heat treatment of the reduced metal material. Step 905 includes maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reducing agent using a heat treatment providing device. Step 906 includes discharging the heat-treated reduced metal material. Step 907 includes introducing a preheated hydrogen-containing heat treatment agent carrying third thermal energy into the direct reduction facility using a heat treatment agent supply device to maintain the required heat treatment temperature and to expose the reduced metallic material to the required heat treatment temperature for heat treating the reduced metallic material to obtain a densified reduced metallic material. Step 908 includes introducing the preheated hydrogen-containing reducing agent to maintain the required heat treatment temperature to an extent that the metal oxide material is directly reduced and the cooling rate of the reduced metallic material descending through the direct reduction facility is slowed to maintain the required heat treatment temperature. Step 909 includes stopping the method.

[0475] 12 illustrates a control circuit 50 for a metal material manufacturing configuration 1 according to a further embodiment. The control circuit 50 is configured to control the exemplary methods disclosed herein. The control circuit 50 may include a non-volatile memory NVM 1020, which is a computer memory that can retain stored information even when power is not supplied to the control circuit 50 or the computer. The control circuit 50 further includes a processing unit 1010 and a read / write memory 1050.

[0476] The NVM 1020 includes 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 and is used to control the function of the control circuit 50.

[0477] Additionally, the control circuit 50 includes a bus controller (not shown) and a serial communications port (not shown) that provides a physical interface through which information may be transferred in both directions separately.

[0478] The control circuit 50 may include a suitable type of I / O module (not shown) for input and output signal transmission, and an A / D converter (not shown) for converting varying signals from temperature detectors of the direct reduction equipment and heat treatment providing device for detecting the temperature of the introduced preheated hydrogen-containing reducing agent and / or the actual heat treatment temperature and / or preheated hydrogen-containing heat treatment agent into binary code suitable for processing by the computer of the control circuit 50.

[0479] The control circuit 50 may use a different monitoring unit (not shown) of the direct reduction facility to monitor the heat treatment temperature and / or the properties of the reduced metallic material that withstands heat treated reoxidation.

[0480] The control circuit 50 further comprises an input / output unit (not shown) for corresponding to the date and time. The control circuit 50 may also comprise an event counter (not shown) for counting the number of events occurring during the regulation of the chemical reactions and / or heat treatments to obtain the densified reduced metallic material.

[0481] Additionally, the control circuit 50 includes an interrupt unit (not shown) for multitasking and real-time calculations. The NVM 1020 also includes a second memory unit 1040 for external control operations.

[0482] A data medium adapted to store a data program P includes a driver routine adapted to command the operation of the metallic material production arrangement 1 .

[0483] The data program P is adapted to operate the control circuit 50 in performing the exemplary methods described herein. The data program P includes routines for executing commands 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.

[0484] The data program P may further be stored in the independent memory 1060 and / or in the read / write memory 1050. The data program P may be stored in an executable format or in a compressed data format.

[0485] When the processing unit 1010 is described as performing a particular function, it is understood that the processing unit 1010 executes a particular portion of a program stored in the independent memory 1060 or a particular portion of a program stored in the read / write memory 1050.

[0486] The processing unit 1010 is associated with a signal (data) port 1099, such as a serial bus, for communication via a first data bus 1015, which may be adapted to be electrically coupled to electronic control circuitry of an operator interface circuit (not shown).

[0487] In this way, the operator is able to control and monitor the metal material production setup 1 via the display of the electronic control circuitry.

[0488] The non-volatile memory NVM 1020 is adapted to communicate with the processing unit 1010 via a second data bus 1012. The independent memory 1060 is adapted to communicate 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 port 1099 may be connectable to, for example, a data link of a network coupled to the control circuit 50.

[0489] Data received by the signal port 1099 may be temporarily stored in the second memory unit 1040. Once the received data is temporarily stored, the processing unit 1010 is ready to execute program code according to an exemplary method.

[0490] Preferably, the signal (received by signal port 1099) includes information about the operational status of metallic materials production configuration 1 and / or direct reduction facility.

[0491] The signals received at signal port 1099 may be used by control circuitry 50 to control and monitor the direct reduction and heat treatment.

