Utilization of residual iron in granular metal unit manufacturing facilities, and related systems, apparatus, and methods.

Abstract

This disclosure discloses waste reduction systems and methods for the production of granular metal units (GMUs). A typical method includes receiving a first feed of molten iron and producing GMUs by granulating the molten iron injected into a target material of a reactor. The method may include removing residual fine particles of the GMUs through a classifier based on a threshold particle size and mixing the residual fine particles with a second feed of molten iron to produce additional GMUs.

Description

TECHNICAL FIELD

[0001] The present technology generally relates to the production of granular metal units, as well as related systems and methods.

BACKGROUND ART

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS This application relates to the following applications, the disclosures of which are incorporated herein by reference in their entirety: U.S. Patent Application “RAILCARS FOR TRANSPORTING GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS” [Attorney Reference No. 084553.8072.US00] filed on September 11, 2024; U.S. Patent Application “LOADING GRANULATED METALLIC UNITS INTO RAILCARS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS” [Attorney Reference No. 084553.8073.US00] filed on September 11, 2024; “LOW-SULFUR GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND U.S. Patent Application Titled "METHODS" [Attorney Reference Number 084553.8074.US00], U.S. Patent Application Titled "CONTINUOUS GRANULATED METALLIC UNIT PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" [Attorney Reference Number 084553.8075.US00] filed on September 11, 2024, U.S. Patent Application Titled "USE OF A BASIC OXYGEN FURNACE TO PRODUCE GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" [Attorney Reference Number 084553.8076.US00] filed on September 11, 2024, and "LOW-CARBON GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, U.S. patent application titled "DEVICES, AND METHODS" [Attorney reference number 084553.8077][US00], a U.S. patent application filed on September 11, 2024, entitled "TORPEDO CARS FOR USE WITH GRANULATED METALLIC UNIT PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" [Attorney reference number 084553.8078.US00], a U.S. patent application filed on September 11, 2024, entitled "TREATING COOLING WATER IN IRON PRODUCTION FACILITIES, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" [Attorney reference number 084553.8079.US00], a U.S. patent application filed on September 11, 2024, entitled "PROCESSING GRANULATED METALLIC UNITS WITHIN ELECTRIC ARC FURNACES, AND ASSOCIATED SYSTEMS AND A U.S. patent application titled "METHODS" [Attorney reference number 084553.8081.US00].

[0003] Granular pig iron (GPI) is a type of pig iron that has been granulated into small, uniform particles, making it easier to handle, transport, and use in various metallurgical processes compared to conventional pig iron. Demand for GPI is steadily increasing due to its versatile use across various industries, including automotive, construction, and manufacturing. The growing popularity of GPI stems from its high purity, consistent quality, and the efficiency it brings to the production of steel and other iron-based products.

[0004] Granular pig iron is produced by rapidly cooling molten pig iron with water to form granules. This process, known as granulation, is typically carried out in a blast furnace. However, current manufacturing methods often result in intermittent production cycles due to various operational constraints, including the need for regular maintenance, fluctuations in raw material supply, and energy consumption issues. These interruptions not only affect overall efficiency but also lead to increased manufacturing costs and variability in product quality. Therefore, an improved manufacturing process is needed that can ensure continuous and stable granulation of pig iron, thereby increasing productivity and reducing operating costs.

[0005] The features, aspects, and advantages of the technology of this disclosure can be better understood by referring to the following drawings. [Brief explanation of the drawing]

[0006] [Figure 1] This is a schematic block diagram of a continuous granular metal unit (GMU) manufacturing system according to an embodiment of this technology. [Figure 2] Figure 1 is a plan view of the continuous GMU manufacturing system according to an embodiment of this technology. [Figure 3] Figure 2 is an enlarged view of the continuous GMU manufacturing system. [Figure 4] This is a schematic process flow diagram showing the granulation of iron according to an embodiment of this technology. [Figure 5] This block diagram shows a part of a GMU manufacturing system according to an embodiment of this technology. [Figure 6] Figure 5 is a block diagram showing the recycling of residual fine powder in the GMU manufacturing system according to an embodiment of this technology. [Figure 7] Figure 5 is a block diagram showing the recycling of residual fine powder in the GMU manufacturing system according to an embodiment of this technology. [Figure 8] This is a flowchart of the waste reduction process for manufacturing a GMU according to an embodiment of this technology. [Modes for carrying out the invention]

[0007] Those skilled in the art will understand that the features shown in the drawings are for illustrative purposes only and that variations are possible, including different features and / or additional features and their arrangement.

[0008] I. overview Embodiments of this technology relate to waste reduction systems and methods for the production of granular metal units (GMUs). Residual iron (also called treated iron) waste is a by-product of iron processing that contains various forms of impurities. Such waste can contribute to environmental pollution, including soil, water, and air contamination. Removing residual iron waste from the environment (e.g., treating contaminated soil, water, or air) is difficult, and preventing these harmful effects through appropriate waste management techniques in compliance with environmental regulations and standards can be inefficient and costly. Therefore, there is a need for iron production systems and methods that produce zero or near-zero residual iron waste.

[0009] During operation, residual iron waste is formed as a by-product during the production of GMU. Residual iron waste may include, for example, thin slabs, steel, ladle scraps, sintered materials, scrap, slag, iron powder, or residual fine powder (e.g., GMU with particle sizes too small to be further processed). Various by-products and impurities are generated by melting, granulation, desulfurization, and transfer, and can be recovered as residual iron waste throughout the entire process.

[0010] Embodiments of the present technology address at least some of the above problems and include methods and systems for recycling different types of residual iron into the manufacturing process. For example, embodiments of the present technology include a method for producing GMU particles by receiving molten iron and granulating the molten iron. Granulation includes injecting the molten iron into a target material of a reactor and removing residual fine particles of GMU particles (e.g., the final product) by a classifier. The classifier can separate the residual fine particles from the GMU based on a threshold particle size. The method may also include recycling the residual fine particles by mixing them with a second feed of molten iron, different from a first feed of molten iron, to produce additional GMU particles. As another example, embodiments of the present technology include a method for generating residual iron such as ladle scraps, thin slabs, steel, sintered products, scrap, slag, or iron powder as by-products in the production of GMU particles. The method may include mixing at least a portion of the residual iron with metal scrap (used as raw material for molten iron) to produce a mixture, and recycling at least a portion of the mixture into a blast furnace and / or basic oxygen converter to produce molten iron. Furthermore, the method may include using external residual pulverized or residual iron recycled within the system to produce molten iron and / or GMU particles.

