Equipment and process for producing metal alloys and gas treatment method

Abstract

The present invention is intended for the field of metallurgy, in particular iron and steel metallurgy in integrated mills. In particular, the present invention discloses a process and equipment for the direct production of metal alloys with a reduced carbon content, such as steel, in an electric self-reduction reactor, with the aim of achieving zero net CO2 emissions. The invention also relates to agglomerate compositions containing metal oxides and carbonaceous elements suitable for the production of metal alloys, such as low-carbon steel. Finally, the present invention discloses methods for recovering, treating and reusing gases generated during the production of the aforementioned metal alloys.

Description

EQUIPMENT AND PROCESS FOR PRODUCTION OF METAL ALLOYS AND GAS TREATMENT METHOD FIELD OF INVENTION

[0001] The present invention relates to the field of metallurgy, particularly iron and steelmaking in integrated plants. More specifically, the present invention relates to processes, equipment, and methods for the direct production of low-carbon metal alloys, such as steel, in a self-reducing electric reactor-type shaft furnace. STATE OF THE TECHNIQUE

[0002] The reduction of metal oxides to produce metal alloys is already a well-established process in metallurgy, performed in shaft furnaces (blast furnaces). This process generates reducing gas and energy at the base of the shaft furnace, and these elements are directed in countercurrent to a charge column containing alternating layers of ore and coke or charcoal in close contact. The center of the furnace and the crucible are filled with coke, a fuel derived from coal, or charcoal, which are used to operate the blast furnace. Their combustion generates reducing gas. The accumulation of these fuels in the center of the furnace or in the crucible, where the molten metal is retained, forms the so-called "coke foot." This type of process results in the production of a metal with a high carbon content, since the fuels used are hydrocarbons rich in this element.In the case of iron alloys, this intermediate metal is called pig iron, which must undergo various treatments in steel mills to be transformed into steel.

[0003] This method is called gas / solid mode in allusion to the reduction process being based on the interaction of successive layers. Solids of ore and coke, or charcoal, are loaded from the top, permeated by a reducing gas generated at the base of the blast furnace and directed in a countercurrent until it escapes through the top of the furnace. This is how blast furnaces operate, using a coke column, or "coke foot," supported at the bottom of the furnace, filling the entire crucible. This serves both to support the charge and to generate the energy and gas required for the process by injecting heated air. Furthermore, the coke column ensures gas distribution throughout the blast furnace.

[0004] Due to the arrangement of the coke foot as described, the molten metal necessarily passes through and mixes with the coke or charcoal, absorbing carbon until it reaches saturation, when it reaches the crucible at the bottom of the furnace. This carbon absorption, in the case of iron, requires a subsequent step, in which excess carbon and other contaminants are removed from the metal to obtain the final steel. These carbon reduction treatments and conversion of pig iron into steel result in significant increases in the capital and operating costs of the process.

[0005] Furthermore, due to the action of blast furnaces, which generate reducing gas, energy from burning fossil fuels, and the injection of preheated air enriched with O2 (or not) into the coke or charcoal column at the base of the furnace, the gas generated during the reduction-fusion process relies on permeation through the pores of the feedstock. This significantly slows down the reaction. In the case of blast furnaces, it can take up to 8 hours for the feedstock to descend from the top to the base. This requires large blast furnaces, with a feedstock height of between 20 and 25 meters and diameters of up to 14 meters. In addition to these bottlenecks, the reliance on coal results in a high carbon footprint for the process.

[0006] Considering the numerous problems of the current state of the art, incompatible with current climate action goals, the lack of more efficient solutions from an energy and economic point of view becomes evident, allowing, at the same time, the radical elimination of the fossil carbon footprint through biomass coal and green energy. OBJECTIVES OF THE INVENTION

[0007] The present invention aims to reveal a process and equipment for direct production of metal alloys with reduced carbon content, such as steel, in a self-reduction electric reactor, aiming at zero net CO2 emissions.