[0492] The signal received at the signal port 1099 may be used for historical data and data related to the operation of the metal material manufacturing configuration 1.

[0493] The metal material manufacturing configuration 1 may be configured to couple to a data network via a signal port 1099 configured for an electrical interface that expressly provides electrical compatibility and associated data transfer, and this data may include information regarding the status of the metal material manufacturing configuration 1 and the temperature detector. Data may also be manually supplied to the computer via any suitable communication device, such as a display (not shown).

[0494] The individual sequences of the method may be carried out by a computer that executes a data program P stored in the independent memory 1060 or in the read / write memory 1050. When the computer executes the data program P, the method steps according to any embodiment disclosed herein are performed.

[0495] A data program product may be provided that includes program code stored on a data medium, which is readable on a computer, and when the data program P is executed on the computer, the exemplary method steps described herein are performed.

[0496] FIG. 13 shows a metallic material production arrangement 1, such as a sponge iron production arrangement 1, according to a further embodiment.

[0497] Alternatively, there is provided a method for directly reducing a first thermal energy-bearing iron ore oxide material 5 into densified reduced iron material 16 using a sponge iron production configuration 1. The first thermal energy-bearing iron ore oxide material 5 is provided by an iron ore oxide material providing unit 3, such as an iron ore oxide pelletizer and / or an iron ore oxide preheating device.

[0498] Alternatively, the temperature of the iron ore oxide material retaining the first thermal energy is achieved using an iron ore oxide material providing unit 3 configured to produce and / or preheat the iron ore oxide material 5 retaining the first thermal energy or substantially the first thermal energy.

[0499] Alternatively, the iron ore oxide material providing unit 3 is electrically coupled to a control circuit 50 adapted to control the first thermal energy of the iron ore oxide material 5 input to the direct reduction facility 7.

[0500] Alternatively, the temperature of the first thermal energy-carrying iron ore oxide material 5 provided by the iron ore oxide material providing unit 3 corresponds to a predetermined temperature determined to avoid "sticking" (sticking of iron ore oxide material particles to each other) in the upper internal part of the direct reduction equipment 7.

[0501] Such “sticking” may prevent subsequent direct reduction of the iron ore oxide material in the upper interior portion UP of the direct reduction plant 7.

[0502] Alternatively, the predetermined temperature of the iron ore oxide material 5, which is important to avoid "sticking", is controlled by the control circuit 50 to be typically between about 800°C and about 1000°C, preferably between about 875°C and about 925°C.

[0503] Alternatively, the control circuit 50 is adapted to adjust the first thermal energy of the iron ore oxide material to a predetermined temperature to avoid "sticking".

[0504] During charging and direct reduction, it may be essential to avoid "sticking" of iron ore oxide material particles and / or pellets, as such "sticking" would prevent continued operation of the direct reduction plant 7. Avoidance of "sticking" or reduction of the sticking index SI can be achieved by avoiding very high temperatures (greater than 1200°C) in the upper interior parts of the direct reduction plant.

[0505] Alternatively, the predetermined temperature of the iron ore oxide material 5 may be adjusted by the control circuit 50 based on specific characteristics of the direct reduction and / or specific characteristics of the iron ore oxide material input to the direct reduction facility and / or specific process parameters of the iron ore oxide pelletizer and / or specific process parameters of the iron ore oxide preheating device. the external shape of the iron ore oxide pellets, and / or the porosity and / or density of the iron ore oxide material, and / or the mineralogical characteristics of the iron ore material, and / or the composition of the iron ore oxide material, and / or Cohesion, and / or the iron oxide material pellet size of the iron ore oxide material, and / or the direct reduction rate of the iron ore oxide material, and / or the hydrogen content of the hydrogen-containing reducing agent, and / or the desired temperature of the furnace gas, and / or The output temperature of the iron ore oxide material provided by the iron ore oxide pelletizer and / or the iron ore oxide preheating device may be an output temperature of the iron ore oxide material. Taking into consideration the temperature of the first thermal energy, the composition of the preheated hydrogen-containing reducing agent, and the degree of direct reduction at a particular level in the direct reduction facility, an efficient heat treatment is performed to obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0506] Alternatively, the predetermined temperature of the iron ore oxide material 5 is adjusted by the control circuit 50 based on the residence time during which the iron ore oxide material 5 is directly reduced and / or exposed to a hydrogen-containing reducing agent in the direct reduction facility.