[0011] Accordingly, this technology describes a method and system that enables the production of more molten iron and / or GMU particles by recycling different types of residual iron waste, namely residual fines separated from the final GMU product by a classifier, and other residual iron such as thin slabs, steel, ladle scraps, sintered material, scrap, slag, or iron powder recovered during the process, within the system. This technology can significantly reduce environmental waste and improve the production efficiency of the GMU production system. Additional advantages of embodiments of this technology are described elsewhere in this specification.

[0012] In the figures, the same reference numeral indicates a generally similar and / or identical element. Many of the details, dimensions, and other features shown in the figures are merely illustrative of a particular embodiment of the disclosed technology. Therefore, other embodiments may have other details, dimensions, and features without departing from the spirit or scope of this disclosure. Furthermore, those skilled in the art will understand that various further embodiments of the disclosed technology can be implemented without some of the details described below.

[0013] The disclosed GMU manufacturing systems are designed for continuous operation. Compared to discontinuous GMU manufacturing systems, embodiments of this technology improve energy efficiency and reduce emissions by minimizing the need for frequent shutdowns and restarts often associated with excessive exhaust and / or inefficient operation. As described herein, some embodiments include (i) a desulfurization unit that reduces sulfur content in the molten metal to reduce sulfur dioxide (SO2) emissions, (ii) a dust collection unit that filters particulate matter to reduce air pollution, (iii) infrastructure that recycles fine powder, slag, iron slag, and other residual / previously processed iron to mitigate the environmental impact of raw material extraction and conserve natural resources, and / or (iv) a water management and cooling system that minimizes heat loss, improves the thermal efficiency of the manufacturing process, and optimizes water consumption. Overall, continuous GMU manufacturing systems improve productivity while minimizing greenhouse gas emissions and waste, contributing to more sustainable industrial practices and helping to mitigate climate change.

[0014] Related to this, conventional iron production has a significant environmental impact due to its high energy consumption and emission of pollutants. Therefore, embodiments of this technology related to GMU manufacturing systems can mitigate this impact. Sulfur, phosphorus, and silicon in GMU adversely affect the quality and properties of the final metal product, causing problems such as reduced ductility, toughness, and weldability, surface defects, and brittleness. These impurities also contribute to the formation of non-metallic inclusions and excess slag, complicating metal processing and impairing product quality. Sulfur, in particular, accelerates wear and erosion of metal processing equipment, increasing maintenance costs and shortening the lifespan of the equipment. Embodiments of this technology include methods for partially removing these impurities, improving the quality and durability of the final metal product, increasing the efficiency and lifespan of processing equipment, and resulting in cost reduction and more sustainable manufacturing practices.

[0015] Furthermore, the disclosed technology aims to reduce iron loss and further mitigate the climate impact of iron production by recycling residual iron and residual fines within a GMU production system, as described above. A typical method includes, for example, receiving a first feed of molten iron and producing GMU by granulating the molten iron injected into a target material in a reactor. The method may include removing residual fines from the GMU through a classifier based on a threshold particle size and recycling the residual fines by mixing them with a second feed of molten iron to produce additional GMU.

[0016] II. Embodiment of a Continuous Granular Metal Unit Manufacturing System Figure 1 is a schematic block diagram of a continuous GMU production system 100 ("System 100") according to an embodiment of the present technology. As described elsewhere in this specification, GMU may include granular iron (GI), granular pig iron (GPI), granular steel (GS), or GMU. In connection therewith, molten metal may include molten pig iron or molten steel. As used herein, the term "continuous" should be interpreted as meaning a continuous operation cycle including batch or semi-batch operation lasting at least 4 hours, 6 hours, 8 hours, 10 hours, 12 hours, 16 hours, 20 hours, or 24 hours. System 100 may include a furnace unit 110, a desulfurization unit 120, a granulation unit 130 including a first granulation unit 130a and a second granulation unit 130b, and a cooling system 140. The furnace unit 110 can receive input materials (e.g., iron ore, coke, limestone, and / or preheated air) and / or recycled materials, which can be supplied from downstream components of the system 100, as will be described in more detail herein. The following equations (1) to (6) illustrate in detail some of the chemical processes controlled by the furnace unit.

[0017] C + O2 → CO2(1) CO2 + C → 2CO (2) Fe2O3 + 3CO → 2Fe + 3CO2 (3) Fe2O3 + 3C → 2Fe + 3CO (4) CaCO3 → CaO + CO2 (5) CaO + SiO2 → CaSiO3(6)

[0018] Equation (1) represents the combustion of coke, which is a type of carbon. When coke reacts with oxygen gas introduced into the furnace (for example, via an oxygen lance), carbon dioxide is generated. This exothermic reaction releases a large amount of heat that is essential for maintaining the high temperature required for subsequent reactions. The carbon dioxide generated in Equation (1) further reacts with additional coke to produce carbon monoxide, as shown in Equation (2). This endothermic reaction helps moderate the temperature inside the furnace unit 110. Equations (3) and (4) represent the reduction of iron ore (Fe₂O₃). As shown in Equation (3), iron oxide reacts with the carbon monoxide generated in Equation (2), and the carbon monoxide acts as a reducing agent to convert iron ore into iron, producing carbon dioxide as a by-product. Alternatively, as shown in Equation (4), iron ore can be directly reduced by coke, but this is less common. Equations (5) and (6) represent the formation of slag. As shown in Equation (5), calcium carbonate / limestone (CaCO₃) can decompose into calcium oxide and carbon dioxide under the high temperature of the furnace unit 110. As shown in Equation (6), the calcium oxide then reacts with silica (SiO₂), which is an impurity in iron ore, to form calcium silicate (CaSiO₃), also known as slag. The furnace unit 110 can discharge molten iron (from Equations (3) and (4)) and slag (from Equations (5) and (6)).

[0019] In some embodiments, input materials (for example, coke, iron ore and / or limestone) contain sulfur that can remain in the molten iron discharged by the furnace unit 110. The torpedo car 102 or other transfer vessel can transfer the molten iron from the furnace unit 110 to the desulfurization unit 120. The desulfurization unit 120 may include equipment for reducing the sulfur content of the molten iron. For example, one or more lances can be used to supply magnesium (Mg), calcium carbide (CaC₂), or other sulfur reducing agents to the molten iron. In some embodiments, the molten iron is desulfurized while remaining in the torpedo car 102. The following Equations (7) and (8) detail the reaction between sulfur and the sulfur reducing agent.

