Use of a basic oxygen converter for producing metal granules, and related systems, apparatus, and methods.

Abstract

This specification discloses systems and methods for producing granular metal materials (GMUs) using a molten metal processing unit. In some embodiments of the present art, a molten metal processing system for producing GMUs includes a molten metal processing unit comprising a granulation unit. The granulation unit may include a tilting device positioned to receive and tilt a ladle, a control device operably connected to the tilting device to control the tilting of the ladle, a tundish positioned to receive molten metal from the ladle, and a reactor positioned to receive molten metal from the tundish. The reactor may be configured to cool the molten metal to form granular metal materials (GMUs).

Description

TECHNICAL FIELD

[0001] The present technology relates generally to converting basic oxygen furnace equipment for the production of metallic granular bodies, as well as related systems, apparatuses, and methods. BACKGROUND ART

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 581,946, filed on 11 September 2023, entitled “SYSTEM AND METHOD FOR CONTINUOUS GRANULATED PIG IRON (GPI) PRODUCTION,” the disclosures of which are incorporated herein by reference in their entirety. This application relates to the following applications, the disclosures of which are incorporated herein by reference in their entirety. U.S. Patent Application No. [Agent Reference Number 084553.8072.US00] filed on September 11, 2024, titled "RAILCARS FOR TRANSPORTING GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS", U.S. Patent Application No. [Agent Reference Number 084553.8073.US00] filed on September 11, 2024, titled "LOADING GRANULATED METALLIC UNITS INTO RAILCARS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS", and "LOW-SULFUR GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND U.S. Patent Application No. [Agent Reference Number 084553.8074.US00] titled "METHODS", U.S. Patent Application No. [Agent Reference Number 084553.8075.US00] filed on September 11, 2024, titled "CONTINUOUS GRANULATED METALLIC UNITS PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS", U.S. Patent Application No. [Agent Reference Number 084553.8077] filed on September 11, 2024.[US00], a US patent application filed on September 11, 2024, titled "TORPEDO CARS FOR USE WITH GRANULATED METALLIC UNIT PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" [Agent reference number 084553.8078.US00], a US patent application filed on September 11, 2024, titled "TREATING COOLING WATER IN IRON PRODUCTION FACILITIES, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" [Agent reference number 084553.8079.US00], a US patent application filed on September 11, 2024, titled "USE OF RESIDUAL IRON WITHIN GRANULATED METALLIC UNIT PRODUCTION FACILITIES, AND ASSOCIATED SYSTEMS, DEVICES, AND U.S. Patent Application No. [Agent Reference Number 084553.8080.US00] titled "METHODS," and U.S. Patent Application No. [Agent Reference Number 084553.8081.US00] filed on September 11, 2024, titled "PROCESSING GRANULATED METALLIC UNITS WITHIN ELECTRIC ARC FURNACES, AND ASSOCIATED SYSTEMS AND METHODS."

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

[0004] Granulated pig iron is produced by rapidly cooling molten iron with water to form granules. This process, known as granulation, is usually carried out after the blast furnace. However, current manufacturing methods are often characterized by intermittent production cycles due to various operational constraints such as the need for regular maintenance, fluctuations in raw material supply, and energy consumption issues. Such interruptions not only affect overall efficiency but also lead to increased production costs and variability in product quality. Therefore, there is a need for an improved production process that can ensure continuous and stable iron granulation to improve productivity while 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.

[0006] 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 and / or additional features and their arrangement. [Brief explanation of the drawing]

[0007] [Figure 1] This is a schematic block diagram of a molten metal processing system configured according to this embodiment of technology. [Figure 2] Figure 1 is a plan view of the molten metal processing system configured according to an embodiment of this technology. [Figure 3] This is a schematic partial lateral cross-sectional view of a basic oxygen reactor vessel configured according to an embodiment of this technology. [Figure 4] This is a schematic plan view of two granulation units in a first arrangement, configured according to an embodiment of the present technology. [Figure 5] This is a schematic plan view of two granulation units in a second arrangement, configured according to an embodiment of the present technology. [Figure 6] Figures A to C are schematic partial side views showing the tilting of a transfer container according to an embodiment of this technology. [Figure 7] This is a front perspective view of a tundish configured according to an embodiment of this technology. [Figure 8A] This is a rear perspective view of a tundish configured according to an embodiment of this technology. [Figure 8B] This is a lateral cross-sectional view of a tundish configured according to an embodiment of the present technology. [Figure 9] This is a perspective view of a stopper rod assembly configured according to an embodiment of this technology. [Figure 10] This is a perspective view showing the assembled tundish and stopper rod assembly configured according to an embodiment of this technology. [Figure 11] This is a schematic cross-sectional view of a granulation reactor configured according to an embodiment of this technology. [Figure 12] This is a schematic side view of an ejector configured according to an embodiment of this technology. [Figure 12B] This is an enlarged lateral cross-sectional view of an ejector configured according to an embodiment of this technology. [Figure 13] This is a schematic side view of a dewatering assembly configured according to an embodiment of this technology. [Figure 14] This is a schematic side view of a classifier assembly configured according to an embodiment of this technology. [Figure 15] This is a schematic process flow diagram showing iron granulation according to an embodiment of this technology. [Figure 16] This flowchart shows a GMU manufacturing method according to an embodiment of this technology. [Modes for carrying out the invention]

[0008] I. Overview This technology generally relates to systems, apparatus, and methods for converting or retrofitting basic oxygen converter (BOF) equipment or molten metal processing units for the production of granulated metallic units (GMUs). GMUs can be produced by forming molten iron in a blast furnace and rapidly cooling the molten iron with water to form granules. However, GMU production can require a number of large and complex pieces of equipment, such as flow control devices, overhead cranes, ladles, and lances. Constructing a new GMU manufacturing facility from scratch can be very expensive.

[0009] Embodiments of this technology address at least some of the aforementioned problems by converting or retrofitting BOF facilities for GMU production and repurposing much of the existing equipment within the BOF facilities. As described herein, some embodiments of this technology may include a molten metal processing system for producing metal granules, comprising a molten metal processing unit including a ladle, a granulation unit, and an overhead crane. The ladle may be shaped to receive and contain molten iron inside. The granulation unit may include a tilting device positioned to receive and tilt the ladle, a control device operably connected to the tilting device to control the tilting of the ladle, a tundish positioned to receive molten iron from the ladle, and a reactor positioned to receive molten iron from the tundish. The reactor may be configured to cool the molten iron to form GMU. The overhead crane may be configured to transfer the ladle to and from the tilting device.

[0010] Specific details of several embodiments of this technology are described below with reference to Figures 1 to 16. Other details describing well-known structures and systems, often relating to furnaces, rails, conveyor belts, exhaust hoods, automatic control systems, etc., are not described in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of this technology. Many of the details, dimensions, angles, and other features shown in the figures are merely illustrative of specific embodiments of this technology. Therefore, other embodiments may have other details, dimensions, angles, and features without departing from the spirit or scope of this technology. Thus, those skilled in the art will understand that this technology may have other embodiments with additional elements, or that it may have other embodiments that do not include some of the features shown and described below with reference to Figures 1 to 16.

[0011] II. Embodiments of Molten Metal Processing Systems Figure 1 is a schematic block diagram of a molten metal processing production system 100 ("System 100") configured according to an embodiment of the present technology. As described elsewhere in this specification, the granular metal material (GMU) may include pig iron (GPI) or granular steel (GS). In connection with this, the molten metal may include molten iron or molten steel. In some embodiments, System 100 includes a continuous system that can operate in continuous operating cycles of at least 2 hours, 4 hours, 6 hours, 8 hours, 10 hours, 12 hours, 16 hours, 20 hours, or 24 hours, including batch or semi-batch operation. The duration of the continuous operating cycle may be determined at least in part by the size of the GMU produced by System 100. In some embodiments, System 100 can produce at least 2,000 tons, 4,000 tons, 6,000 tons, 8,000 tons, 10,000 tons, or more of GMU per hour. In some embodiments, System 100 is configured primarily to produce GMU.