[0507] Alternatively, the residence time is defined as the time during which the iron ore oxide material 5 is subjected to direct reduction and heat treatment to complete the direct reduction process. X is directly reduced to iron Fe to form densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0508] Alternatively, the residence time within the direct reduction facility 7 is determined by the height to width ratio within the direct reduction facility.

[0509] Alternatively, the residence time in the direct reduction equipment 7 is about 0.5 to 5.0 hours, preferably 1 to 4 hours.

[0510] Alternatively, the residence time in the direct reduction equipment 7 is about 2 to 6 hours, preferably 3 to 4 hours.

[0511] Alternatively, the residence time in the direct reduction equipment 7 is about 0.25 to 1.5 hours, preferably 0.5 to 1.25 hours.

[0512] Alternatively, the temperature and / or mass flow rate of the hydrogen-containing reducing agent may be controlled by the control circuit 50. The specific process parameters of the direct reduction, and / or The specific characteristics of the iron ore oxide material and / or the specific process parameters may be adjusted based on: the external shape of the iron ore oxide pellets, and / or the porosity and / or density of the iron ore oxide material, and / or the mineralogical characteristics of the iron ore material, and / or the composition of the iron ore oxide material, and / or Cohesion, and / or the iron oxide material pellet size of the iron ore oxide material, and / or the direct reduction rate of the iron ore oxide material, and / or the hydrogen content of the hydrogen-containing reducing agent, and / or the desired temperature of the furnace gas, and / or The output temperature of the iron ore oxide material provided by the iron ore oxide pelletizer and / or the iron ore oxide preheating device may be an output temperature of the iron ore oxide material. Taking into consideration the temperature of the first thermal energy, the composition of the preheated hydrogen-containing reducing agent, and the degree of direct reduction at a particular level in the direct reduction facility, an efficient heat treatment is performed to obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0513] Alternatively, the control of the temperature of the iron ore oxide material (first thermal energy) input at the top and the temperature of the hydrogen-containing reducing agent (second thermal energy) introduced into the direct reduction equipment is determined / controlled by a control circuit based on the mass flow rate of the iron ore oxide material input and / or the mass flow rate of the hydrogen-containing reducing agent introduced.

[0514] Alternatively, the control of the mass flow rate of the hydrogen-containing reducing agent introduced into the direct reduction equipment is determined / controlled by a control circuit based on the temperature of the iron ore oxide material introduced at the top (first thermal energy) and / or the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy), to optimize the chemical reduction reaction and / or limit the high temperature steam content in the direct reduction equipment and / or maintain a required ratio of high temperature steam to hydrogen to efficiently carry out the chemical reduction reaction.

[0515] Alternatively, the method includes the step of feeding the first thermal energy-carrying iron ore oxide material 5 into an upper interior portion UP of the direct reduction installation 7 via a metal oxide material feeding device A.

[0516] Alternatively, the direct reduction facility 7 has an upper internal portion UP, a lower internal portion LP, and an intermediate internal portion IP located between the upper internal portion and the lower internal portion LP.

[0517] Alternatively, a step of introducing a preheated hydrogen-containing reducing agent H that retains second thermal energy directly into the reduction equipment 7 via a reducing agent input device B is provided.

[0518] Alternatively, the direct reduction equipment 7 is configured to utilize the first thermal energy of the iron ore oxide material 5 to further heat the introduced preheated hydrogen-containing reducing agent H, thereby causing a chemical reaction between the hydrogen in the introduced preheated hydrogen-containing reducing agent H and the iron ore oxide material 5, thereby enabling direct reduction of the iron ore oxide material 5 in the upper internal portion UP.

[0519] Alternatively, the direct reduction facility 7 is configured to allow the reduced iron material 16 and / or iron ore oxide material 5 to be directly reduced to descend into a lower interior portion LP which includes the heat treatment zone HZ.

[0520] Alternatively, the direct reduction facility 7 is configured to allow the preheated hydrogen gas-containing reducing agent H to rise within the direct reduction facility 7 and contact the iron ore oxide material 5 as it descends.