[0020] Mg+S→MgS (7) CaC2+S→CaS+2C (8)

[0021] The product substance containing magnesium sulfide (MgS) and calcium sulfide (CaS) is in a solid state (e.g., solid particles) that does not dissolve in molten iron, so that it can be more easily removed in the desulfurization unit 120 and / or further downstream. As further described herein, reducing the sulfur content can improve the quality of GMU products and / or enable the manufacturing process to be continuous. After the desulfurization process, the torpedo car 102 can transfer the molten iron from the desulfurization unit 120 to the granulation unit 130. In some embodiments, as indicated by the dashed arrow, the desulfurization unit 120 is bypassed, and the molten iron is directly transferred from the furnace unit 110 to the granulation unit 130. In particular, conventional facilities may not include a desulfurization unit, or may lack the ability to desulfurize molten iron. One of the reasons is that in conventional steelmaking facilities, molten iron is directly supplied from the blast furnace to the converter, and granulation of molten iron is only selected when the converter is shut down. Since the production of GMU is a backup operation of such facilities, the increased complexity and cost associated with the installation of desulfurization equipment may not be economical.

[0022] In some embodiments, the temperature of the molten iron is within a predetermined range before reaching the granulation unit 130. For example, maintaining the molten iron in a sufficiently fluid state can help to more reliably form uniform granules and avoid premature solidification that can cause irregular granule shapes and sizes. In some embodiments, the system includes one or more heaters 115 before and / or after the desulfurization unit 120, for example, to reheat the molten iron in the torpedo car 102. For example, if the temperature of the molten iron is below a threshold temperature value, the heater 115 can be used to raise the temperature of the molten iron in the torpedo car 102 to within a desired temperature range. The threshold temperature value varies with the composition and may be 2300 to 2500°F, 2300 to 2400°F, or 2340 to 2350°F. In some embodiments, the heater 115 includes one or more oxygen lances.

[0023] The torpedo car 102 can transfer molten iron to one of the granulation units 130. Figure 1 shows two granulation units 130, but it will be understood that the system 100 may include one, three, four, five, six or more granulation units 130. Each granulation unit 130 may include a granulation reactor that receives molten iron and granulates it to form a granular product. For example, the granulation reactor may include a cavity that holds water, and the molten iron can be transferred (e.g., injected, sprayed) towards a target in the reactor that holds the water. The water can be kept at a sufficiently low temperature by a cooling system 140 (for example, by directly cooling by pumping water between the granulation unit 130 and the cooling system 140, or by indirectly cooling by pumping a coolant separate from the water that receives the molten iron). In some embodiments, each granulation unit 130 includes one or more components that control the flow rate of molten iron from the torpedo car 102 to the granulation reactor. As those skilled in the art will understand, flow rate control can affect the shape, size, and quality of the granular product. The granulation unit 130 may also include a dehydration assembly that dries the granular product from the granulation reactor to discharge the GMU. The granulation unit 130 may further include a classification assembly that filters the filtrate from the dehydration assembly to discharge the fine powder.

[0024] System 100 may further include a product processing unit 150 that receives GMU discharged by the granulation unit 130 (e.g., a dewatering assembly) and a shipping facility 155 located downstream of the product processing unit 150. In addition, System 100 may further include a fine powder processing unit 160 that receives fine powder discharged by the granulation unit 130 (e.g., a classification assembly) and a shipping facility 165 located downstream of the fine powder processing unit 160. In some embodiments, the product processing unit 150 and / or the fine powder processing unit 160 each include one or more conveyor belts, flow dividers, storage areas, etc. System 100 may further include a torpedo preparation unit 170 that can remove slag and / or quiche from the torpedo car 102. For example, after supplying molten iron to the granulation unit 130, the torpedo car 102 can proceed to the torpedo preparation unit 170 to be washed or prepared for the next cycle in which the molten iron is transferred. The removed slag can then be transferred to the slag processing machine 175. The system 100 may further include a scrap storage area 180 that can receive thin slabs and / or iron slag from the granulation unit 130.

[0025] As shown in Figure 1, fine powder from the shipping facility 165, slag and / or iron from the granulation unit 130, and / or thin slabs and / or iron slag from the scrap storage area 180 can be returned to the furnace unit 110 as recycled material. In some embodiments, the recycled material is processed (e.g., pelletized) before being supplied to the furnace unit 110. Furthermore, emissions from various components of the system 100 can be collected and led to dust collection units 190 (e.g., baghouse, scrubber, etc.). In Figure 1, for example, emissions from the desulfurization unit 120 and the granulation unit 130 are led to a first dust collection unit 190a, and emissions from the torpedo preparation unit 170 are led to a second dust collection unit 190b. Each dust collection unit 190 can filter the emissions to remove dust from them and then send them to a chimney (not shown) for releasing clean exhaust gas into the atmosphere, and the removed dust can be led to further processing.

[0026] Figure 2 is a plan view of the continuous GMU manufacturing system 100. The plan view shown in Figure 2 is merely an example, and it will be understood that in other embodiments the components of system 100 can be arranged differently. As shown, system 100 may further include an electrical building 202 and a power generation unit 204 that provide power to system 100. As will be further described herein, one or more components of system 100 can be driven by electricity rather than, for example, hydraulics. The furnace unit 110 can be located away from many other components of system 100. A torpedo car 102 or other transfer vessel (not shown) can transfer molten iron from the furnace unit 110 to the desulfurization unit 120 along a track indicated by a dashed line.

[0027] Referring here to Figure 3, an enlarged plan view of system 100, the desulfurization unit 120 can desulfurize the molten iron while it remains in the torpedo car 102. Once the molten iron is desulfurized, the torpedo car 102 can continue along the track to the granulation unit 130. The torpedo car 102 can supply the molten iron to either the first granulation unit 130a or the second granulation unit 130b, for example, depending on the availability of each granulation unit 130. The GMU produced by each granulation unit 130 can be transported downstream via one or more conveyor belts that form part of the product processing unit 150. The fine powder generated by each granulation unit 130 can be transported to a fine powder bunker located adjacent to the granulation unit 130 and finally sent to the shipping facility 165. As shown in Figure 3, the first dust collection unit 190a can be connected to the desulfurization unit 120 and the granulation unit 130 via piping in order to collect waste from the desulfurization unit 120 and the granulation unit 130, respectively.

