Electrometallurgical metallothermic process and installation

Abstract

The invention proposes a unitary metallothermic technology with sequential or multi-sequential continuous serial operation. The proposed technology includes a metallothermic process and a complementary metallothermic installation, used to release the existing potential chemical energy at the atomic level and use it to obtain caloric and / or thermoelectric energy simultaneously with the production of metals or alloys, of powders and slags. This invention proposes the use of metal oxides originating from metal ores or / and from some metallic oxide waste, using metal reducing agents together with reaction moderators consisting of alloying materials, reaction inhibitors and fluxes. The objective technical problem that the invention solves is the cheap production of cleaner thermoelectric energy, complementary to the sequential or to the serial continuous multi- sequential obtaining of some steel / metallurgical products, by using the potential chemical energy existing at the atomic level in the metallothermic mixtures, for the simultaneous obtaining of two different types of products.

Description

[0001] ELECTROMETALLURGICAL METALLOTHERMIC PROCESS AND

[0002] INSTALLATION

[0003] 1.0 DESCRIPTION OF THE INVENTION

[0004] The technical field to which the invention refers is the ecological obtaining of thermoelectric energy and metallurgical products.

[0005] The patent application (hereinafter - CBI) proposes as the primary source of energy, the potential chemical energy existing at the atomic level. This has a high share in metallothermic mixtures consisting of metallothermic reactants (some metal oxides and suitable reducing agents), plus reaction moderators (alloying materials, reaction inhibitors and fluxes).

[0006] Some metallothermic mixtures (thermites) generate, through redox reactions, with sequential or multi-sequential continuous serial unfolding, metals / alloys, non- metals and heat that can be converted by classical methods into electrical energy.

[0007] The raw materials, precursors of the metallothermic (thermites) reactants are represented by the oxidic components from ores and / or dross, in parallel with a series of metal reducing precursors (for example - Aluminium or chemical compounds with Sodium, Calcium, etc.), alongside of precursors of reaction moderators consisting of alloying materials (e.g., ferroalloys), reaction inhibitors (e.g., nail chips) and fluxes (e.g., CaCOa).

[0008] The state of the art knows various methods and installations for the production of thermoelectric energy using various fuels (coal, natural gas, crude oil, etc.) and separately from the sequential or continuous elaboration of some metallurgical products, using specific ores or metal dross (oxidic waste), but does not know processes and installations for sequential processing, with continuous progress, of ores and / or oxidic waste (dross) of some metals capable of, through specific redox reactions, allowing the energetic self-maintenance of the processing, offering for use the released energy surplus.

[0009] The known processes are energy-consuming and generate polluting gases (NOx, CO2, SO2, SO3or H2S).

[0010] From a metallurgical point of view, the state of the art knows processes and technologies for reducing some metal oxides using carbon, carbon monoxide or / and hydrogen. For example, three classic technologies are known for the production of steel, which process the iron oxides existing in the ores using carbon monoxide and / or hydrogen as a reducing agent.

[0011] The three types of technologies currently used for the industrial production of steels are shown schematically in figure 1 , according to the article “Exploring Hydrogen with POSCO #3 The Future of Steel — Hydrogen-based Steelmaking - Official POSCO Newsroom”.

[0012] Modern iron and steel solutions, of the DRI type, mainly use either gaseous combinations consisting of carbon monoxide (75%) and 25% hydrogen or 100% hydrogen (H-iron technologies) but these are not exergonic and consequently do not allow the exploitation of any energy surplus generated by the release of potential chemical energy existing at the atomic level.

[0013] Among these, the H-IRON technology, for the hydrogen reduction of iron ore oxides in a fluidized bed, is known and frequently applied for applications aiming, above all, at the production of iron powders with high purity (85-90%), and more recently, for the production of steels without greenhouse gas emissions.

[0014] The three solutions, previously presented, for the “cleaner” production of steels are not of the continuous type and, in addition, they consume a lot of energy.

[0015] Moreover, the H-iron technology is also relatively dangerous because it uses hydrogen under pressure, at temperatures of around 650°C (Mihai Cojocaru - Metallic Powders, chap. 2.1. Fair Partners Publishing House. Bucharest 2009).

[0016] The most promising metallurgical technologies, such as H-lron, propose obtaining hydrogen by using “green” electricity, which, however, is expensive.

[0017] The typical molar equation for the hydrogen reduction of metal oxides is of the type:

[0018] MeO + H2 — > Me + H2O, (1), where:

[0019] MeO is the metal oxide and Me is the resulting metal.

[0020] The production of hydrogen through the electrolysis of water, with the use of “green energy”, represents yet another technical-economic challenge for which the time for finding the solution may last even after the 2050s. Then it is expected that 18% of the steel industry will be based on hydrogen (according to Goldman Sachs).

[0021] In the state of the art, continuous or discontinuous metallothermic methods are also known, for the direct reduction of metal oxides (DRI type methods) using some of the metals to the left of iron, in the Beketov - Volta series, which can avoid the production of greenhouse gases but do not also offer electricity supply solutions.

[0022] Thus, it is significant that only in the last 10 years more than 200 patent titles have appeared that refer to metallothermic solutions for the reduction of metal oxides without also addressing the possibility of producing thermoelectric energy.