[0012] The system 100 can include a molten metal processing unit 104 and a blast furnace 102 disposed outside the molten metal processing unit 104. As will be described in further detail herein, the blast furnace 102 can receive input raw 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. The following equations (1) to (6) list part of the chemical processes controlled in the blast furnace 102. 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)

[0013] Equation (1) represents the combustion of coke, which is carbon in its original form. When coke reacts with oxygen gas introduced into the furnace (e.g., via an oxygen lance), it forms carbon dioxide. This exothermic reaction releases a considerable amount of heat, which is essential for maintaining the high temperature required for subsequent reactions. As shown by equation (2), the carbon dioxide produced by equation (1) further reacts with additional coke to form carbon monoxide. This endothermic reaction helps maintain a moderate temperature inside the blast furnace 102. Equations (3) and (4) represent the reduction of iron ore (Fe2O3). As shown by equation (3), iron oxide reacts with the carbon monoxide produced by equation (2), acting as a reducing agent to convert the iron ore into iron, producing carbon dioxide as a byproduct. Alternatively, as shown by equation (4), iron ore can be reduced directly by coke, though less commonly. Equations (5) and (6) represent the formation of slag. As shown by equation (5), calcium carbonate / limestone (CaCO3) can be decomposed into calcium oxide and carbon dioxide at the high temperature of blast furnace 102. As shown by equation (6), the calcium oxide can then react with silica (SiO2), an impurity in the iron ore, to form calcium silicate (CaSiO3), also known as slag. Blast furnace 102 can produce molten metal (according to equations (3) and (4)) and slag (according to equations (5) and (6)).

[0014] The molten metal processing unit 104 may include a scrap yard 106, a charging aisle 108, a furnace aisle 110, and a tapping aisle 120. The charging aisle 108 may be a space for transfer vessels 122 (e.g., torpedo cars, ladles, etc.) that hold molten metal from the blast furnace 102. The furnace aisle 110 may include one or more BOF vessels 112. The scrap yard 106 may function as a stockpile area for scrap that may be supplied to the BOF vessels 112. The tapping aisle 120 may include additional transfer vessels 122 that can receive the product from the BOF vessels 112. Returning to the blast furnace 102, the transfer vessels 122 may transfer molten metal from the blast furnace 102 to the molten metal processing unit 104 via either route A or route B.

[0015] In route A, the molten metal is transported directly to the desulfurization unit 140 of the molten metal processing unit 104, or via the transfer vessel 122 through the charging aisle 108. The desulfurization unit 140 may include an apparatus for reducing the sulfur content in the molten metal. For example, one or more lances may be used to deliver magnesium (Mg), calcium carbide (CaC2), or other sulfur reducing agents to the molten metal. In some embodiments, desulfurization of the molten metal is performed while it is still inside the transfer vessel 122. In some embodiments, the molten metal is desulfurized in the torpedo car, and then the desulfurized molten metal is transferred to the ladle. The following equations (7) and (8) list the reactions between sulfur and the sulfur reducing agents. Mg+S→MgS (7) CaC2+S→CaS+2C (8)

[0016] The resulting substances, including magnesium sulfide (MgS) and calcium sulfide (CaS), do not dissolve in the molten metal and therefore remain solid (e.g., as solid particles), making them easier to remove in the desulfurization unit 140 and / or further downstream. As further described herein, reducing the sulfur content improves the quality of GMU products and / or makes the production process continuous. In particular, conventional facilities may not include a desulfurization unit or may lack the capacity to desulfurize the molten metal otherwise. One reason for this is that conventional steelmaking facilities feed the molten metal directly from the blast furnace to the basic oxygen converter and only granulate the molten metal when the basic oxygen converter is shut down. Since GMU production is a backup operation for such facilities, the increased complexity and cost associated with installing desulfurization equipment may not be economically viable.

[0017] After the desulfurization process, the desulfurized molten metal can be supplied to a basic oxygen converter (BOF) vessel 112 in the furnace passage 110. The BOF vessel 112 can reheat the molten metal and / or reduce its carbon content. For example, oxygen gas can be supplied to the molten metal in the BOF vessel 112 using one or more oxygen lances. The oxygen reacts with the carbon present in the molten metal to cause combustion, reheating the molten metal to a temperature below a desired temperature range such as 2000-3000°F, 2300-2500°F, 2300-2400°F, or 2340-2350°F, or below the liquidus / carbon equilibrium / eutectic point of iron. Furthermore, or or, the desired temperature can be at least 100°F, 200°F, 300°F, or 400°F higher than the solidification temperature, depending on the chemical structure of the composition (e.g., the silicon content of the composition). Furthermore, the reaction between oxygen and carbon can reduce the carbon content in the molten metal, which may be desirable for adjusting the material properties of the final product. For example, the resulting GMU may have a sufficiently low carbon content and be more similar to steel. The molten metal can then be transferred from the BOF container 112 to the transfer container 122 in the supply passage 120. On the other hand, in route B, the desulfurization unit 140 and the BOF container 112 are omitted, and the molten metal is transferred directly from the blast furnace 102 to the transfer container 122 in the discharge passage 120.

[0018] As shown in Figure 1, the molten metal processing unit 104 may further include an overhead crane 130, one or more granulation units 150, and a cooling system 160. The overhead crane 130 can be controlled (e.g., using a control device 105) to transport a transfer container 122 (e.g., a ladle) containing molten metal to a downstream unit within the molten metal processing unit 104. In some embodiments, the overhead crane 130 transports the transfer container 122 to one or more granulation units 150. The system 100 may include one, two, three, four, five, six, or more granulation units 150. Each granulation unit 150 may include a granulation reactor that receives molten metal, granulates it, and forms a granular product. For example, the granulation reactor may include a cavity that contains water and / or additives that help achieve a desired heat capacity and / or thermal conductivity, and the molten metal may be transferred (e.g., poured, sprayed) onto a target in the reactor containing the water. The water can be kept at a sufficiently low temperature by the cooling system 160 (for example, by directly cooling it by pumping water between the granulation unit 150 and the cooling system 160, or by indirectly cooling it by pumping a coolant separate from the water receiving the molten metal). In some embodiments, each granulation unit 150 includes one or more components for controlling the flow of molten metal from the transfer container 122 to the granulation reactor. As those skilled in the art will recognize, flow control can affect the shape, particle size, and quality of the granular product. The granulation unit 150 may also include a dehydration assembly for drying the granular product from the granulation reactor to produce GMU. The granulation unit 150 may further include a classifier assembly for filtering the filtrate from the dehydration assembly to produce fine powder.

[0019] The molten metal processing unit 104 may further include a product processing unit 170 that receives GMU produced by the granulation unit 150 (e.g., a dewatering assembly) and a fine powder processing unit 172 that receives fine powder of GMU produced by the granulation unit 150 (e.g., a classifier assembly). In some embodiments, the product processing unit 170 and / or the fine powder processing unit 172 each include one or more conveyor belts, diverters, stockpile locations, etc. The molten metal processing unit 104 may further include a transfer container preparation unit 180 that can remove slag and / or quiche graphite from the transfer container 122. For example, after delivering the molten metal to the granulation unit 150, the transfer container 122 can be transported to the transfer container preparation unit 180 by an overhead crane 130 for cleaning or otherwise preparation for the next transfer cycle of the molten metal.

[0020] System 100 may additionally include a product loading section 171, a fine powder loading section 173, a slag processing section 182, and a scrap storage section 184 outside the molten metal processing unit 104. The product loading section 171 is located downstream of the product processing unit 170 to receive GMU products. The fine powder loading section 173 is located downstream of the fine powder processing unit 172 to receive GMU fine powder. The slag processing section 182 is located downstream of the transfer container preparation unit 180 to receive slag removed from the transfer container. The scrap storage section 184 is located downstream of the granulation unit 150 to receive flaky pig iron and / or iron skulls. As shown in Figure 1, the fine powder from the fine powder loading section 173, the slag and / or iron from the tundish of the granulation unit 150, and / or flaky pig iron and / or iron skulls from the scrap storage section 184 can be returned to the blast furnace 102 as recycled material. In some embodiments, the recycled material is processed (e.g., pelletized) before being supplied to the blast furnace 102.