[0028] Returning to Figure 2, the cooling system 140 may be positioned adjacent to the granulation unit 130 to cool the granulation unit 130 as needed. The product processing unit 150 may include a storage area 252 for storing the GMU product. One or more conveyor belts may extend between each granulation unit 130 and the storage area 252, and between the storage area 252 and the shipping facility 155. In some embodiments, the shipping facility 155 includes a building from which a desired amount of GMU can be measured and transported to a railcar or other transport vehicle. In some embodiments, the GMU is then transported to an electric arc furnace (not shown) for steelmaking. After supplying molten iron to the granulation unit 130, the torpedo car 102 may continue along the track to reach the torpedo preparation unit 170. As described above with reference to Figure 1, the torpedo preparation unit 170 can facilitate the removal of slag and / or quiche from the torpedo car 102. A second dust collection unit 190b can be connected to the torpedo preparation unit 170 via piping to collect waste from the torpedo preparation unit 170.

[0029] Referring to Figures 1-3, System 100 is expected to be able to continuously produce GMU, unlike conventional GMU manufacturing systems. First, the incorporation of the desulfurization unit 120 offers several advantages. For example, GMU with a lower sulfur content produces less slag when melted in the downstream electric arc furnace, saving associated time, cost, and energy consumption. Using GMU with a lower sulfur content also makes it easier to maintain the desired chemical composition and temperature, reducing the frequency of adjustments and interruptions during the melting cycle. Lower sulfur levels may also result in less wear and damage to other components of the system, thereby reducing the need for maintenance and the associated downtime.

[0030] Secondly, by including multiple granulation units 130, it becomes possible to granulate molten iron in parallel using separate granulation units. The granulation units 130 can also function as backups for each other if one of the granulation units 130 fails (for example, due to a component malfunction, maintenance, etc.). Furthermore, in some embodiments, the various components of the granulation unit 130 are modular. For example, each component can be easily and independently removed (for example, for maintenance) and / or replaced (via an overhead crane, etc.) without affecting the operation of other components.

[0031] Figure 4 is a schematic process flow diagram showing iron granulation according to an embodiment of the present technology. A torpedo car 410 can transport molten metal from a furnace unit 110 or a desulfurization unit 120 to a granulation unit 130 (see Figure 1). A torpedo controller 412 controls the inclination angle of the torpedo car 410 to transfer (e.g., inject) the molten metal from the torpedo car 410 to the runner 420 at a desired flow rate. In some embodiments, the molten metal can be transferred from the torpedo car 410 to a ladle (not shown) instead of the runner 420, and the molten metal can be transferred from the ladle to the runner 420. The ladle may include an inclined ladle and / or include a slide gate or valve with associated control devices. In some embodiments, the granulation unit 130 may further include a trough, bucket, tray or other collector 415 located below the torpedo car 410, ladle, runner 420 and / or tundish 440 to receive any molten metal or other material that may spill out. Molten metal can flow through the runner 420 into the tundish 440. An exhaust hood 430 (like other exhaust hoods) may be positioned to collect exhaust from the molten metal flowing through the runner 420 and the tundish 440. A stopper rod assembly 450 may be coupled to the tundish 440 and act to control the flow of molten metal from the tundish 440 into the granulation reactor 460. In some embodiments, a tundish nozzle preheater 442 may be positioned to heat the nozzle or outlet of the tundish 440 (e.g., using natural gas) to prevent, for example, molten metal from solidifying at the outlet of the tundish 440 and blocking the outlet.

[0032] The granulation reactor 460 can receive chilled water from a chilled water supply source. Molten metal exiting the tundish 440 can collide with a target in the granulation reactor 460 and spray into the water accumulated inside the granulation reactor 460. The granulation reactor 460 can granulate the molten metal to form a granular product, for example by cooling the molten metal. The heated water can be sent to a tank, a hotwell pump 462, and finally returned to the cooling system 140. In some embodiments, a drain pump 466 is included between the granulation reactor 460 and the tank for maintenance. An ejector 470 can receive ejector water and / or compressed air to transfer the granular product from the granulation reactor 460 to a dewatering assembly 480. The dewatering assembly 480 can dry the granular product and filter it (for example, depending on the particle size) to discharge the GMU product. In some embodiments, the first and second granulation units 130 are configured to produce GMU at a rate matching the discharge rate of the furnace unit 110. The filtrate from the dewatering assembly 480 can be sent to a classification assembly 490, which can separate and discharge the GMU fine powder. The discharge from the classifier (e.g., residual water and the particles contained therein) can be sent to a drain pump 464 or other treatment. Various components of the granulation unit 130 can be driven electrically, hydraulically and / or by other means.

[0033] III. Embodiments of Residual Iron and Residual Fine Powder Recycling in a GMU System Figure 5 is a partial block diagram showing a GMU manufacturing system 500 according to an embodiment of the present technology. As described elsewhere in this specification, system 500 can be configured to produce GMU including GI, GPI, and / or GS. System 500 corresponds to a part of a GMU manufacturing system (e.g., system 100 described with respect to Figure 1, and system 130 described with respect to Figure 4). System 500 includes a blast furnace (BF) and / or basic oxygen converter (BOF) 502 (also called a furnace unit), one or more transfer vessels 522 (e.g., molten iron transfer vessels such as torpedo cars or ladle cars), a desulfurization system 504 (also called a desulfurization unit), a granulation system 506 (also called a granulation unit), a slag removal system 508 (also called a slag processor), and a classifier 510 (also called a classification assembly).