[0008] The present invention has as a second objective to reveal compositions of agglomerates containing metal oxides and carbonaceous elements suitable for the production of metal alloys, such as low carbon steel.

[0009] Furthermore, the present invention discloses methods of recovery, treatment and reuse of gases generated during the production of said metal alloys. SUMMARY OF THE INVENTION

[0010] The present invention discloses a process that allows the direct production of low-carbon metal alloys in an electric self-reduction reactor with reduced need for post-treatment, significantly reducing capital and operating production costs. These results are achieved by using metal oxide agglomerates with carbonaceous elements responsible for their reduction, dosed in an appropriate proportion. This reduction depends solely on the energy supply, providing a considerable reduction in processing time of 20 to 30 minutes, compared to 8 hours in the current method. requires the slow penetration of reducing gas and energy into each particle of the charge. This difference results in a charge column only 0.5 to 4 meters high in the self-reduction electric reactor, which eliminates the need for a coke foot, either as a supporting element or as a power source. Additionally, the molten metal accumulates in a crucible, now free of carbonaceous elements, and the final carbon content of the molten metal can be adjusted by injecting O2 via lances, if and when necessary.

[0011] In addition to the metal alloy production process, the present invention also discloses equipment with suitable configurations for this purpose. Agglomerates and their compositions are also described, as well as methods for optimizing the energy and environmental aspects of the process through the capture and reuse of the resulting gases.

[0012] The production process according to the proposed invention is based on the calculated carbon dosage in the agglomerate charge to produce metal in the typical carbon range of steels. The reduction is carried out in a self-reduction electric reactor, without coke or coal, and equipped with O2 lances for possible composition adjustments. The molten metal will be the same as that currently produced in LD / BOF (Linz-Donawitz or Basic Oxygen Furnace) converters, with only final adjustments planned in ladle furnaces or degassing units, as is currently standard practice.

[0013] Furthermore, the present invention reveals a process for producing metal alloys that uses agglomerates comprising a mixture of metal oxides and carbonaceous elements, the carbonaceous elements comprising in their composition, among others: fines of mineral coal, thermal coal, metallurgical coal or biocarbon of vegetable or animal origin, pure or in mixtures in any proportions.

[0014] The referred process comprises the generation of energy for injection into the electric self-reduction reactor produced by at least one of the following methods: plasma torch, using the same process gas energized to the plasma state, with the electrical energy coming in whole or in part from generation from this same gas; or electrical heating of the crucible, via induction or electric arc, with this electrical energy also coming, in whole or in part, from this same process gas.

[0015] Another aspect of the present invention relates to equipment for producing metal alloys especially adapted to produce metal alloys using agglomerates, comprising a mixture of metal oxides and carbonaceous elements, said equipment having means for injecting energy into the base of the self-reduction electric reactor in the agglomerate charging column without the need for a coke column, and also being provided with means for injecting O2 into the metal contained in the crucible for fine adjustment of composition.

[0016] Furthermore, the present invention also relates to a method of treating gases resulting from the production of metal alloys comprising the following steps: a) collecting gaseous by-products in the upper portion of the self-reduction electric reactor (1) through the gas collector (8); b) subjecting the gaseous by-products to treatment steps; and c) redirecting the treated by-product.

[0017] The by-product treated in step c) is redirected to energy cogeneration.

[0018] Step b) involves at least one selective removal step of CO2 and H2O.

[0019] Step b) comprises at least one water recovery step by condensation.

[0020] According to another aspect of the present invention, there is revealed an equipment for producing metal alloys comprising at least one self-reduction electric reactor comprising at least one agglomerate charging column, at least one gas collector, at least one crucible, at least one slag collector channel, at least one gas collector and at least one O2 injection lance.

[0021] Furthermore, the self-reduction electric reactor operates powered by electrical energy. Power generation for injection into the self-reduction electric reactor is produced by at least one of the following methods: plasma torch, electric induction, and / or electric arc.