[0021] Furthermore, emissions from various components of system 100 can be collected and sent to one or more dust collection units 190 within the molten metal processing unit 104 (e.g., one or more baghouses, one or more scrubbers, one or more sedimentation separators, etc.). For example, emissions from the desulfurization unit 140, the granulation unit 150, and the transfer container preparation unit 180 can be collected via a fume hood (draft chamber) and sent via pipes to the dust collection unit 190. The dust collection unit 190 can filter the emissions to remove dust, allowing the clean exhaust gas to be sent to a chimney (not shown) and released into the atmosphere, and the removed dust to be led to further processing 192.

[0022] Figure 2 is a plan view of a BOF GMU system 100 configured according to an embodiment of the present technology. As shown, the blast furnace 102 can be located away from the molten metal processing unit 104. The molten metal processing unit 104 may include a charging passage 108, a furnace passage 110 adjacent to the charging passage 108, and a dispensing passage 120 adjacent to the furnace passage 110. The desulfurization unit 140 may be located away from the charging passage 108, and the granulation unit 150 may be located adjacent to the charging passage 108. In the illustrated embodiment, the overhead crane 130 can move along an L-shaped path extending laterally from the charging passage 108, the furnace passage 110, the dispensing passage 120, the desulfurization unit 140, and the granulation unit 150. Thus, the overhead crane 130 can transport a transfer container 122 from the dispensing passage 120 to the desulfurization unit 140 and / or the granulation unit 150. Furthermore, the molten metal processing unit 104 may include a scrap yard 106, one or more dust collection units 190, a return water sump 202, and an oxygen storage area 204. The return water sump 202 can receive, for example, water recovered from a classifier included in the granulation unit 150. The oxygen storage area 204 can store, for example, oxygen for the oxygen lance used in the BOF container 112.

[0023] Referring together to Figures 1 and 2, for example, if GMU is produced by converting a BOF (Blow-of-Fuel) facility or molten metal processing unit rather than constructing a new GMU manufacturing facility, costs can be significantly reduced because much of the necessary equipment may already be present in the BOF facility. Such existing equipment may include selected components within the overhead crane 130, desulfurization unit 140, transfer container 122, and granulation unit 150, as will be discussed in further detail herein. Thus, in embodiments of this technology, it is expected that GMU can be produced at a fraction of the cost of constructing a new manufacturing facility, and that production can be started much sooner, as time associated with constructing a new manufacturing facility is saved.

[0024] Furthermore, unlike conventional GMU manufacturing systems, system 100 is expected to be able to continuously produce GMU. Firstly, including the desulfurization unit 140 offers several advantages. For example, GMU with a lower sulfur content generates less slag when melted in a downstream electric arc furnace, thus saving associated time, cost, and energy consumption. For example, relatively low sulfur and / or carbon content can improve the throughput of downstream electric arc furnaces (EAFs) and / or ladle metallurgical furnaces (LMFs), increasing production. Also, using GMU with a low sulfur content makes it easier to maintain the desired chemical composition and temperature, reducing the frequency of adjustments and interruptions during the melting cycle. In addition, lower sulfur levels result in less wear on other components of the system, reducing the need for maintenance and the associated downtime.

[0025] Secondly, by including multiple granulation units 150, molten metal can be granulated in parallel in separate granulation units. Furthermore, the presence of multiple granulation units 150 allows them to function as backups for each other if any of them stop working (e.g., due to component failure, maintenance, etc.) or during blowouts. Moreover, in some embodiments, the various components of the granulation unit 150 are modular. For example, each component can be easily and independently removed (e.g., for maintenance) and / or replaced (e.g., by an overhead crane) without affecting the operation of other components.

[0026] As described above, System 100 is designed for continuous operation. Compared to discontinuous GPI manufacturing systems, embodiments of this technology improve energy efficiency and reduce emissions by minimizing the need for frequent shutdowns and restarts associated with excessive exhaust and / or inefficient operation. As described herein, some embodiments include (i) a desulfurization unit that reduces sulfur dioxide (SO2) emissions by reducing the sulfur content in the molten metal; (ii) a dust collection unit that reduces air pollution by filtering and removing particulate matter; (iii) infrastructure that reduces the environmental impact of raw material extraction and protects natural resources by recycling fine powder, slag, iron skull, and other residual and / or previously processed metals; and / or (iv) a water management and cooling system that minimizes heat loss, improves the thermal efficiency of the production process, and optimizes water consumption. Overall, the GMU continuous manufacturing system 100 contributes to more sustainable industrial practices and helps mitigate climate change by increasing productivity while minimizing greenhouse gas emissions and waste.

[0027] Furthermore, conventional iron production has a significant environmental impact due to high energy consumption and the emission of pollutants. Therefore, embodiments of this technology related to GMU manufacturing systems can mitigate these impacts. Sulfur, phosphorus, and silicon in GPI adversely affect the quality and properties of the final metal product, leading to problems such as reduced ductility, toughness, and weldability, as well as 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. Specifically, sulfur accelerates wear and corrosion of metalworking machines, increasing maintenance costs and reducing equipment lifespan. Embodiments of this technology include methods for partially removing these impurities, which can improve the quality and durability of the final metal product, extend the efficiency and lifespan of processing equipment, and lead to cost reductions and a more sustainable manufacturing method.

[0028] Figure 3 is a schematic partial lateral cross-sectional view of a BOF container 112 configured according to an embodiment of the present technology. As described above with reference to Figure 1, the BOF container 112 can be used when route A is adopted. The BOF container 112 may include a shell 302 (e.g., a steel shell) that defines an internal chamber for receiving material, and a liner material 303 (e.g., a fire-resistant liner) along the inner surface of the shell 302. The shell 302 may include a plug hole 304 from which the BOF container 112 can feed material, and a smoke collection hood or pipe 306 extending from the top of the shell 302. As shown, one or more oxygen lances 308 can be inserted into the internal chamber of the BOF container 112.

[0029] During operation, the BOF container 112 can receive molten metal 305 from a transfer vessel, such as a torpedo car coming from the blast furnace 102. In some embodiments, molten slag 307 may be present on the surface of the molten metal 305. An oxygen lance 308 can be operated to supply oxygen gas (e.g., from an oxygen storage area 204) to the molten metal 305 and molten slag 307. The oxygen gas can heat the molten metal 305 and reduce its carbon content at the same time by burning off any residual carbon in the material (e.g., leftover coke). Although the molten metal 305 may have cooled during transport from the blast furnace 102 to the BOF container 112, the temperature of the molten metal 305 can be raised to a desired temperature range where premature solidification of the molten metal 305 is avoided. As those skilled in the art will understand, by keeping the molten metal 305 in a fluid state, appropriate granulation can be easily carried out downstream of the BOF container 112. The waste generated in the BOF container 112 can be sent to the dust collection unit 190 or other waste collection unit via a smoke collection hood or pipe 306.

[0030] Figure 4 is a schematic plan view of two granulation units 450 in a first arrangement, configured according to an embodiment of the present technology. In the illustrated embodiment, the first granulation unit 450a and the second granulation unit 450b are arranged side by side. In the first arrangement, the components of the first granulation unit 450a and the second granulation unit 450b can be arranged in the same or substantially similar layout. Each granulation unit 450 may include a tilting device 410, a tundish 420, a granulation reactor 430, an ejector 440, a dewatering assembly 460, and a classifier assembly 470. The tilting device 410 may be sized and positioned to accommodate one transfer container 122 (e.g., a ladle carried by an overhead crane 130). The tundish 420 may be positioned to receive molten metal from the transfer container 122 and supported directly above the granulation reactor 430. The dewatering assembly 460 can be located next to the tilting device 410 and the granulation reactor 430. The ejector 440 can extend between the granulation reactor 430 and the dewatering assembly 460. The classifier assembly 470 can be located next to the dewatering assembly 460.