[0034] The BF and / or BOF 502 are configured to melt iron material (e.g., iron scrap) to form molten iron. The molten iron is transferred by one or more transfer containers 522 (e.g., ladles or torpedo cars) to a desulfurization system 504 where the molten iron is treated to remove sulfur and / or other undesirable components. The molten iron is then transferred to a granulation system which includes, for example, a tundish that receives the molten iron (e.g., a tundish 440 in Figure 4) and a reactor that receives the molten iron from the tundish and produces GMU by injecting the molten iron into a target material. The granulation process includes cooling and solidifying the molten iron in the reactor as GMU. The GMU is treated by one or more slag removal systems 508 to remove slag and residual iron generated as byproducts during granulation. After slag removal, the GMU is transferred to a classifier 510 which separates the final product GMU 520 from residual fine particles 512 based on a threshold particle size. The classifier 510 may be a screw (spiral) classifier, a vibrating screen classifier, a cyclone classifier, a sedimentation tank classifier, or any other suitable classifier. The threshold particle size may be, for example, 1 millimeter (mm), 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. The final product GMU 520 having a particle size exceeding the threshold particle size can be collected and stored, for example, in a GMU pellet storage facility. The GMU pellet storage facility can enable the transportation and management of GMU in a convenient manner. The GMU pellet storage facility can be transported, for example, by rail. In some embodiments, the final product GMU 520 accounts for at least 95% by weight (e.g., at least 95% by weight, 96% by weight, 97% by weight, 98% by weight, or 99% by weight) of the iron fed into the system 500. In some embodiments, residual fine particles constitute less than 20% by weight, less than 15% by weight, less than 10% by weight, less than 5% by weight, less than 4% by weight, less than 3% by weight, less than 2% by weight, or less than 1% by weight of the GMU having a particle size exceeding the threshold particle size.

[0035] Residual fines 512, containing iron particles with a particle size below a threshold particle size and therefore unsuitable for further processing, are recycled into one or more transfer containers 522 and mixed with molten iron received from the BF and / or BOF 502. In some embodiments, the residual fines 512 constitute 0.5% by weight or less, 1% by weight or less, 2% by weight or less, or 5% by weight or less of the iron (e.g., including the final product GMU 520) introduced into the system 500. For example, the residual fines 512 may have a particle size of less than 1 mm and may account for 0.5% by weight of the iron introduced into the system. Mixing may involve melting the residual fines 512 with molten iron in the transfer container 522. In some embodiments, the temperature of the residual fines is maintained above a certain temperature during the recycling transfer to ensure that the residual fines 512 is at an appropriate temperature when added to the transfer container 522. Additionally or alternatively, the residual fines can be continuously recycled into the transfer containers.

[0036] In some embodiments, the residual fine powder is heated by latent heat in the transfer container 522 to remove moisture (e.g., the residual fine powder is dried in the transfer container 522). The heating is performed before adding molten metal from the BF and / or BOF 502. The residual fine powder 512 can be maintained at a temperature above a threshold temperature (e.g., above 212°C) for a certain period of time in the transfer container 522 to remove all or almost all moisture, so that the residual fine powder is dry when the molten iron received from the BF and / or BOF 502 is added. Drying can prevent the residual fine powder from scattering when the molten iron is added to melt the powder. The residual fine powder 512 is recycled by mixing it with molten iron before the desulfurization system 504 and / or slag removal system 508, so that the recycled residual fine powder can be desulfurized and / or slag removed (e.g., slag is removed from the residual fine powder). By recycling the residual fine particles 512 into the transfer container 522 as input to the BF and / or BOF 502, it is possible to reduce the potential losses that may occur when small-particle residual fine particles are blown out to the top of the BF and / or BOF 502. Furthermore, adding residual fine particles to the BF and / or BOF 502 may cause pressure drop problems in the BF and / or BOF 502.

[0037] Figure 5 also shows the recycling of residual iron 514 within system 500. The slag removal system 508 can separate residual iron 514 from other impurities in the slag produced as a byproduct. Residual iron 514 may have varying particle sizes and may contain various types of materials. Residual iron may contain any type of treated iron. As used herein, treated iron may contain any treated material, including, for example, iron that has been refined and / or alloyed in an industrial process. Examples of residual iron include thin slabs, steel, ladle scraps, sintered materials, scrap, slag, or iron powder. In some embodiments, slag removal may include removing or scooping the slag from the surface of the iron and recovering the slag in a slag pot (also known as a slag pan or slag ladle). Residual iron 514 can be further separated from the slag by various methods such as magnetic separation, gravity separation, or flotation separation. In some embodiments, slag removal may include separating thin slabs from other impurities. In some embodiments, thin slabs account for up to 1% by weight, 2% by weight, or 3% by weight of the iron introduced into the system 500. In some embodiments, residual iron 514 (e.g., iron powder or thin slabs) is recovered by a cyclone separator coupled to a granulation system 506 or a slag removal system 508. The cyclone separator may be configured to remove particles from the air, gas, or liquid flow within the system 500 by vortex separation. In some embodiments, thin slabs are picked up from the top of the slag or via a slag pot. In some embodiments, residual iron 514 may include ladle sludge, which is metal solidified in the transfer vessel, tundish, reactor, or other vessel of the system 500. Ladle sludge can be removed from the system 500, for example, manually (using a hammer, chisel, or scraper) or mechanically (using a tool such as a pneumatic hammer or hydraulic breaker). In some embodiments, residual iron 514 can be further recovered from the slag generated in the BF and / or BOF 502 and / or desulfurization system 504 (for example, after sulfur has been removed).

[0038] Residual iron 514 recovered during slag removal or as part of any other process in System 500 is recycled by transferring the residual iron to the BF and / or BOF 502 to form molten iron. The residual iron can be mixed with raw materials (e.g., iron scrap) in the BF and / or BOF 502.

[0039] In some embodiments, System 500 has a lower iron loss rate than conventional granular iron production systems that do not recycle residual fines or residual iron, as System 500 does. For example, while conventional systems may have a total iron loss of more than 5%, System 500 has a total iron loss of 5% or less (e.g., less than 4%, less than 3%, less than 2%, or less than 1%).

[0040] In some embodiments, the system 500 can further receive external residual fine particles 518 and / or external residual iron 516 (e.g., material produced by another iron manufacturing facility) and recycle the external residual fine particles 518 and / or external residual iron 516 in a similar manner as recovered residual fine particles 512 and residual iron 514 within the system 500.

[0041] Figure 6 is a block diagram illustrating the recycling of residual fines in the granular iron production system 500 of Figure 5 according to an embodiment of the present technology. As described with respect to Figure 5, residual fines 512 and optionally external residual fines 518 can be recycled by mixing the residual fines with molten iron in one or more transfer containers 522. In the embodiment of Figure 6, one or more transfer containers 522 include a torpedo car 602 (e.g., the torpedo car 102 described with respect to Figure 1) and are configured to transfer molten iron from the BF 502 (or BOF) to further processing (e.g., the desulfurization system 506 in Figure 5).