[0022] The agglomerate charge column comprises a mixture of metal oxides and carbonaceous elements. These carbonaceous elements include at least: coal fines, thermal coal, metallurgical coal, or biocarbon of plant or animal origin.

[0023] Additionally, the agglomerated load is between 0.5 and 4 m in height.

[0024] The self-reduction electric reactor also comprises a crucible fitted with an electric induction coil configured to heat the liquid metal contained in the crucible.

[0025] The electric self-reduction reactor also comprises at least one O2 injection lance connected to the crucible, configured to inject oxygen directly into the crucible.

[0026] The crucible at the bottom of the self-reduction electric reactor is configured to separate the slag supernatant and the molten metal bottom for distinct leakage routes, and this collection and separation of the molten material occurs continuously and in a siphoned manner, without the need for interruptions in the operation of the self-reduction electric reactor.

[0027] The present invention also discloses a method for treating gases originating from the production of metal alloys. This method comprises the steps: collecting the gaseous byproducts in the upper portion of the self-reduction electric reactor through the gas collector, subjecting the gaseous byproducts to treatment steps, and redirecting the treated byproduct.

[0028] In the stage of redirecting the treated by-product, the treated by-product is redirected to energy cogeneration.

[0029] Furthermore, the gas treatment method involves at least one fines removal step and at least one water recovery step by condensation.

[0030] In another aspect of the present invention, the process for producing metal alloys is revealed, which comprises the steps: manufacturing agglomerates of metal oxides and carbonaceous elements, producing steel using the agglomerates of metal oxides and carbonaceous elements.

[0031] The first step comprises adding to a mixer at least one binding agent in a proportion of 1% to 5% in mass, biocarbon in a proportion of 15% to 25% by mass, iron ore in a proportion of 60% to 75% by mass and slag-forming agents in a proportion of 7% to 10% by mass.

[0032] The second stage requires the injection of electrical energy into the self-reduction electric reactor. Furthermore, the second stage involves the injection of O2 and the use of a column of agglomerate feed containing a cluster of metal oxides and carbonaceous elements, with the carbonaceous elements comprising at least: coal fines, thermal coal, metallurgical coal, or biocarbon of plant or animal origin.

[0033] Finally, the generation of energy for the metal alloy production process depends on the injection of electrical energy into the self-reduction reactor, produced by at least one of the following methods: plasma torch, electric induction, or electric arc. The result of this metal alloy production process is the production of metal alloys with carbon contents ranging from 0.05% to 2.00%. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The present application presents figures to illustrate possible non-limiting configurations of the present invention.

[0035] Figure 1 illustrates an electric self-reduction reactor configured for operation using power generation to heat the liquid metal in the crucible by an electric induction coil.

[0036] Figure 2 illustrates a self-reduction electric reactor configured for operation using power generation to heat the liquid metal in the crucible by an electric arc.

[0037] Figure 3 illustrates an electric self-reduction reactor configured for operation using plasma torch power generation using the process gas itself.

[0038] Figure 4 illustrates a flowchart describing a configuration of the manufacturing process of the agglomerate briquettes used in the self-reduction electric reactor.

[0039] Figure 5 illustrates a flowchart describing a steel production process configuration using agglomerates and O2 injection.

[0040] The reference numbers used in this application are: 1 - self-reduction electric reactor; 2 - agglomerate charging column; 3 - molten metal outlet by siphon; 4 - crucible; 7 - slag collection channels; 8 - gas collector; 9 - O2 injection lance and 14 - induction coil. DETAILED DESCRIPTION OF THE INVENTION

[0041] Before describing the invention in detail, it should be understood that it is not limited to the specific component parts of the apparatus described, as such components may vary. It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. It should be noted that, as used in the specification and appended claims, the singular forms "um," "an," "0," and "a" include singular and / or plural referents, unless the context clearly indicates otherwise. Furthermore, it should be understood that, where parameter ranges delimited by numerical values ​​are provided, the ranges are deemed to include such limiting values.