[0521] Alternatively, the heat treatment zone HZ is configured to expose the reduced iron material 16 and / or the iron ore oxide material 5 to be directly reduced to a predetermined heat treatment temperature, thereby obtaining a reduced iron ore material 16 including reduced iron ore particles bonded together, and forming a heat-treated and / or heat-hardened and / or densified reduced iron ore material 16.

[0522] Alternatively, the heat treatment zone HZ is configured to maintain a predetermined heat treatment temperature by the introduction of a preheated hydrogen-containing reducing agent.

[0523] Alternatively, the method includes the step of discharging the reduced iron material 16 that has been heat treated in the heat treatment zone.

[0524] The preheated hydrogen-containing reducing agent H contains about 80-100% hydrogen, preferably up to 100% hydrogen by volume.

[0525] Alternatively, the temperature of the hydrogen gas-containing reducing agent H supplied to the direct reduction equipment 7 can be about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0526] Alternatively, the temperature of the hydrogen-containing reducing agent H introduced into the direct reduction equipment 7 is about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0527] Alternatively, the temperature of the hydrogen-containing reducing agent H introduced into the direct reduction equipment 7 is about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0528] Alternatively, the temperature of the hydrogen-containing reducing agent H introduced into the direct reduction equipment 7 is about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0529] Alternatively, the temperature of the hydrogen-containing reducing agent H introduced into the direct reduction equipment 7 is about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0530] Alternatively, the hydrogen-containing reducing agent H is introduced into the upper internal portion UP and / or the lower internal portion LP and / or the middle internal portion IP.

[0531] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 is maintained at 200°C to about 500°C, preferably about 300°C to about 400°C.

[0532] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 by retaining thermal energy is 300°C to about 600°C, preferably about 400°C to about 500°C.

[0533] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 by retaining thermal energy is 400°C to about 700°C, preferably about 500°C to about 600°C.

[0534] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 is maintained at 500°C to about 800°C, preferably about 600°C to about 700°C.

[0535] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 by retaining thermal energy is 600°C to about 900°C, preferably about 700°C to about 800°C.

[0536] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 by retaining thermal energy is 700°C to about 1000°C, preferably about 800°C to about 900°C.

[0537] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction facility 7 is maintained at 800°C to about 1100°C, preferably about 900°C to about 1000°C.

[0538] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 is maintained at 900°C to about 1200°C, preferably about 1000°C to about 1100°C.

[0539] Alternatively, the temperature of the iron ore oxide material 5 fed into the direct reduction equipment 7 is maintained at 1000°C to about 1300°C, preferably about 1100°C to about 1200°C.

[0540] Alternatively, the chemical reaction comprises a substantially or completely endothermic chemical reaction.

[0541] Alternatively, the thermal energy consumed by the direct reduction in the upper interior portion UP includes the first thermal energy and / or the second thermal energy.

[0542] Alternatively, the thermal energy consumed by the direct reduction in the intermediate internal portion IP includes the first and / or second thermal energy.

[0543] Alternatively, the thermal energy consumed by the direct reduction in the lower internal portion LP includes the second thermal energy.

[0544] Alternatively, heat treatment is defined as the densification (passivation) of the iron ore oxide material and / or reduced iron ore material to be directly reduced.

[0545] Alternatively, the iron ore oxide material and / or reduced iron material to be directly reduced by heat treatment is controlled by a first control circuit (not shown) and / or a control circuit adapted to adjust the second thermal energy of the hydrogen-containing reducing agent H using a reducing agent thermal energy adjusting device (not shown) to control the required heat treatment temperature determined to achieve the desired quality of the produced sponge iron and / or densified reduced metal material and / or semi-molten reduced metal material and / or passivated reduced metal material.

[0546] Alternatively, the heat treatment temperature is controlled within the range of 150 to 550°C, preferably 250 to 450°C.

[0547] Alternatively, the heat treatment temperature is controlled within the range of 200 to 600°C, preferably 300 to 500°C.

[0548] Alternatively, the heat treatment temperature is controlled within the range of 250 to 650°C, preferably 350 to 550°C.