[0042] Figure 7 is a block diagram illustrating the recycling of residual fine particles in the GMU manufacturing system 500 of Figure 5 according to an embodiment of the present technology. As described with respect to Figure 5, residual fine particles 512 and optionally externally sourced residual fine particles 518 can be recycled by mixing the residual fine particles with molten iron in one or more transfer containers 522. In the embodiment of Figure 7, one or more transfer containers 522 include a torpedo car 602 and a ladle 702. In Figure 7, the torpedo car 602 is configured to transfer molten iron from the BF 502 (or BOF) to the ladle 702. The ladle 702 is further configured to transfer the molten iron to further processing (e.g., a desulfurization system 506 in Figure 5). As shown in the figure, in the embodiment of Figure 7, residual fine particles 512 and optionally externally sourced residual fine particles 518 are recycled to be mixed with molten iron in the ladle 702.

[0043] As used herein, a torpedo car is an elongated, insulated transport container mounted on a railway vehicle for transporting molten iron. In contrast, a ladle is an open-top container for transporting molten iron, which can be moved manually or mechanically. The open-top design of the ladle 702 allows for chemical processing, such as desulfurization, deoxidation, and / or slag removal processes, while residual granules 512 and external residual granules 518 are mixed with the molten iron from BF502. In contrast, the torpedo car 602, due to its insulation, can provide better temperature control for mixing recycled granules with the molten iron. Therefore, in some embodiments, a combination of a torpedo car (configured for transport) and a ladle (configured for chemical processing and transport) is beneficial.

[0044] As illustrated with reference to Figure 5, in some embodiments, the residual fine powder 512 is heated by latent heat in the torpedo car 602 and / or ladle 702 to remove moisture (e.g., the residual fine powder is dried). The heating can be done before adding molten metal from the BF and / or BOF 502. For example, the residual fine powder 512 is maintained in the torpedo car 602 and / or ladle 702 at a temperature above a threshold temperature (e.g., above 212°C) for the time required to dry the residual fine powder. The dried residual fine powder can then be combined with the molten iron received from the BF and / or BOF 502.

[0045] Figure 8 is a flow chart of a process 800 for producing a GMU and / or reducing waste according to an embodiment of the present technology. This process can be carried out by the system 500 described with respect to Figure 5. Process 800 includes receiving a first feed of molten iron (process portion 802). The molten iron can be generated by a BF and / or BOF 502 and supplied to a desulfurization system 504 by one or more transfer containers 522 and further supplied to a granulation system 506.

[0046] Process 800 includes producing GMU by granulating molten iron injected into a target material of a reactor (process portion 804). For example, the granulation system includes a reactor configured to granulate molten iron to form GMU. Process 800 includes removing residual fine particles of the GMU by a classifier (e.g., classifier 510) (process portion 806). The classifier removes residual fine particles based on a threshold particle size (e.g., a threshold particle size of 1 mm, 2 mm, 3 mm, or 4 mm), thereby ensuring that the residual fine particles 512 have a particle size less than the threshold particle size, and the product GMU 520 has a particle size greater than or equal to the threshold particle size. Process 800 includes producing additional GMU by mixing the residual fine particles with a second feed of molten iron (e.g., in a transfer container 522) different from the first feed of molten iron (process portion 808). In some embodiments, mixing the residual fines may include recovering the residual fines in a transfer container (e.g., a torpedo car and / or ladle as described elsewhere in this specification) and adding a second feed of molten iron to the transfer container to melt the residual fines. The melted residual fines and the second feed of molten iron can then be sent by a granulation system (e.g., granulation system 506) to produce additional GMU.

[0047] In some embodiments, process 800 includes generating residual iron (e.g., residual iron 514 in Figure 5) as a byproduct of manufacturing GMU. Residual iron may include one or more of thin slabs, steel, ladle scraps, sintered material, scrap, slag, or iron powder. Residual iron can be recovered during various processes within system 500, such as during slag removal, desulfurization, or in the transfer vessel, tundish, reactor, or other vessel of system 500. Process 800 may include mixing at least a portion of the residual iron with metal scrap to produce a mixture, and feeding at least a portion of the mixture to a BF and / or BOF to produce a first feed of molten iron. In some embodiments, process 800 includes additional steps not shown in Figure 8. The additional steps may be before, after, or between process parts 802 and 808.

[0048] conclusion It will be apparent to those skilled in the art that modifications may be made to the details of the embodiments described above without departing from the underlying principles of the present art. In some cases, well-known structures and functions are not illustrated or described in detail to avoid unnecessarily obscuring the description of the embodiments of the present art. While the steps of a method may be presented in a specific order herein, in alternative embodiments the steps may be performed in a different order. Similarly, certain aspects of the present art disclosed in the context of a particular embodiment may be combined with or excluded in other embodiments. Furthermore, while advantages related to a particular embodiment of the present art may be disclosed in the context of that embodiment, other embodiments may also exhibit such advantages, and not all embodiments are required to exhibit such advantages or other advantages disclosed herein so that they do not necessarily fall within the scope of the present art. Thus, the present disclosure and the associated art may encompass other embodiments not expressly shown or described herein, and the present invention is not limited to the appended claims.

[0049] Throughout this disclosure, the singular forms “a,” “an,” and “the” include plural references unless the context explicitly indicates otherwise. The terms “comprising,” “including,” and “having” should be interpreted as including at least the described features(s) so as not to exclude any more identical and / or additional types of features.

[0050] References herein to “one embodiment,” “one embodiment,” “several embodiments,” or similar expressions mean that certain features, structures, operations, or characteristics described in relation to an embodiment may be included in at least one embodiment of the Art. Therefore, not all occurrences of such words or expressions herein necessarily refer to the same embodiment. Furthermore, various specific features, structures, operations, or characteristics may be combined in any preferred manner in one or more embodiments.

[0051] Unless otherwise specified, all numbers representing concentrations and other numerical values ​​used in this specification and the claims should be understood in all cases as being modified by the term “approximately”. Therefore, unless otherwise noted, the numerical parameters described in the following specification and the appended claims are approximations and may vary depending on the desired properties required by the Art. At a minimum, and not as an attempt to limit the application of principles equivalent to those in the claims, each numerical parameter should be interpreted with respect to the reported number of significant figures, by applying at least common rounding techniques. Furthermore, all ranges disclosed herein should be understood to encompass any and all subranges contained therein. For example, the range “1 to 10” includes any and all subranges between the minimum value of 1 and the maximum value of 10 (including these), i.e., any and all subranges where the minimum value is greater than or equal to 1 and the maximum value is less than or equal to 10 (e.g., 5.5 to 10).