[0042] It should also be understood that the embodiments disclosed herein should not be construed as individual embodiments that are not related to each other. Features discussed in connection with one embodiment should also be disclosed in connection with other embodiments shown herein. If, in a case, a specific feature is not disclosed in connection with one embodiment but with another, one skilled in the art would understand that this does not necessarily mean that the feature is not intended to be disclosed in connection with the other embodiment. One skilled in the art would understand that the essence of this application is to also disclose the feature in connection with the other embodiment, but that for the sake of clarity and to keep this specification to a manageable volume, this has not been done.

[0043] According to a first aspect, the present invention relates to a process for producing metal alloys comprising low carbon contents aiming at zero net CO2 emissions.

[0044] This process uses clusters of metal oxides and carbonaceous elements (or simply “clusters”).

[0045] According to a preferred embodiment of the present invention, the agglomerates comprise a mixture of metal oxides and carbonaceous elements in a proportion calculated to produce metals with a desired carbon content. In the case of producing iron alloys, it is desirable that the final metal alloy have, for example, a carbon content in the range of steel. The ratio between the two components must also take into account that the amount of carbonaceous element must be sufficient to promote the reduction-fusion of the metal oxides.

[0046] The agglomerates of the present invention can be produced in different formats, including briquettes, pellets or any other format that a person skilled in the art deems suitable in view of a specific application. Additionally, these agglomerates can be obtained by cold curing, which greatly reduces their production costs.

[0047] According to a preferred embodiment of the present invention, the metal oxide of the agglomerate is iron oxide. Alternatively, it may consist of oxides of other metals or a mixture thereof, with or without iron oxide.

[0048] According to one embodiment, the carbonaceous elements of the agglomerate comprise at least one of the following ingredients: coal fines, preferably fines used in PCI (pulverized coal injection) or, alternatively, fines of other coals; coals for thermal or metallurgical use; or biocarbons of plant or animal origin (e.g., biocarbon from agricultural and urban forestry residues). Alternatively, the carbonaceous elements of the agglomerate comprise a mixture of the aforementioned ingredients.

[0049] In addition to metal oxides and carbonaceous elements, agglomerates may comprise other ingredients such as ash fluxing elements, gangue, slag, and organic and inorganic binders.

[0050] According to the metal alloy production process of the present invention, the agglomerates are continuously added into the electric self-reduction reactor 1, preferably through the upper portion of the furnace. Once inside the electric self-reduction reactor 1, the agglomerate descends with the progressive melting of the agglomerate charge column 2 to high temperatures suitable for the reduction of the oxides and maintenance of the liquid metal, with an iron-rich composition, approximately 99% of the total concentration, in the crucible 4. In general, considering the time from loading at the top to melting at the base of the furnace, the reduction-melting process of the agglomerates takes about 20 min.

[0051] Furthermore, the metal alloy production process comprises the following steps: manufacturing of agglomerates of metal oxides and carbonaceous elements, producing steel using agglomerates of metal oxides and carbonaceous elements.

[0052] In a preferred embodiment of the present invention, the first step of the metal alloy production process comprises the addition in a mixer of at least one binding agent in a proportion of, preferably, 1% to 10% by mass, even more preferably the proportion is 1% to 5% by mass.

[0053] A binding agent is a substance used to bind fine particles of materials such as iron ore or coal together, forming pellets or briquettes that are essential for pelletizing, briquetting, and sintering processes. These agents help create cohesive, stable structures that can withstand handling, transportation, and the high temperatures of blast furnaces, improving the efficiency and quality of the final product.

[0054] In a preferred embodiment of the present invention, the first step of the metal alloy production process comprises adding biocarbon to a mixer in a proportion of preferably 10% to 30% by mass, even more preferably, the proportion is 15% to 25% by mass.

[0055] In a preferred embodiment of the present invention, the first step of the metal alloy production process comprises adding iron ore to a mixer in a proportion of preferably 55% to 80% by mass, even more preferably the proportion is 60% to 75% by mass.