[0031] In particular, many of the components of the granulation unit 450, such as the dewatering assembly 460 and the classifier assembly 470, are arranged side by side rather than overlapping each other vertically, for example. This allows the overhead crane 130 to access each component more easily and to lift and remove the components for maintenance and / or replacement. As will be further discussed herein, each component may include a lift lug that the overhead crane 130 can hook onto and lift and move. This layout can be in contrast to conventional facilities where components are arranged overlapping each other, making it difficult to quickly lift and remove them by a crane.

[0032] Figure 5 is a schematic plan view of two granulation units 550 in a second arrangement, configured according to an embodiment of the present technology. In the illustrated embodiment, the first granulation unit 550a and the second granulation unit 550b are arranged side by side. Unlike the first arrangement shown in Figure 4, in the second arrangement, the components of the first granulation unit 550a and the components of the second granulation unit 550b are not arranged in the same or substantially similar layout. Instead, they are arranged substantially mirror-like, with the tilting devices 410, tundishes 420, and granulation reactors 430 of the two granulation units 550 positioned at opposite ends relative to the same components of the other granulation unit 550. The dewatering assembly 460 and the classifier assembly 470 are positioned between the tilting devices 410, tundishes 420, and granulation reactors 430 of the two granulation units 550. Compared to the first arrangement in Figure 4, the second arrangement in Figure 5 allows the two transfer containers 122 to be spaced apart from each other, and the dewatering assemblies 460 to be placed close together and facing each other. This makes it possible, for example, to recover the GMU product using a single container or conveyor.

[0033] Referring together to Figures 4 and 5, it will be understood that the illustrated embodiments merely show examples of the arrangement or layout of the granulation units, and that the components can be arranged in different ways. Furthermore, in some embodiments, the system 100 may include only one granulation unit, or it may include three, four, five, six, or more granulation units.

[0034] Figures 6A to 6C are schematic partial side views showing the tilting of the transfer container 122 according to an embodiment of the present technology. It is understood that the tilting of the transfer container 122 shown in Figures 6A to 6C may be either the first arrangement in Figure 4 or the second arrangement in Figure 5. Referring to Figure 6A, an overhead crane 130 (not shown) can carry the transfer container 122 containing molten metal and place it on the tilting device 410. A control device 612 can be operably connected to the tilting device 410 to control the tilting of the transfer container 122. In some embodiments, for safety reasons, the operator and other workers are positioned to the left of the granulation reactor 430, and the overhead crane 130 does not intersect with the workers' path.

[0035] Referring together to Figures 6B and 6C, the tilting device 410 may include a linear actuator 614 or other powered component that can lift and tilt the transfer container 122. By tilting the transfer container 122, the molten metal inside can be transferred (e.g., poured) into the tundish 420. The control device 612 can operate the linear actuator 614 to tilt the transfer container 122 in a controlled manner so that the molten metal flows from the transfer container 122 into the tundish 420 at a desired flow rate without, for example, excessive overflow or splashing of molten metal from the tundish which could lead to material loss. As shown in Figure 6C, the tilting device 410 can tilt the transfer container 122 at an angle greater than 90 degrees.

[0036] Figures 7, 8A, and 8B are a front perspective view, a rear perspective view, and a side cross-sectional view of a tundish 420 configured according to an embodiment of the present art, respectively. The tundish 420 may include a tundish body 740, a cover 748 positioned over at least a portion of the tundish body 740, and an overflow channel 745 detachably connected to the front of the tundish body 740. The tundish body 740 may define a cavity that can receive and hold molten metal. More specifically, the cavity may include an upper opening 742 located near the rear of the tundish body 740 that is not covered by the cover 748 and receives a flow of molten metal from the transfer container 122, and an outlet 743 located at the bottom of the tundish body 740, near the front end of the tundish body 740. As best shown in Figure 8B, the tundish body 740 may have a sloping bottom surface that allows molten metal to flow down toward the outlet 743. In some embodiments, the tundish 420 further includes a nozzle 847 at the outlet 743 to ensure controlled flow of molten metal out of the outlet 743. The nozzle 847 may be made of silica carbide, graphite, a non-wetting material, and / or other suitable material. In some embodiments, the nozzle 847 may be vibrating. The inner surface of the tundish body 740 defining the cavity may be lined with a lining material 747 such as refractory lining, silica, alumina, magnesium-free material, and / or other suitable lining. For example, the lining material 1347 may be the same or similar material as the sacrificial refractory lining contained in the blast furnace 102. A portion of the bottom surface of the tundish body 740 directly below the upper opening 742 may be covered with an impact pad 849 (Figure 8B) that can absorb the impact of the molten metal flow being transferred (e.g., poured) from the transfer container 122.

[0037] In some embodiments, the tundish 420 further includes one or more flow control devices 845 (e.g., molten steel hydrostatic flow control devices) connected to the side wall of the tundish body 740 and extending at least partially (e.g., downward, upward, or laterally) into the cavity. The flow control devices 845 may be static in structure or adjustable in structure whose position and / or orientation relative to the tundish body 740 can be controlled. In some embodiments, the flow control devices 845 include a solid plate. In some embodiments, the flow control devices 845 include a plate through which one or more holes penetrate and / or are aligned at one or more angles. In some embodiments, the tundish 420 further includes a level sensor 749a attached to the side wall of the tundish body 740, and / or one or more load sensors 749b attached to the bottom surface of the tundish body 740. Furthermore, the tundish 420 may include a plurality of trunnions or lifting lugs 741 connected to the side wall of the tundish body 740 and extending outward.

[0038] To avoid obscuring specific details of the tundish 420, the cover 748 shown in Figure 7 is omitted in Figures 8A and 8B, but can be positioned to prevent splashing and overflow of molten metal from the tundish 420, which, without which would lead to significant material loss. As shown in Figure 7, the cover 748 can be shaped and sized such that the upper opening 742, which receives the molten metal flow from the transfer container 122, remains exposed, located near the rear end of the tundish 420. The cover 748 includes a refractory lining (patterned in Figure 7) which also prevents other materials (e.g., molten metal or slag splashed from the transfer container 122) from entering the tundish 420 at locations other than the upper opening 742. The cover 748 may have a curved edge 749 on the front end side of the tundish 420 that exposes a portion of the cavity directly above the outlet 743. In some embodiments, a stopper rod assembly (referring to and described below in further detail with reference to Figures 9 and 10) can be coupled to the front of the tundish 420 so that the stopper rod assembly extends into the portion of the cavity exposed by the curved edge 749 and reaches the outlet 743. It will be understood that the cover 748 may have other shapes and / or sizes to prevent spillage while allowing the stopper rod assembly to reach the outlet 743.

[0039] The overflow channel 745 can define an overflow outlet 746 through which excess material can drain from the tundish 420. As best shown in Figure 8B, the overflow outlet 746 can be positioned higher than the outlet 743 so that molten metal drains out of the tundish 420 primarily through the outlet 743. The overflow channel 745 can be detachably connected to the tundish body 740, for example, via bolts and / or other fasteners. When transporting the tundish 420 to a cleaning / repair area, the overflow channel 745 can be detached from the tundish body 740, which is advantageous for easier handling. For example, the cleaning / repair area may include a machine capable of inverting the tundish 420, and detaching the overflow channel 745 makes it easier to place the tundish 420 on the machine.

[0040] During operation, the molten metal flowing out of the transfer container 122 is received at the upper opening 742 of the tundish 420. The cover 748 can help ensure that only the molten metal flow enters the tundish 420 and can also prevent splashes from overflowing from the sides of the tundish body 740. After the molten metal flow hits the impact pad 849, the molten metal flows downward toward the outlet 743 and can eventually accumulate in the cavity. The surface level of the molten metal can be measured by the level sensor 749a and the weight of the molten metal in the cavity can be measured by the load sensor 749b. In some embodiments, the measurements from the level sensor 749a and / or the load sensor 749b are transmitted to the control device 612 (A-C in Figure 6) to control the tilt angle of the transfer container 122 to achieve a desired flow rate at any given time. For example, if the level sensor 749a and / or the load sensor 749b indicate that there is too much molten metal, the control device 612 may reduce the tilt angle, for example, until the level sensor 749a and / or the load sensor 749b indicate that a sufficient amount of molten metal has flowed out of the outlet 743 and / or the overflow outlet 746, allowing the transfer container 122 to be tilted further.