[0052] The foregoing disclosure should not be interpreted as reflecting an intention that any claim requires more features than those explicitly described in that claim. Rather, as reflected in the following claims, the embodiments of the invention are in fewer combinations than all the features of any single aforementioned disclosed embodiment. Thus, the claims following the embodiments for carrying out the invention are explicitly incorporated into the embodiments for carrying out the invention, and each claim stands independently as a separate embodiment. This disclosure includes all variations of the independent claims and their dependent claims.

[0053] This technology is illustrated, for example, in accordance with various embodiments described below as numbered clauses or embodiments (1, 2, 3, etc.) for convenience. These are provided as examples and do not limit the technology. Note that any dependent clause may be combined in any way and incorporated into the corresponding independent claim.

[0054] 1. A method for manufacturing granular metal units (GMUs), Receiving the first supply of molten iron, The GMU is produced by granulating the molten iron injected into the target material of the reactor, Based on the threshold particle size, residual fine particles of the GMU are removed through a classifier, The method comprising mixing the residual fine powder with a second feed of molten iron, which is different from the first feed of molten iron, to produce additional GMU.

[0055] 2. The method according to any one of the provisions of this specification, wherein mixing the residual fine powder with the second feed of molten iron comprises melting the residual fine powder with the second feed of molten iron.

[0056] 3. The method according to any one of the provisions of this specification, comprising adding the residual fine powder to a transfer container having a temperature above a threshold temperature, wherein the transfer container is configured to remove moisture from the residual fine powder for a threshold time, and adding molten iron to the transfer container to melt the residual fine powder in the transfer container.

[0057] 4. The method according to any one of the provisions of this specification, wherein mixing the residual fine powder comprises adding the residual fine powder to a transfer container and melting the residual fine powder in the transfer container by adding molten iron to the transfer container.

[0058] 5. The method according to any one of the provisions of this specification, wherein the threshold particle size is 1 millimeter (mm) or less, 2 mm or less, 3 mm or less, 4 mm or less, 5 mm or less, 6 mm or less, 7 mm or less, 8 mm or less, 9 mm or less, or 10 mm or less.

[0059] 6. The method according to any one of the provisions of this Specification, wherein the residual fine powder constitutes less than 20% by weight, less than 15% by weight, less than 10% by weight, less than 5% by weight, less than 4% by weight, less than 3% by weight, less than 2% by weight, or less than 1% by weight of the GMU having a particle size exceeding the threshold particle size.

[0060] 7. The method according to any one of the provisions of this Specification, further comprising producing slag as a by-product in the production of the GMU particles, wherein the residual fine powder accounts for 70% by weight or less, 60% by weight or less, 50% by weight or less, 40% by weight or less, 30% by weight or less, or 20% by weight or less of the slag.

[0061] 8. The method according to any one of the provisions of this specification, further comprising desulfurizing the molten iron before producing the GMU.

[0062] 9. The method according to any one of the provisions of this specification, further comprising decarburizing the molten iron before producing the GMU.

[0063] 10. Producing slag as a by-product when manufacturing the GMU, To separate residual iron from the aforementioned slag, Mixing at least a portion of the residual iron with metal scrap to produce a mixture, The method according to any one of the provisions of this specification, further comprising supplying at least a portion of the mixture to a blast furnace and / or a basic oxygen converter to produce molten iron.

[0064] 11. The method according to any one of the provisions of this specification, further comprising maintaining the temperature of the residual fine powder above a threshold temperature until the residual fine powder is mixed with the second feed of molten iron.

[0065] 12. The method according to any one provision of this specification for receiving the molten iron from the blast furnace.

[0066] 13. The method according to any one provision of this specification, wherein the molten iron is received from a basic oxygen converter.

[0067] 14. Receiving residual fine particles from the outside, The method according to any one of the provisions of this specification, further comprising mixing the residual fine powder from the outside with a second feed of molten iron in a transfer container to produce the GMU.

[0068] 15. The method according to any one provision of this specification, wherein mixing the residual fine powder comprises adding the residual fine powder to a ladle, removing moisture from the residual fine powder by heating, and melting the residual fine powder in the ladle by adding molten iron to the ladle.

[0069] 16. Receiving residual iron from external sources, Mixing at least a portion of the residual iron with metal scrap to produce a mixture, The method according to any one of the provisions of this specification, further comprising supplying at least a portion of the mixture to a blast furnace and / or a basic oxygen converter to produce a first feed of molten iron.

[0070] 17. As a by-product of manufacturing the GMU, residual iron is produced, which includes one or more of the following: thin cast slabs, steel, ladle scraps, sintered material, scrap, slag, or iron powder. Mixing at least a portion of the residual iron with metal scrap to produce a mixture, The method according to any one of the provisions of this specification, further comprising supplying at least a portion of the mixture to a blast furnace and / or a basic oxygen converter to produce a first feed of molten iron.

[0071] 18. Granulation as described in any one of the provisions of this specification, comprising cooling and solidifying the molten iron injected into the target material of the reactor.

[0072] 19. A method for manufacturing a GMU, Receiving the first supply of molten iron, The GMU is produced by granulating the molten iron injected into the target material of the reactor, The process of manufacturing the aforementioned GMU involves removing residual iron, which includes one or more of the following as by-products: thin slabs, steel, ladle scraps, sintered material, scrap, slag, or iron powder. Mixing at least a portion of the residual iron with an additional metal to produce a mixture, The method comprising supplying at least a portion of the mixture to a blast furnace and / or a basic oxygen converter to produce a second feed of molten iron different from the first feed of molten iron, thereby producing additional GMU.

[0073] 20. The method according to any one of the provisions of this specification, wherein the removal of the residual iron includes separating the residual iron from slag produced as a byproduct in the production of GI particles.

[0074] 21. Removing residual fine particles of GI particles based on threshold particle size through a classifier, The method according to any one of the provisions of this specification, further comprising mixing the residual fine powder with a second feed of molten iron different from the first feed of molten iron to produce additional GI particles.