[0056] In a preferred embodiment of the present invention, the first step of the metal alloy production process comprises the addition of slag-forming agents to a mixer in a proportion of preferably 5% to 15% by mass, even more preferably a proportion of 7% to 10% by mass.

[0057] In metallurgy, slag-forming agents are substances added during metal melting to facilitate the formation of slag, a layer of non-metallic residue. These agents help remove impurities such as oxides and sulfur, protect the molten metal from oxidation, control its chemical composition, and regulate the process temperature.

[0058] In a preferred embodiment of the present invention, the second stage of the metal alloy production process comprises the injection of O2.

[0059] In a preferred embodiment of the present invention, the generation of energy required to carry out the process of the present invention can be conducted by different strategies, including: plasma torch, induction or electric arc and any combination thereof.

[0060] Furthermore, in a preferred embodiment of the present invention, energy generation is carried out via a plasma torch, with the gas used in the plasma torch being the same gas generated by the self-reduction electric reactor 1 itself and captured at the top of the same.

[0061] In one embodiment of the present invention, the plasma torches are arranged at the base of the self-reducing electric reactor 1, along the circumference of the lower section or in line, in the same plane or distinct planes.

[0062] Furthermore, in a preferred embodiment of the present invention, energy generation in the self-reduction electric reactor 1 occurs through continuous heating of the liquid metal present in the crucible 4, either by induction via eddy currents or an electric arc generated by electrodes.

[0063] In another preferred embodiment of the present invention, the self-reduction electric reactor 1, adapted to operate powered by electrical energy, has a crucible 4 located in the lower portion of the self-reduction electric reactor 1. Said crucible 4 is equipped with an electric induction coil 14 configured to heat the liquid metal by induced eddy currents that transmit energy to the agglomerate charging column 2, or electrodes for generating an electric arc from AC or DC current.

[0064] Plasma torch processes involve injecting energy into the agglomerate charge column 2, formed by the same agglomerates defined above, using current industrial-technology plasma torches formed by energizing the same gas from the process reactions to the plasma state. In this case, there is no combustion of any kind inside the electric self-reduction reactor 1 . The energy contained in the torch gases and to be transmitted to the process is electrical in origin, generated in whole or in part from the gases generated by the reduction reactions within the agglomerates. Its energetic value depends on the analysis of the reductant's volatiles and their proportion in the agglomerates.

[0065] Another way of using the present invention is for the crucibles 4 of the furnaces to be heated by eddy currents generated by induction coils, or by an electric arc generated by electrodes. The agglomerate charging column 2 will be continuously fed and will rest on the metal and slag in crucible 4, which will be continuously poured, as described in the other modes. The top gas will be used directly or for cogeneration, and the composition of this collected gas will be rich in carbon monoxide (CO) and carbon dioxide (CO2).

[0066] Furthermore, the self-reduction electric reactor 1 of the present invention can be adapted to simultaneously support more than one of the energy generation modalities mentioned herein.

[0067] Within the scope of the present invention, the term “plasma torch” refers to a process of generating energy for the operation of the self-reduction electric reactor 1. It refers to equipment that produces and controls a highly energetic, ionized and concentrated material, obtained from the ionization of a working gas, called plasma.

[0068] Within the scope of the present invention, the term "eddy currents" refers to a phenomenon of electromagnetic induction. More specifically, these are induced electric currents present in conductive materials such as metals, in the case of the present invention molten metal, in which these currents circulate when subjected to a varying magnetic field.

[0069] According to another aspect of the present invention, the self-reduction electric reactor 1 is especially adapted for the production of metal alloys using agglomerates comprising metal oxides and carbonaceous elements for their reduction.

[0070] According to a configuration of the present invention, the self-reduction electric reactor 1 is of the shaft furnace type with a circular cross-section or any other, but with reduced dimensions in relation to the blast furnaces commonly used in the production of metal alloys by the gas / solid mode.