[0041] The flow control device 845 can perform multiple functions. Firstly, the flow control device 845 can suppress agitation of the molten metal at the rear of the tundish 420. When the molten metal is transferred (e.g., poured) from the transfer container 122, its flow can cause splashing, waves, or other forms of turbulence around the upper opening 742. The flow control device 845 can act as a barrier to prevent agitation from moving toward the outlet 743. In some embodiments, the flow control device 845 is controllable to adjust its height. As a result, the molten metal flow out of the tundish 420 through the outlet 743 can be made relatively calm and / or laminar. Secondly, the flow control device 845 can act as a barrier to prevent slag or other impurities suspended on or near the surface of the molten metal from moving toward the outlet 743. Slag accumulated at the upper opening 742 can be scooped off the surface or eventually discharged from the tundish 420 through the overflow outlet 746. As a result, the molten metal flowing out of the tundish 420 through the outlet 743 can be made relatively slag-free. Thirdly, the flow control device 845 can act as an vortex suppressor that can prevent, or at least suppress, the formation of vortices in the molten metal. It is understood that the tundish 420 may include multiple flow control devices 845, and that different flow control devices 845 may have different shapes and / or dimensions and / or extend in different directions to provide the various functions described herein.

[0042] In the illustrated embodiment, the tundish 420 includes a total of four lifting lugs 741, as best shown in Figures 7 and 8A. The overhead crane 130 (Figure 1) can be operated to lift, lower, and / or transport the tundish 420 using the lifting lugs 741. For example, the distance between the tundish 420 and other components of the granulation unit 150 can be increased or decreased by repositioning the tundish 420 to a lower or higher position using the overhead crane 130. In another example, the overhead crane 130 can be used to remove the tundish 420 from the granulation unit 150, for example, for maintenance. Since the system 100 is a continuous system and there may be no conventional "downtime" in which components can be maintained on-site, the ability to quickly and easily transport the tundish 420 for maintenance or replacement can be important in ensuring that the system 100 remains in continuous operation.

[0043] Figure 9 is a perspective view of a stopper rod assembly 980 configured according to an embodiment of the present technology. The stopper rod assembly 980 may include a base plate 982, a vertical member 984 extending vertically from the base plate 982, a horizontal member 986 extending horizontally from the vertical member 984, a motor 985 operably connected to the vertical member 984 and / or the horizontal member 986, and a stopper rod 988 extending downward from the tip of the horizontal member 986. The base plate 982 is connectable to a tundish 420 and, for example, bolted to the tundish body 740. The stopper rod 988 may be shaped and sized to fit the outlet 743 and / or nozzle 847 of the tundish 420. In some embodiments, the stopper rod 988 includes a refractory lining or other suitable lining to protect the stopper rod 988 from hot molten metal. During operation, a control device (not shown) is used to drive the motor 985, which moves the horizontal member 986 and thus the stopper rod 988 vertically along the length of the vertical member 984. Therefore, by remotely controlling the stopper rod 988, the outlet 743 of the tundish 420 can be selectively blocked, thereby controlling the flow of molten metal out of the tundish 420.

[0044] Figure 10 is a perspective view showing the assembled tundish 1040 and stopper rod assembly 1050 configured according to an embodiment of the present technology. Although Figure 10 shows a different embodiment of the tundish and stopper rod assembly from Figures 7 to 9, it is understood that the tundish 420 and stopper rod assembly 980 shown in Figures 7 to 9 can be assembled similarly. In the illustrated embodiment, the tundish 1040 includes a tundish body 1041, a cover 1048 positioned on top of the tundish body 1041, and an overflow channel 1045 detachably coupled to the front side of the tundish body 1041. The stopper rod assembly 1050 may include a mounting frame 1051, an actuator 1056 (e.g., a linear actuator) fixed to the mounting frame 1051, a vertical member 1052 connected to the actuator 1056 and extending upward, a horizontal member 1054 extending horizontally from the upper end of the vertical member 1052, and a stopper rod 1058 connected to the tip of the horizontal member 1054 and extending downward. As shown in the figure, the mounting frame 1051 can be attached to the outer wall of the tundish body 1041 via fasteners, brackets, or other connecting mechanisms. More specifically, the mounting frame 1051 can be fixed in a position aligned with the outlet 1043 of the tundish 1040. The horizontal member 1054 may extend beyond the side wall of the tundish body 1041 so that the stopper rod 1058 hangs directly above the outlet 1043.

[0045] During operation, the actuator 1056 can move the vertical member 1052 between a raised position (shown in Figure 10) and a lowered position. When the vertical member 1052 is in the raised position, the stopper rod 1058 is separated from the outlet 1043, allowing molten metal to flow out of the outlet 1043. When the vertical member 1052 is in the lowered position, the stopper rod 1058 can at least partially block the outlet 1043, obstructing the passage of the molten metal flow. Those skilled in the art will understand that by precisely controlling the actuator 1056, the position of the stopper rod 1058 can be adjusted to various heights between the raised and lowered positions, thereby blocking the outlet 1043 to various degrees. Thus, by controlling the actuator 1056, the flow rate through the outlet 1043 of the tundish 1040 can be controlled at various levels.

[0046] Attaching the stopper rod assembly 1050 directly to the tundish 1040, rather than to a frame structure supporting the tundish 1040, for example, is advantageous in that it enhances the level of safety during operation. For example, if the stopper rod 1058 becomes stuck at the outlet 1043 or elsewhere, the tundish 1040 and the stopper rod assembly 1050 can be removed together for repair. If the stopper rod assembly 1050 is attached to another structure (for example, a frame structure that cannot be easily removed from the field), separating the tundish 1040 and the stopper rod assembly 1050 in the field can be difficult and dangerous.

[0047] Figure 11 is a schematic cross-sectional view of a granulation reactor 430 configured according to an embodiment of the present technology. The granulation reactor 430 may include a reactor body 1160 and a spray head or target 1163 connected to the reactor body 1160. The reactor body 1160 may define a cavity 1166 inside and an overflow channel 1162 extending to surround the top of the cavity 1166. As shown, the cavity 1166 and the overflow channel 1162 may open at the top to receive material from above. More specifically, the cavity 1166 may be positioned to receive molten metal flowing out of a tundish 420 through an outlet 743 and a nozzle 847. The reactor 430 may include an outlet 1168 for the cavity 1166 at the bottom of the reactor body 1160. The overflow channel 1162 can be configured to receive material overflowing from the tundish 420 (e.g., molten metal mixed with slag). For example, the length of the overflow channel 745 (of the tundish 420) can be set so that the overflow material flows down into the overflow channel 1162 (of the granulation reactor 760). The overflow material received in the overflow channel 1162 can be removed through an outlet and sent for further processing. In some embodiments, the granulation reactor 430 further includes a lifting lug connected to the reactor body 1160 so that the granulation reactor 430 can be easily lifted by an overhead crane 130.

[0048] The target 1163 can be fixed in the center of the cavity 1166. For example, in some embodiments, the target 1163 is fixed via one or more supports (e.g., a tripod) extending from the reactor body 1160. Cooling water can enter the cavity 1166 through the reactor body 1160 and be stored and / or circulated.

[0049] During operation, the granulation reactor 430 receives cooling water continuously or intermittently from the cooling system 160, so that at least a portion of the cavity 1166 is filled with cooling water. The volume of the cavity 1166 can be 10,000 to 1,000,000 gallons or 20,000 to 40,000 gallons. The molten metal flowing down from the tundish 420 can collide with the target 1163. The target 1163 can be shaped and sized so that the molten metal is scattered in different directions. The molten metal that enters the cooling water is cooled and granulated. Those skilled in the art will understand that the distance the molten metal falls between the tundish 420 and the target 1163 can affect the shape, size, and quality of the resulting granular product. As described above, the height of the tundish 420 relative to the target 1163 can be adjusted with the overhead crane 130 to produce granular products with desired properties (e.g., shape, size, quality). The formed granular product can be exited from the granulation reactor 430 via outlet 1168.