[0549] Alternatively, the heat treatment temperature is controlled within the range of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0550] Alternatively, the heat treatment temperature is controlled within the range of about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0551] Alternatively, the heat treatment temperature is controlled within the range of about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0552] Alternatively, the heat treatment temperature is controlled within the range of about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0553] Alternatively, the heat treatment temperature is controlled within the range of about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0554] Alternatively, the heat treatment temperature is controlled by a control circuit that controls the temperature of the hydrogen gas-containing reducing agent H.

[0555] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 100 to 500°C, preferably 200 to 400°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 600 to 1100°C, preferably 700 to 1000°C.

[0556] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 200 to 600°C, preferably 300 to 500°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 700 to 1200°C, preferably 800 to 1100°C.

[0557] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 300 to 700°C, preferably 400 to 600°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 700 to 1100°C, preferably 750 to 950°C.

[0558] Alternatively, the temperature of the iron ore oxide material introduced into the top (first thermal energy) is controlled to a range of 400 to 800°C, preferably 500 to 700°C, and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction equipment (second thermal energy) is controlled to a range of 800 to 1300°C, preferably 900 to 1200°C.

[0559] Alternatively, the first thermal energy of the iron ore oxide material 5 is utilized in the upper interior portion UP and / or the top portion 81 to further heat the remaining hydrogen and / or water vapor of the preheated hydrogen-containing reducing agent.

[0560] Alternatively, the top gas contains water vapor produced by a chemical reaction between oxygen in the iron oxide material and hydrogen in the hydrogen-containing reducing agent.

[0561] Alternatively, the remaining hydrogen in the hydrogen-containing reducing agent can be defined as the hydrogen-containing reducing agent that has not yet been consumed in the direct reduction in the main part of the upper internal part and that has risen within the direct reduction equipment 7 to the top 81 of the upper internal part UP (inside the furnace top of the direct reduction equipment).

[0562] Alternatively, as the preheated hydrogen-containing reducing agent rises in the direct reduction equipment, the preheated hydrogen-containing reducing agent has a higher water vapor content and a lower hydrogen content, but the remaining hydrogen still allows chemical reaction and efficient direct reduction of the metal oxide material (iron ore oxide material) to occur at the top 81.

[0563] Alternatively, the first thermal energy may be utilized in this manner in the top portion 81 to further heat the remaining hydrogen and induce a chemical reaction between at least a portion of the remaining hydrogen and oxygen in the metal oxide material (iron ore oxide material), resulting in a direct reduction that efficiently removes oxygen from the iron ore oxide material.

[0564] Alternatively, the excess preheated hydrogen-containing reducing agent H, which includes excess hydrogen gas and hot steam, forms a top gas TG at the top 81, which is removed from the reduction facility 7 directly via the top gas removal device D.

[0565] Alternatively, the first thermal energy may be utilized in this manner to further heat the remaining hydrogen to effect an efficient direct reduction at the top 81 and / or to prevent cooling of the remaining hydrogen of the hydrogen-containing reducing agent not yet consumed at the top 81 to effect an efficient direct reduction.

[0566] Therefore, any incidental low / ambient temperature iron ore oxide material (if unheated iron ore oxide material is added) introduced into the direct reduction facility 7 will prevent cooling of the remaining hydrogen in the hydrogen-containing reductant in the top portion 81.

[0567] This has the effect of producing passivated reduced iron materials such as sponge iron in an energy-saving manner, while at the same time obtaining top gas TG containing hot steam that can be used in the high-temperature electrolysis unit.

[0568] In this manner, a densification process is achieved to produce densified reduced iron material, which prevents reoxidation and allows for safe, cost-effective transport of the reduced iron material, such as sponge iron, to metal manufacturers.

[0569] In this manner, customers, such as metal manufacturers, are provided with a metal material production setup configured to produce reduced iron material (carbon-free) that is resistant to reoxidation for cost-effective, safe, and refractory transport of the reduced metal material.

[0570] The present disclosure is not limited to the examples described above, but it will be apparent to those skilled in the art that there are many possibilities for modification and combination of the examples described without departing from the basic idea defined in the appended claims.