[0071] In a preferred embodiment of the present invention, the self-reduction electric reactor 1 has a column of agglomerate charge 2 between 1 and 4 meters, preferably between 1 and 3 meters, even more preferably the size of the column is between 1 and 2 meters.

[0072] Furthermore, as the metal melts at the base of the agglomerate feed column 2 of the self-reduction electric reactor 1, the metal flows to the lower portion of the same, depositing in the crucible 4. Once in the crucible 4, the molten material spontaneously separates into slag and liquid metal due to the difference in density. The crucible 4 at the bottom of the self-reduction electric reactor 1 is configured to allow the separation of these two portions, directing the slag supernatant and the molten metal bottom to separate leakage routes. This collection and separation of the molten material occurs continuously and siphoned, without the need to interrupt the operation of the self-reduction electric reactor 1.

[0073] Once the molten material reaches crucible 4, the metal can have its carbon content reduced by injecting O2 directly into crucible 4. This injection is carried out using an 029 injection lance, either lateral or central, installed in the self-reduction electric reactor itself at 1.

[0074] Simultaneously with the collection of the molten material, the gaseous byproducts generated during the reduction-fusion process are collected. These gases are collected in the upper portion of the electric autoreduction reactor 1 and can be directed for subsequent treatment, either for reuse in the generation of energy for the electric autoreduction reactor 1 or for other purposes.

[0075] In a preferred embodiment of the present invention, a method for treating gases resulting from the production of metal alloys is proposed, comprising the steps: submission of gaseous by-products to the upper portion of the self-reduction electric reactor 1 through the gas collector 8; submission of the gaseous by-products to treatment steps; and redirection of the treated by-product.

[0076] In a preferred embodiment of the present invention, the gaseous by-products submission step comprises at least one water recovery step by condensation and one fines removal step.

[0077] In a preferred embodiment of the present invention, the self-reduction electric reactor 1 has a gas collector 8 in its upper portion configured to collect the gaseous by-product generated during the agglomerate fusion reduction process.

[0078] Additionally, in a preferred embodiment of the present invention, the self-reduction electric reactor 1 comprises a crucible 4 in its lower portion configured to receive the molten material resulting from the reduction fusion of the agglomerates. Said crucible 4 is provided with a siphon system for the continuous flow of the molten metal separately from the slag.

[0079] The slag, which accumulates in the supernatant portion of the melt in crucible 4 due to its lower density, is continuously removed through slag collector channels 7 in the upper portion of crucible 4. This slag is composed of the ore gangue, reducer, flux, and binder present in the composition of the self-reducing agglomerate. The composition of the residue collected by slag collectors 7 shows a high concentration of SiO2, approximately 46%, followed by CaO, at approximately 41%.

[0080] According to a preferred embodiment of the present invention, the self-reduction electric reactor 1 is provided with O2 injection lances 9 with the injection end located in the crucible 4, so as to allow direct supply of O2 to the molten metal accumulated therein. The volume of O2 injected by the O2 injection lances 9 can be controlled in order to adjust the carbon content of the molten metal to desired ranges, for example, adjusted to the typical ranges of steels.

[0081] In a preferred embodiment of the present invention, metal alloys with a carbon content ranging from 0.05% to 2.00% are produced.

[0082] According to the present invention, the O2 injection lances 9 for adjusting the carbon content of the molten metal can be incorporated into any self-reduction electric reactor configurations 1 disclosed in the present report, regardless of the power generation mode used.

[0083] According to yet another aspect of the present invention, it relates to a method for treating the gaseous by-products collected in the upper portion of the self-reduction electric reactor 1.

[0084] After the gases are captured, they may undergo some treatment stages to reuse them for energy generation in the self-reduction electric reactor 1, or for use in electricity generation or heating.