[0050] Figures 12A and 12B are a schematic side view and an enlarged side cross-sectional view, respectively, of an ejector 440 configured according to an embodiment of the present technology. Referring to Figure 12A, the ejector 40 may include an inlet 1272 and a jet inlet 1273, and the ejector 440 may be connected to a lift line 1274 having a first lockbox 1275a, a second lockbox 1275b, and an outlet 1278. The inlet 1272 may be positioned at the outlet 1168 of the granulator 430 to receive granular product. In the illustrated embodiment, the inlet 1272 has a funnel shape substantially corresponding to the shape of the lower part of the granulator 430. The jet inlet 1273 may be connected to receive a jet of water and / or compressed air that can provide sufficient pressure to push the granular product up the lift line 1274. In the illustrated embodiment, the ejector 440 and the lift line 1274 are attached to the rail 1276, which allows the ejector 440 and the lift line 1274 to be easily removed from the granulation unit 150 for maintenance, thereby giving the granulation unit 150 modularity.

[0051] Next, referring to Figure 12B, which shows an enlarged side cross-sectional view of the first lockbox 1275a, the first lockbox 1275a can be connected internally to the lift line 1274 where the lift line 1274 changes angle. In other words, the first lockbox 1275a functions as a corner space or dead zone extended from the lift line 1274. During operation, as the granular product and water and / or compressed air flow from the granulation reactor 430 flows through the lift line 1274, the first lockbox 1275a can collect the granular material 1277. The granular material 1277 can remain in the corners of the first lockbox 1275a due to the velocity and pressure of the fluid. Therefore, the first lockbox 1275a can help reduce wear on the lift line 1274 by effectively dealing with the impact and abrasion caused by the granular material changing direction, and the accumulation of granular material 1277 can act as a buffer that absorbs the impact of the incoming material and reduces the flow velocity. In some embodiments, the lift line 1274 is lined with a liner material 1271 such as ceramic, silicon carbide, titanium, tungsten carbide, and / or other suitable material.

[0052] Figure 13 is a schematic side view of a dewatering assembly 460 configured according to an embodiment of the present technology. The dewatering assembly 460 may include a frame structure 1381, a dewatering screen 1384 supported by the frame structure 1381, and an imaging device 1385 positioned to capture an image of the product on the dewatering screen 1384. The outlet 1278 of the lift line 1274 may be connected to the inlet 1382 of the dewatering assembly 460 so that the dewatering screen 1384 can receive moist granular product from the granulation reactor 430 via the ejector 440. The dewatering assembly 460 may further include an outlet chute 1386 at the end of the dewatering screen 1384 so that the sieved product can be collected separately.

[0053] During operation, as granular product from the lift line 1274 moves from the inlet 1382 to the outlet chute 1386, the dewatering screen 1384 can filter out water and particles below the threshold size. The threshold size can be 0.1 to 10 mm, for example, about 0.1 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. The filtered particles can be fed towards the classifier assembly 470 via the pipe 1388 located below the dewatering screen 1384, and the product reaching the outlet chute 1386 can form the GMU product. In some embodiments, an imaging device 1385 can be used to perform optical particle size analysis with visual inspection of the particle size distribution. If the particles as a whole are smaller than expected or desired, it may indicate that the flow rate of the molten metal is too high. Therefore, the images captured by the imaging device 1385 can be used in a feedback loop with components of the flow rate management system 100, such as (i) a control device 612 that controls the tilt angle of the transfer container 122, (ii) a control device that adjusts the position of the flow rate control device 845 in the tundish 420, (iii) a motor 985 or actuator 1056 that adjusts the height of the stopper rod 988 or 1058, and / or (iv) an overhead crane 130 that adjusts the height of the tundish 420 relative to the granulation reactor 430.

[0054] Figure 14 is a schematic side view of a classifier assembly 470 configured according to an embodiment of the present technology. The classifier assembly 470 may include a housing 1492 having an inlet 1494 and an outlet chute 1498 connectable to a pipe 1388. During operation, the inlet 1494 can receive slurry (e.g., water and GMU fines) from the dewatering assembly 460 via the pipe 1388. The GMU fines can be separated and discharged via the outlet chute 1498 for individual recovery. The remaining water can be discharged, for example, to a return water sump 202.

[0055] Figure 15 is a schematic process flow diagram showing metal granulation according to an embodiment of the present technology. A transfer vessel 122 can transport molten metal from the blast furnace 102 and / or the desulfurization unit 140 to the granulation unit 150 (see Figure 1). A control device 612 can control the tilt angle of the transfer vessel 122 and operate a tilting device 410 to transfer (e.g., pour) molten metal from the transfer vessel 122 to the tundish 420 at a desired flow rate. The transfer vessel 122 may include a slide gate or valve with associated control devices. In some embodiments, the granulation unit 150 further includes a trough, bucket, tray, or other recovery device positioned below the transfer vessel 122 and / or the tundish 420 to receive any spilled molten metal or other material. A fume hood 1502 may be positioned to collect waste from the molten metal flowing through the tundish 420. The stopper rod assembly 980 can be connected to the tundish 420 and actuated to control the flow of molten metal from the tundish 420 to the granulation reactor 430.

[0056] The granulation reactor 430 can receive cooling water from a chilled water supply source. Molten metal leaving the tundish 420 can be impacted against a target in the granulation reactor 430 and sprayed in a spray onto the water accumulated inside the granulation reactor 430. The granulation reactor 430 can granulate the molten metal to form granular products, such as by cooling the molten metal. The heated water can be sent to a tank and then to a hotwell pump and finally returned to the cooling system 160. In some embodiments, a drain pump 1532 is included between the granulation reactor 430 and the tank for maintenance purposes. The ejector 440 can receive ejector water and / or compressed air and transfer the granular products from the granulation reactor 430 to the dewatering assembly 460. The dewatering assembly 460 can dry the granular products and filter them (e.g., by particle size) to produce GMU products. In some embodiments, the granulation unit 150 is configured to produce GMU at a rate matching the production rate of the blast furnace 102. The filtrate from the dewatering assembly 460 can be sent to a classifier assembly 470, which can sort the material to produce GMU fine powder. The waste from the classifier (e.g., residual water and particulate matter contained therein) can be sent to the return water sump 202 or other treatment. The various components of the granulation unit 150 can be driven electrically, hydraulically, and / or otherwise.

[0057] III. Manufacturing Method of GMU Figure 16 is a flowchart of Method 1600 for producing a GMU in a molten metal processing unit according to an embodiment of the present technology. The steps of Method 1600 are described below in a specific order, but one or more steps may be performed in a different order or omitted, and Method 1600 may include additional and / or alternative steps. Furthermore, Method 1600 described below may be described with reference to embodiments of the present technology described herein, but Method 1600 may also be carried out using other embodiments of the present technology.

[0058] Method 1600 begins in block 1602 by transferring molten metal to a ladle in a molten metal processing unit. In some embodiments, the transfer includes operating a torpedo car to transfer molten metal from a blast furnace outside the molten metal processing unit to a ladle inside the molten metal processing unit.

[0059] In block 1604, method 1600 continues by transporting the ladle to a granulation unit within the molten metal processing unit. The granulation unit may include a tilting device positioned to receive and tilt the ladle. In some embodiments, the molten metal processing unit includes a plurality of granulation units, and transport may include transporting the ladle to one of the plurality of granulation units. In some embodiments, transport may include operating an overhead crane of the molten metal processing unit to transport the ladle to the granulation unit.

[0060] In block 1606, method 1600 is continued by tilting the ladle using a tilting device to transfer the molten metal to the tundish of the granulation unit. For example, the tilting device may include a linear actuator, and a control device operably connected to the linear actuator can be used to tilt the ladle in a controlled manner so that the molten metal entering the tundish is at a desired flow rate.