Claims

1. A method for directly reducing a metal oxide material (5) having a first thermal energy to a reduced metal material (16) using a metal material production configuration (1), comprising: The method for providing the metal oxide material (5) that retains the first thermal energy by a metal oxide material providing unit (3) includes the steps of: a step of feeding the metal oxide material (5) having the first thermal energy into a direct reduction facility (7) via a metal oxide material feeding device (A); introducing a preheated hydrogen-containing reducing agent (H) having a second thermal energy into the direct reduction equipment (7) through a reducing agent input device (B); a step of reducing the metal oxide material (5) by utilizing the first thermal energy of the metal oxide material (5) to heat or further heat the introduced preheated hydrogen-containing reducing agent (H) and causing a chemical reaction between the introduced preheated hydrogen-containing reducing agent (H) and the metal oxide material (5); exposing the reduced metallic material to a heat treatment temperature required to obtain a densified reduced metallic material by heat treatment of the reduced metallic material; maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reducing agent (H) using a heat treatment providing device (17); Discharging the heat-treated reduced metallic material (16); A method comprising:

2. 2. The method of claim 1, further comprising introducing a third thermal energy-bearing preheated hydrogen-containing heat treatment agent (HT) into the direct reduction facility (7) using a heat treatment agent supply device (30) to expose the reduced metallic material (16) to the required heat treatment temperature to maintain the required heat treatment temperature and to obtain the densified reduced metallic material by the heat treatment of the reduced metallic material (16).

3. 3. The method of claim 1 or 2, wherein the introduction of the preheated hydrogen-containing reducing agent (H) causes the direct reduction of the metal oxide material (5), and the step of maintaining the required heat treatment temperature is performed to an extent that the cooling rate of the reduced metal material (16) descending through the direct reduction facility (7) can be slowed to maintain the required heat treatment temperature.

4. 4. The method according to claim 1, further comprising preheating the hydrogen-containing reducing agent (H) introduced into the direct reduction facility (7) to the required heat treatment temperature using a reducing agent preheating device (20) of the heat treatment providing device (17).

5. 5. The method of claim 1, wherein maintaining the required thermal treatment temperature comprises adjusting the second thermal energy using a reducing agent thermal energy adjustment device (17′) electrically coupled to a first control circuit (50′) configured to operate the reducing agent thermal energy adjustment device (17′) to control the required thermal treatment temperature.

6. 6. The method of claim 1, wherein maintaining the required heat treatment temperature comprises adjusting the mass flow rate of the hydrogen-containing reductant (H) introduced into the direct reduction facility (7) using a reductant mass flow regulating device (17'') electrically coupled to a second control circuit (50'') configured to operate the reductant mass flow regulating device (17'') to control the required heat treatment temperature.

7. 7. The method of claim 1, wherein maintaining the required heat treatment temperature comprises adjusting a residence time for keeping the reduced metallic material in the direct reduction facility for a specific residence time using a residence time adjusting device electrically coupled to a third control circuit configured to operate the residence time adjusting device to achieve a specific residence time and control the required heat treatment temperature.

8. 8. The method according to any one of claims 1 to 7, wherein the step of providing the required heat treatment temperature comprises regulating pressurization within the direct reduction facility using a pressure regulating device (17'''') electrically coupled to a fourth control circuit (50'''') configured to operate the pressure regulating device (17'''') to control the required heat treatment temperature.

9. A metallic material production setup (1) adapted for directly reducing a first thermal energy-bearing metal oxide material (5) into a reduced metallic material (16), comprising: a metal oxide material providing unit (3) configured to provide the metal oxide material (5) that retains the first thermal energy; A direct reduction facility (7), a metal oxide material input device (A); a reducing agent input device (B) configured to introduce a second thermal energy-carrying hydrogen-containing reducing agent (H); Equipped with a direct reduction zone (RZ) of the direct reduction equipment (7) configured to utilize the first thermal energy of the metal oxide material (5) to heat or further heat the introduced hydrogen-containing reducing agent (H) and cause a chemical reaction between the introduced hydrogen-containing reducing agent (H) and the metal oxide material (5), thereby reducing the metal oxide material (5); a heat treatment zone (HZ) of the direct reduction facility (7) configured to heat treat the reduced metallic material (16) by exposing the reduced metallic material to a heat treatment temperature required to obtain a densified reduced metallic material by heat treatment of the reduced metallic material; a heat treatment providing device (17) configured to maintain the required heat treatment temperature by the introduction of the preheated hydrogen-containing reducing agent (H); a metallic material discharge device (c) configured to discharge the heat-treated reduced metallic material (16); A metal material manufacturing configuration (1) characterized by:

10. 10. The metallic material manufacturing configuration (1) according to claim 9, further comprising a reducing agent pre-heating device (20) of the heat treatment providing device (17) adapted to pre-heat the hydrogen-containing reducing agent (H) introduced into the direct reduction facility (7).