[0085] Suitable treatments for reusing collected gases include fines removal and H2O removal by condensation. Furthermore, fines removal reveals a high concentration of Fe2Ü3, approximately 65%, followed by high carbon concentrations, approximately 20%, due to the use of hydrocarbons in the self-reduction electric reactor 1 .

[0086] The present invention combines the appropriate dosage of reducing carbon in the agglomerates, the elimination of the presence of the “coke foot” in the crucible 4 of the electric self-reduction reactor 1 and the final adjustment feature of the O29 lances, so as to allow the continuous pouring of a metal with carbon content in the steel range, without passing through the intermediate pig iron product.

[0087] From the above fact it follows that the present invention dispenses with the production of intermediate metal, pig iron in the case of iron reduction, the metal produced in the electric self-reduction reactor 1 being already in the typical composition range of steels, and can be directly directed, as is currently common practice, to the finishing and composition and temperature adjustment sections in ladle or deoxidation furnaces before continuous casting.

[0088] The present invention presents clear advantages in relation to prior art solutions, among which the following are worth highlighting: greater energy efficiency; reduction or elimination of the carbon footprint; reduction of operational costs due to increased energy efficiency and the possibility of using lower-value raw materials; reduction of capital costs of integrated plants due to the elimination of coke ovens, sintering and LD / BOF steelmaking; and the replacement of fossil carbon burning with electrical energy sources.

[0089] All these benefits make it economically viable to achieve Net-Zero CO2 Emission or negative emissions when coupled with CCS (Carbon Capture and Storage) / CCUS (Carbon Capture, Utilization and Storage) systems.

[0090] All the modes described above allow for mixed or combined versions.

[0091] An example of iron ore used in the present invention - MUSA - is found in Table 1, with the respective mass percentages. Table 1 - composition of an example of iron ore (MUSA).

[0092] An example of the composition of the raw material found in a type of biochar used in the present invention - bagasse biochar - is found in Table 2, with the respective mass percentages. Table 2 - composition of an example of biochar.

[0093] An example of the composition of the binder used - hydrated lime - is found in Table 3, with the respective mass percentages. Table 3 - composition of an example of a binder.

[0094] An example of a flux - furnace slag - is found in Table 4, with the respective mass percentages. Table 4 - composition of an example of flux.

[0095] An example of the composition of fines is found in Table 5, with the respective mass percentages. Table 5 - composition of an example of fine returns.

[0096] An example of the top gas composition is found in Table 6, with the respective mass percentages. Table 6 - Example of top gas composition

[0097] An example of the composition of the process slag is found in Table 7, with the respective mass percentages. Table 7 - example of slag composition.

[0098] An example of the composition of the metal (steel) resulting from the process is found in Table 8, with the respective mass percentages. Table 8 - example of metal composition (steel).

[0099] In comparison with traditional blast furnaces, in the self-reduction electric reactor 1 of the present invention, there is no high charge column that characterizes blast furnaces and that rests on the bottom of the crucible. The metal produced in blast furnaces is contaminated with carbon from the coke base until it reaches saturation (approximately 4.5% carbon). In the electric self-reduction reactor 1, it is possible to produce, directly in the reduction reactor, metal alloys in the steel range (0.1–1.0% carbon) without the coke column or briquettes, so that the metal in the crucible is free of carbon saturation, making it possible to dispense with steel mills, which are primarily dedicated to reducing the carbon content of the metal, typical of blast furnace pig iron, which is saturated with carbon at approximately 4.5% carbon, to the composition ranges of steels as previously defined.

[0100] It should be noted that the drawings presented are not necessarily to scale and are merely conceptual in nature. Nevertheless, it is expressly provided that all combinations of elements that perform the same function in substantially the same manner to achieve the same results as the elements claimed herein are within the scope of the present invention. Finally, it should be noted that the scope of protection of the present invention encompasses other possible variations and is not limited solely by the content of the claims alone, including possible equivalents.