[0061] In block 1608, method 1600 continues by discharging the molten metal from the tundish toward the reactor of the granulation unit. In some embodiments, method 1600 further includes moving (e.g., oscillating) a stopper rod to control the flow rate of molten metal flowing out of the tundish outlet.

[0062] In block 1610, method 1600 is continued by granulating the molten metal in the reactor to form metal granules (GMU). For example, the reactor may contain cooling water, and the molten metal may be dropped, poured, sprayed, or otherwise transferred into the water to cool the molten metal into GMU.

[0063] In some embodiments, method 1600 further includes supplying molten metal to a BOF container of a molten metal processing unit and supplying oxygen to the molten metal in the BOF container before block 1602. The molten metal can then be transferred from the BOF container to a ladle. The supply of oxygen may include heating the molten metal in the BOF container and / or reducing its carbon content. In some embodiments, method 1600 further includes reducing the sulfur content of the molten metal, such as by adding at least one of calcium carbide or magnesium to the molten metal.

[0064] IV. Examples This technology is described in accordance with various embodiments, for example, as numbered embodiments (1, 2, 3, etc.) for convenience. These are provided as embodiments and are not limiting to this technology. Note that any of the dependent embodiments can be combined in any combination and each can be included in an independent embodiment. Other embodiments can be presented in the same manner.

[0065] 1. A molten metal processing system for producing granular metal materials (GMU), Including a molten metal processing unit, The molten metal processing unit is A granulation unit includes a tilting device positioned to receive a ladle, a control device operably connected to the tilting device to control the tilting of the ladle, a tundish positioned to receive molten metal from the ladle, and a reactor positioned to receive the molten metal from the tundish. The reactor is configured to cool the molten metal to form a GMU, the system.

[0066] 2. The molten metal processing unit is, The ladle is configured to receive and contain the molten metal, The system according to any embodiment of this specification further includes an overhead crane configured to transport the ladle to and from the tilting device.

[0067] 3. The molten metal processing unit is, A basic oxygen converter (BOF) vessel configured to receive the molten metal, The system according to any of the embodiments herein further comprises an oxygen lance insertable into the BOF container for supplying oxygen gas to the molten metal.

[0068] 4. The system according to any embodiment herein, wherein the molten metal processing unit further comprises an oxygen lance configured to supply oxygen gas to the molten metal, the oxygen gas configured to react with carbon in or on the molten metal to heat the molten metal.

[0069] 5. The system according to any embodiment herein, wherein the molten metal processing unit further comprises an oxygen lance configured to supply oxygen gas to the molten metal, the oxygen gas configured to react with carbon in or on the molten metal to reduce the carbon content of the molten metal.

[0070] 6. The system according to any of the embodiments herein, wherein the molten metal processing unit further comprises a desulfurization unit configured to reduce the sulfur content of the molten metal.

[0071] 7. The system according to any embodiment herein, wherein the molten metal processing unit further comprises a desulfurization unit configured to reduce the sulfur content of the molten metal, the desulfurization unit configured to reduce the sulfur content of the molten metal by supplying the molten metal with at least one of calcium carbide or magnesium.

[0072] 8. The ladle includes a first ladle, the granulation unit includes a first granulation unit, and the molten metal processing unit further includes a second ladle and a second granulation unit arranged adjacent to the first granulation unit. The second granulation unit is, A second tilting device is positioned to receive and tilt the second ladle, A second control device operably connected to the second tilting device and controlling the tilting of the second ladle, A second tundish positioned to receive the molten metal from the second ladle, The system includes a second reactor positioned to receive the molten metal from the second tundish, The system according to any of the embodiments herein, wherein the second reactor is configured to cool the molten metal to form metal granules (GMU).

[0073] 9. The system according to any embodiment herein, wherein the granulation unit further includes a stopper rod assembly connected to the tundish, the stopper rod assembly including a stopper rod and an actuator operably connected to move the stopper rod in and out of the outlet of the tundish.

[0074] 10. The system according to any embodiment of this specification, wherein the granulation unit further includes an ejector positioned to receive the GMU from the reactor and a lift line positioned downstream of the reactor, the lift line including a curved region, the ejector further including a lock box in the curved region, the lock box configured to receive and store a portion of the GMU received by the ejector.

[0075] 11. The system according to any embodiment herein, wherein the granulation unit further comprises an ejector positioned to receive the GMU from the reactor and a lift line positioned downstream of the reactor, the inner surface of which the lift line is lined with a liner material comprising ceramic, silicon carbide, titanium, and / or tungsten carbide.

[0076] 12. The system according to any embodiment herein, wherein the granulation unit further comprises a dewatering assembly located downstream of the reactor, the dewatering assembly being configured to dry the GMU and filter the GMU by particle size.

[0077] 13. The dehydration assembly is configured to filter GMU fine powder with a particle size of less than 1 millimeter, as described in any of the examples herein.

[0078] 14. The system according to any embodiment of this specification, wherein the granulation unit further includes an imaging device positioned to take an image of the GMU on the dewatering assembly, and the image taken by the imaging device is configured to be used in an optical particle size feedback system to adjust the flow rate of the molten metal entering the reactor.

[0079] 15. The system according to any embodiment of this specification, wherein the granulation unit further comprises a classifier assembly located downstream of the dewatering assembly, the classifier assembly being configured to classify the filtrate received from the dewatering assembly to produce GMU fine powder.

[0080] 16. The granulation unit further includes a dewatering assembly located downstream of the reactor and a classifier assembly located downstream of the dewatering assembly, The system according to any embodiment of this specification, wherein the overhead crane is further configured to selectively and individually lift the tundish, the reactor, the dewatering assembly, or the classifier assembly.

[0081] 17. The system according to any embodiment of this specification, wherein the molten metal processing unit further comprises a dust collection unit, and the granulation unit further comprises a fume hood arranged to collect waste from the tundish and to discharge the waste toward the dust collection unit.

[0082] 18. The system according to any embodiment of this specification, wherein the molten metal processing unit further comprises a transfer container preparation unit configured to remove slag and quiche from the ladle.

[0083] 19. The system according to any embodiment of this specification, further comprising a cooling system configured to supply cooling water to the reactor, wherein the molten metal processing unit further comprises a cooling system.

[0084] 20. A blast furnace configured to melt iron ore to produce the molten metal, The system according to any embodiment of this specification, further comprising a torpedo car configured to transport the molten metal from the blast furnace to the molten metal processing unit.

[0085] 21. A method for producing metal granules (GMU) in a molten metal processing unit, Transferring the molten metal to the ladle of the molten metal processing unit, The granulation unit of the molten metal processing unit includes a tilting device positioned to receive and tilt the ladle, and the ladle is transported to the granulation unit. The ladle is tilted via the tilting device to transfer the molten metal to the tundish of the granulation unit. Discharging the molten metal from the tundish toward the reactor of the granulation unit, and The method comprising granulating the molten metal in the reactor to form a GMU.

[0086] 22. Supplying the molten metal to the basic oxygen converter (BOF) container of the molten metal processing unit, and The method further includes supplying oxygen to the molten metal in the BOF container to form a decarburized molten metal, Transfer is a method according to any of the embodiments herein, comprising transferring the decarburized molten metal from the BOF container to the ladle.

[0087] 23. The method of any of the embodiments herein, wherein the supply of oxygen is provided by heating the molten metal in the BOF container.

[0088] 24. The method according to any of the embodiments herein, wherein the supply of oxygen is to reduce the carbon content of the molten metal in the BOF container.

[0089] 25. The method according to any of the embodiments herein, wherein the transport includes transporting the ladle to one of a plurality of granulation units of the molten metal processing unit.

[0090] 26. The method according to any of the examples herein, further comprising reducing the sulfur content of the molten metal.

[0091] 27. The method of reducing the sulfur content as described in any of the examples herein, comprising adding at least one of calcium carbide or magnesium to the molten metal.