11. The heat treatment providing device (17) a reducing agent thermal energy adjustment device (17') configured to adjust the second thermal energy; a first control circuit (50') electrically connected to the reducing agent thermal energy adjustment device (17') and configured to control the reducing agent thermal energy adjustment device (17') to achieve the required heat treatment temperature; 11. The metallic material manufacturing arrangement (1) according to claim 9 or 10, comprising:

12. The heat treatment providing device (17) a reducing agent mass flow adjusting device (17'') configured to adjust the mass flow rate of the hydrogen-containing reducing agent (H) introduced into the direct reduction equipment (7); a second control circuit (50'') electrically connected to the reducing agent mass flow regulating device (17'') and configured to operate the reducing agent mass flow regulating device (17'') to regulate the mass flow rate of the hydrogen-containing reducing agent (H) to achieve the required heat treatment temperature; 12. The metallic material manufacturing arrangement (1) according to any one of claims 9 to 11, comprising:

13. The heat treatment providing device (17) a residence time adjusting device (17''') configured to adjust the residence time of the reduced metal material (16) in the direct reduction facility (7); a third control circuit (50''') electrically coupled to the residence time adjusting device (17''') and configured to operate the residence time adjusting device (17''') to achieve the specified residence time and control the required heat treatment temperature; 13. The metallic material manufacturing arrangement (1) according to any one of claims 9 to 12, comprising:

14. The heat treatment providing device (17) a pressure adjusting device (17'''') configured to adjust the internal pressure of the direct reduction equipment (7); a fourth control circuit (50'''') electrically connected to the pressure regulating device (17'''') and configured to operate the pressure regulating device (17'''') to control the required heat treatment temperature; 14. A metallic material manufacturing arrangement (1) according to any one of claims 9 to 13, comprising:

15. 15. The metallic material production configuration (1) according to any one of claims 9 to 14, wherein the direct reduction facility (7) comprises a top gas discharge device (D) configured to remove top gas (TG) from the direct reduction facility (7).

16. 16. The metallic material manufacturing configuration (1) according to any of claims 9 to 15, wherein the introduced preheated hydrogen-containing reducing agent (H) comprises 80 to 100% hydrogen, preferably 100% by volume of hydrogen.

17. A data program (P) comprising a computer readable program code for a control circuit (50) of the metallic material production arrangement (1) according to any one of claims 9 to 16, A data program (P) in which the heat treatment providing device (17) is programmed to maintain the required heat treatment temperature by the introduction of the preheated hydrogen-containing reducing agent (H).

18. 9. A product produced by the method of claims 1 to 8, comprising: The product wherein the reduced metal material (16) comprises reduced iron ore particles bonded together to form sponge iron of the heat-treated reduced iron ore material.

19. splitting water into electrolytic hydrogen and oxygen using an electrolysis unit; producing methanol by reacting the electrolytic hydrogen with carbon dioxide; storing the methanol; reforming the methanol with water and / or oxygen to provide carbon dioxide and released hydrogen; providing the released hydrogen to the direct reduction facility (7) as a component of the preheated hydrogen-containing reducing agent (H); providing a step of introducing the preheated hydrogen-containing reducing agent (H) that retains the second thermal energy into the direct reduction equipment (7) through the reducing agent input device; The method of any of claims 1 to 8, further comprising:

20. Simultaneously with the introduction of a first seal gas, the metal oxide material (5) having the first thermal energy is introduced into the direct reduction equipment (7) via the metal oxide material introduction device (A); and / or and simultaneously introducing a second seal gas and discharging the reduced metallic material (16). The method of any of claims 1 to 8, further comprising:

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