Claims

CLAIMS 1. Equipment for producing metal alloys, characterized by the fact that it comprises: at least one self-reduction electric reactor (1) comprising at least one agglomerate charging column (2), at least one gas collector (8), at least one crucible (4), at least one slag collecting channel (7), at least one gas collector (8) and at least one O2 injection lance (9).

2. Equipment for producing metal alloys, according to claim 1, characterized by the fact that the self-reduction electric reactor (1) operates powered by electrical energy.

3. Equipment for producing metal alloys, according to claim 2, characterized by the fact that the generation of energy for injection into the self-reduction electric reactor (1) is produced by at least one of the following methods: plasma torch, electric induction, electric arc.

4. Equipment for producing metal alloys, according to claim 1, characterized in that the agglomerate loading column (2) comprises a mixture of metal oxides and carbonaceous elements.

5. Equipment for producing metal alloys, according to claim 4, characterized in that the carbonaceous elements comprise in their composition at least: mineral coal fines, thermal coals, metallurgical coals or biocarbon of vegetable or animal origin.

6. Equipment for producing metal alloys, according to claim 4, characterized in that the agglomerate loading column (2) is between 0.5 and 4 m in height.

7. Equipment for producing metal alloys, according to claim 1, characterized in that the crucible (4) is equipped with an electric induction coil (14) configured to heat the liquid metal contained in the crucible (4).

8. Equipment for producing metal alloys, according to claim 1, characterized by the fact that the self-reduction electric reactor (1) comprises at least one O2 injection lance (9) connected to the crucible (4) configured to inject O2 directly into the crucible (4).

9. Equipment for producing metal alloys, according to claim 1, characterized by the fact that the crucible (4) at the bottom of the self-reduction electric reactor (1) is configured to separate the slag supernatant and the molten metal bottom for distinct pouring routes; and wherein, this collection and separation of the molten material occurs in a continuous and siphoned manner.

10. Method of treating gases resulting from the production of metal alloys in equipment for producing metal alloys, as defined by any one of claims 1 to 9, characterized by the fact that it comprises the following steps: a) collecting gaseous by-products in the upper portion of the self-reduction electric reactor (1) through the gas collector (8); b) subjecting the gaseous by-products to treatment steps; and c) redirecting the treated by-product.

11. Method according to claim 10, characterized in that the by-product treated in step c) is redirected to energy cogeneration.

12. Method of treating gases resulting from the production of metal alloys, according to claim 10, characterized in that step b) comprises at least one fines removal step.

13. Method of treating gases resulting from the production of metal alloys, according to claim 10, characterized in that step b) comprises at least one step of recovering water by condensation.

14. Process for producing metal alloys characterized by the fact that it comprises the following steps: a) manufacturing of agglomerates of metal oxides and carbonaceous elements; b) producing steel using agglomerates of metal oxides and carbonaceous elements; and in step b), electrical energy is injected into the self-reduction electric reactor (1).

15. Process for producing metal alloys, according to claim 14, characterized in that metal alloys with a carbon content in the range of 0.05% to 2.00% are produced.

16. Process for producing metal alloys, according to claim 14, characterized in that step a) comprises the addition in a mixer of at least one binding agent in a proportion of 1% to 5% by mass, biocarbon in a proportion of 15% to 25% by mass, iron ore in a proportion of 60% to 75% by mass and slag-forming agents in a proportion of 7% to 10% by mass.

17. Process for producing metal alloys, according to claim 14, characterized in that step b) comprises the use of a column of agglomerate charge (2) comprising an agglomerate of metal oxides and carbonaceous elements; and the carbonaceous elements comprise in their composition at least: fines of mineral coal, thermal coal, metallurgical coal or biocarbon of vegetable or animal origin.

18. Process for producing metal alloys, according to claim 14, characterized in that step b) comprises the injection of O2.

19. Process for producing metal alloys, according to claim 14, characterized by the fact that the generation of energy for injection into the self-reduction electric reactor (1) is produced by at least one of the following methods: plasma torch, electric induction, electric arc.

Images