[0075] 22. A system for producing granular iron (GI), A transfer container configured to receive molten iron, The granulation system includes a granulation system configured to receive the molten iron from the transfer container, and the granulation system is A tundish positioned to receive the molten iron, A reactor located downstream of the tundish and arranged to receive the molten iron from the tundish and produce GI particles, The system includes a classifier that receives the GI particles from the reactor and is configured to separate residual fine particles from the GI particles based on a threshold particle size, The transfer container is further configured to receive the residual fine powder, the system.

[0076] 23. The system according to any one of the provisions of this specification, wherein the transport container is a torpedo car.

[0077] 24. The transfer container is a ladle, as described in any one of the provisions of this specification.

[0078] 25. The system according to any one of the provisions of this Specification, further comprising a blast furnace and / or a basic oxygen furnace configured to produce the molten iron.

[0079] 26. The system according to any one of the provisions of this Spec., further comprising a desulfurization system configured to desulfurize the molten iron before the molten iron is received by the granulation system.

[0080] 27. Further comprising a slag removal system located downstream of the granulation system, From the slag generated as a by-product during the production of the aforementioned GI particles, residual iron is obtained, which includes at least one of thin slabs, steel, ladle scraps, sintered material, scrap, slag, or iron powder. The system according to any one of the provisions of this specification, configured to supply the residual iron to a blast furnace and / or a basic oxygen converter to produce the molten iron.

[0081] 28. The system according to any one of the provisions of this specification, wherein the transfer container is configured to receive residual fine particles from an external source and to mix the residual fine particles from the external source with the molten iron in the transfer container to produce additional GI particles.

[0082] 29. Further comprising a blast furnace and / or basic oxygen furnace, the blast furnace and / or basic oxygen furnace is Receiving residual iron from external sources, The aforementioned residual iron from the outside is mixed with metal scrap to produce a mixture. The system according to any one of the provisions of this specification, configured to supply at least a portion of the mixture to the blast furnace and / or the basic oxygen converter to produce molten iron.

Claims

1. A method for manufacturing granular metal units (GMUs), Receiving the first supply of molten iron, The GMU is produced by granulating the molten iron injected into the target material of the reactor, Based on the threshold particle size, the residual fine particles of the GMU are removed through a classifier, The residual fine powder is mixed with a second feed of molten iron, which is different from the first feed of molten iron, to produce additional GMU. The method, including the method described above.

2. The method according to claim 1, wherein mixing the residual fine powder with the second feed of molten iron comprises melting the residual fine powder with the second feed of molten iron.

3. The method according to claim 1, wherein mixing the residual fine powder comprises adding the residual fine powder to a transfer container and melting the residual fine powder in the transfer container by adding molten iron to the transfer container.

4. The method according to claim 1, wherein the threshold particle size is 6 millimeters (mm) or less.

5. The method according to claim 1, wherein the residual fine powder accounts for less than 5% by weight of the GMU having a particle size exceeding the threshold particle size.

6. The method according to claim 1, further comprising generating slag as a by-product in the production of the GMU, wherein the residual fine powder accounts for 60% by weight or less of the slag.

7. The production of slag as a by-product in the manufacturing of the aforementioned GMU, To separate residual iron from the aforementioned slag, Mixing at least a portion of the residual iron with metal scrap to produce a mixture, At least a portion of the mixture is supplied to a blast furnace and / or a basic oxygen converter to produce molten iron, The method according to claim 1, further comprising:

8. The method according to claim 1, further comprising maintaining the temperature of the residual fine powder above a threshold temperature until the residual fine powder is mixed with the second feed of molten iron.

9. The method according to claim 1, wherein the molten iron is received from the blast furnace.

10. The method according to claim 1, wherein the molten iron is received from a basic oxygen converter.

11. Receiving residual fine particles from the outside, The GMU is produced by mixing the residual fine powder from the outside with the second feed of molten iron in a transfer container, The method according to claim 1, further comprising:

12. The method according to claim 1, wherein mixing the residual fine powder comprises adding the residual fine powder to a ladle and melting the residual fine powder in the ladle by adding molten iron to the ladle.

13. Receiving residual iron from external sources, Mixing at least a portion of the residual iron with metal scrap to produce a mixture, At least a portion of the mixture is supplied to a blast furnace and / or a basic oxygen converter to produce the first feed of molten iron, The method according to claim 1, further comprising:

14. As a by-product of manufacturing the aforementioned GMU, residual iron is produced, which includes one or more of the following: thin cast slabs, steel, ladle scraps, sintered material, slag, scrap, or iron powder. Mixing at least a portion of the residual iron with metal scrap to produce a mixture, At least a portion of the mixture is supplied to a blast furnace and / or a basic oxygen converter to produce the first feed of molten iron, The method according to claim 1, further comprising:

15. A method for manufacturing granular metal units (GMUs), Receiving the first supply of molten iron, The GMU is produced by granulating the molten iron injected into the target material of the reactor, The process of manufacturing the aforementioned GMU involves removing residual iron, which includes one or more of the following as by-products: thin cast slabs, steel, ladle scraps, sintered material, slag, scrap, or iron powder. Mixing at least a portion of the residual iron with metal scrap to produce a mixture, At least a portion of the mixture is supplied to a blast furnace and / or a basic oxygen converter to produce a second feed of molten iron different from the first feed of molten iron, thereby producing additional GMU. The method, including the method described above.

16. The method according to claim 15, wherein the removal of the residual iron includes separating the residual iron from the slag generated as a by-product in the production of the GMU.

17. Based on the threshold particle size, the residual fine particles of the GMU are removed through a classifier, The residual fine powder is mixed with a second feed of molten iron, which is different from the first feed of molten iron, to produce additional GMU. The method according to claim 15, further comprising:

18. A system for manufacturing granular metal units (GMUs), A transfer container configured to receive molten iron, A granulation system configured to receive the molten iron from the transfer container, The granulation system includes, A tundish positioned to receive the molten iron, A reactor located downstream of the tundish and arranged to receive the molten iron from the tundish and produce the GMU, A classifier is provided to receive the GMU from the reactor and separate residual fine particles from the GMU based on a threshold particle size. Includes, The transfer container is further configured to receive the residual fine powder separated by the classifier, in the system.

19. The system according to claim 18, wherein the transport container is a torpedo car.

20. The system according to claim 18, wherein the transfer container is a ladle.

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