[0092] 28. The method according to any embodiment of this specification, further comprising moving a stopper rod to control the flow rate of the molten metal flowing out of the outlet of the tundish.

[0093] 29. The method according to any embodiment of this specification, wherein the transport includes transporting the ladle to the granulation unit by operating the overhead crane of the molten metal processing unit.

[0094] 30. The method according to any embodiment of this specification, wherein the transfer includes operating a torpedo car to transfer the molten metal from a blast furnace outside the molten metal processing unit to the ladle inside the molten metal processing unit.

[0095] V. Conclusion Those skilled in the art will see that modifications may be made to the details of the embodiments described above without departing from the underlying principles of this disclosure. 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 this art. In this specification, steps of multiple methods may be presented in a particular order, but in alternative embodiments, multiple steps may be performed in a different order. Similarly, certain aspects of the art disclosed in relation to a particular embodiment may be combined with or excluded in other embodiments. Furthermore, advantages associated with certain embodiments of the art of this disclosure may be disclosed in relation to those embodiments, but other embodiments may also exhibit such advantages, and not all embodiments are required to exhibit such advantages or other advantages disclosed herein so that all embodiments fall within the scope of the art. Thus, this 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.

[0096] Throughout this disclosure, the singular forms “a,” “an,” and “the” include plural references unless the context explicitly indicates otherwise. In addition, the terms “comprising,” “including,” and “having” should be interpreted as including at least the listed(plural) features so as not to exclude any more than a number of the same features and / or additional types of features.

[0097] References herein to “one embodiment,” “an embodiment,” “some embodiments,” or similar formulations 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, the appearance of such words or formulations herein does not necessarily refer to all of the same embodiments. Furthermore, various specific features, structures, operations, or characteristics may be combined in any preferred manner in one or more embodiments.

[0098] Unless otherwise specified, all numbers representing concentrations, shear strengths, and other numerical values ​​used herein and in the claims should be understood to be modified in all cases by the term “approximately.” “Approximately” as used herein can represent a range of plus or minus 10% of the stated value. Therefore, unless otherwise indicated, the numerical parameters set forth in the following specification and the appended claims are approximations that may vary depending on the desired properties to be obtained by the present art. At the very least, and without attempting to limit the application of the doctrine of equivalents to the claims, each numerical parameter should be interpreted by applying ordinary rounding techniques, taking into account the stated number of significant figures. Furthermore, all ranges disclosed herein should be understood to encompass any and all subranges contained therein. For example, the range “1 to 10” is intended to include all subranges between (and including) the stated minimum value of 1 and the stated maximum value of 10, i.e., all subranges having a minimum value of 1 or more and a maximum value of 10 or less, for example, 5.5 to 10.

[0099] The foregoing disclosure should not be interpreted as reflecting an intention that any claim requires more features than expressly stated 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. Accordingly, the claims following the embodiments for carrying out the invention are expressly incorporated herein into the embodiments for carrying out the invention, and each claim stands independently as a separate embodiment. This disclosure includes all substitutions of independent claims with their dependent claims.

Claims

1. A molten metal processing system for manufacturing metal granules (GMU), The molten metal processing system includes a molten metal processing unit. The molten metal processing unit is A tilting device positioned to receive the ladle, A control device operably connected to the tilting device and controlling the tilting of the ladle, A tundish positioned to receive molten metal from the ladle, A reactor arranged to receive the molten metal from the tundish, Includes a granulation unit containing, The reactor is configured to cool the molten metal to form GMU. Molten metal processing system.

2. The molten metal processing unit is The ladle is configured to receive and contain the molten metal, The system according to claim 1, further comprising an overhead crane configured to transport the ladle to and from the tilting device.

3. The molten metal processing unit is A basic oxygen converter (BOF) vessel configured to receive the molten metal, An oxygen lance that can be inserted into the BOF container to supply oxygen gas to the molten metal, The system according to claim 1, further comprising:

4. The system according to claim 1, wherein the molten metal processing unit further includes an oxygen lance configured to supply oxygen gas to the molten metal, the oxygen gas configured to react with carbon in or on the molten metal to reduce the carbon content of the molten metal.

5. The system according to claim 1, wherein the molten metal processing unit further comprises a desulfurization unit configured to reduce the sulfur content of the molten metal, the desulfurization unit configured to reduce the sulfur content of the molten metal by supplying at least one of calcium carbide or magnesium to the molten metal.

6. The ladle includes a first ladle, the granulation unit includes a first granulation unit, the molten metal processing unit further includes a second ladle and a second granulation unit arranged adjacent to the first granulation unit, the second granulation unit is A second tilting device is positioned to receive and tilt the second ladle, A second control device operably connected to the second tilting device and controlling the tilting of the second ladle, A second tundish positioned to receive the molten metal from the second ladle, A second reactor positioned to receive the molten metal from the second tundish, Includes, The system according to claim 1, wherein the second reactor is configured to cool the molten metal to form metal granules (GMU).

7. The system according to claim 1, wherein the granulation unit further includes a stopper rod assembly connected to the tundish, the stopper rod assembly including a stopper rod and an actuator operably connected to move the stopper rod in and out of the outlet of the tundish.

8. The system according to claim 1, wherein the granulation unit further includes an ejector positioned to receive the GMU from the reactor and a lift line positioned downstream of the reactor, the lift line including a curved region, the ejector further includes a lock box in the curved region, the lock box is configured to receive and store a portion of the GMU received by the ejector.

9. The system according to claim 1, wherein the granulation unit further comprises a dewatering assembly located downstream of the reactor, the dewatering assembly being configured to filter GMU fine powder having a particle size of less than 1 millimeter.

10. The system according to claim 1, wherein the granulation unit further comprises a dewatering assembly located downstream of the reactor, the granulation unit further comprises an imaging device arranged to take an image of the GMU on the dewatering assembly, and the image taken by the imaging device is configured to be used in an optical particle size feedback system to adjust the flow rate of the molten metal entering the reactor.

11. The system according to claim 1, wherein the granulation unit further comprises a dewatering assembly located downstream of the reactor, the granulation unit further comprises a classifier assembly located downstream of the dewatering assembly, and the classifier assembly is configured to classify the filtrate received from the dewatering assembly to produce GMU fine powder.

12. The system according to claim 1, wherein the molten metal processing unit further includes a transfer container preparation unit configured to remove slag and quiche from the ladle.

13. A blast furnace configured to melt iron ore to produce the molten metal, A torpedo car configured to transport the molten metal from the blast furnace to the molten metal processing unit, The system according to claim 1, further comprising:

14. A method for producing metal granules (GMU) in a molten metal processing unit, Transferring the molten metal to the ladle of the molten metal processing unit, The granulation unit of the molten metal processing unit includes a tilting device positioned to receive and tilt the ladle, and the ladle is transported to the granulation unit. The ladle is tilted via the tilting device to transfer the molten metal to the tundish of the granulation unit, Discharging the molten metal from the tundish toward the reactor of the granulation unit, The molten metal is granulated in the reactor to form GMU, Methods that include...

15. The molten metal is supplied to the basic oxygen converter (BOF) vessel of the molten metal processing unit, The process involves supplying oxygen to the molten metal in the BOF container to form decarburized molten metal, It further includes, The method according to claim 14, wherein the transfer includes transferring the decarburized molten metal from the BOF container to the ladle.

16. The method according to claim 15, wherein the supply of oxygen includes reducing the carbon content of the molten metal in the BOF container.

17. The method according to claim 14, wherein the transport includes transporting the ladle to one of the plurality of granulation units of the molten metal processing unit.

18. The method according to claim 14, further comprising reducing the sulfur content of the molten metal, wherein the reduction of the sulfur content includes adding at least one of calcium carbide or magnesium to the molten metal.

19. The method according to claim 14, further comprising moving a stopper rod to control the flow rate of the molten metal flowing out of the outlet of the tundish.

20. The method according to claim 14, wherein the transport includes transporting the ladle to the granulation unit by operating the overhead crane of the molten metal processing unit.

Images