[0023] The raw materials, precursors of the metallothermic reactants (oxides and reducing agents) are represented by the oxidizing components from ores and / or dross, in parallel with a series of precursors of metallic reducing agents (for example - aluminium, magnesium or some chemical compounds with sodium, calcium, etc.) and with some precursors of reaction moderators (alloying materials, inhibitors and fluxes).

[0024] The metallothermic technologies can relate to stoichiometric relationships, without falling between them, according to molar equations of type (2).

[0025] MeO + R = Me +RO + Q, (2), where:

[0026] - MeO is the metal oxide subjected to reduction and R represents the metal reducing agent used;

[0027] - Me and RO represent the metal and the resulting oxide, respectively;

[0028] - Q - represents the amount of resulting heat which, in the case of using iron oxides and of aluminium as a reducing agent, can represent about 850 kcal / kg of metallothermic mixture.

[0029] Known metallurgical solutions do not propose the unitary processing of metal ores and / or dross, nor do they address the production of electricity.

[0030] This patent application (CBI) proposes a green metallurgical technology, defined by the significant reduction of the generation of polluting gases (CO, CO2, NOx, H2S, SO2, SO3, etc.), composed of a process and a complementary installation used for the release of potential chemical energy existing at the atomic level and its use for obtaining thermoelectric energy, simultaneously with the production of metallurgical materials (metals, alloys and some non-metallic materials).

[0031] At the same time, this patent application proposes the efficiency of the production of alloys / ferroalloys, slags and specific powders, by eliminating C, GO and H2 reducing agents.

[0032] The CBI aims to capitalize on all the products resulting from the triggered metallothermic reactions.

[0033] Concretely, the CBI aims at the ecological capitalization of the caloric energy released, metals and non-metals resulting from the unitary processing of some metal oxides (existing in ores and / or dross), precursors of metal reducers, regardless of whether they come from ores (e.g., bauxite) or from some processed metal waste (e.g., aluminium shavings), together with precursors of reaction moderators consisting of alloying materials (e.g., ferroalloys), reaction inhibitors (e.g., nail chips) and fluxes (e.g., CaCC ).

[0034] For the unitary processing of raw materials (e.g., ores and / or dross), it is proposed to use a Raw Materials Preparation Plant that allows their transformation into components of thermite recipes (oxides, reducers and reaction moderators).

[0035] The Raw Materials Preparation Plant is a concentrator of some processes and some specialized subassemblies, made up of both unknown components in the state of the art and known components but, used in such a way that together they become capable of leading to new and unexpected results (metallothermic production of thermoelectric energy, simultaneously and complementary to the production of metallic or non-metallic materials).

[0036] This CBI refers to the known DRI technologies by preserving the advantages that established them, while also aiming at the elimination / reduction of the disadvantages that accompany them (high energy consumption from traditional resources, inefficient utilization of available caloric energy, generation of harmful gases, non-unitary processing of ores and oxidic waste, generation of polluting waste).

[0037] To these disadvantages is added the use of coke ovens, furnaces and traditional steel mills which are expensive, polluting and energy consuming, which cumulatively unnecessarily increases the cost price of the resulting products.

[0038] The main advantages that differentiate the CBI proposals from the state of the art are:

[0039] 1 . Eliminating the use of traditional energy resources (hydraulic, wind, fossil fuels, nuclear, photovoltaic, etc.).

[0040] 2. Sequential or multi-sequential production with continuous and more ecological serial operation of some metals / alloys and some non-metals (abrasive and / or heat-resistant materials), complementary to the efficient and non-polluting release of caloric energy that can classically be converted into cheap thermoelectric energy.

[0041] 3. The production prices of the resulting metallic / alloy or non-metallic materials, simultaneously obtaining “green caloric / electrical energy” are much lower, compared to the known values, because only one primary enerav source is used to simultaneously obtain two types of products - heat and metallurgical products. The CBI proposes serial and / or parallel solutions capable of processing with the same process and the same installation, oxidic precursors (from oxidic metallic waste (dross) or / and from various metallic ores without sulphur compounds), reductant precursors metals (e.g., from scrap aluminium, atomised aluminium or oily aluminium slurries) and precursors of reaction moderators (ferroalloys, steel shavings) and fluxes, which they convert into thermite reactants (oxides and reducing agents) and respectively in reaction moderators (alloying materials, reaction inhibitors and fluxes). These, through mixing and homogenization, become metallothermic / thermite mixtures or more simply - thermites capable of behaving as true “metallothermic fuels” that allow the efficient production of thermoelectric energy and metallurgical products. The possibility of flexible use of a variety of eco-friendly thermite mixture recipes (metallothermic fuels), for civil use, which do not generate explosions and which lead to obtaining, within the metallothermic reaction, temperatures between 2100 and 2300°C. The possibility of flexibilization, in real time, of the use of various thermal mixtures (metallothermic fuels), so that, depending on the characteristics of the batches of raw materials, they allow the continuous metallothermic unfolding of different compositional sequences, capable of ensuring that only certain reaction products are obtained, even if the composition of the raw materials varies in real time. Simplification of known steelmaking technologies, by eliminating coke ovens, furnaces and traditional steel mills, in order to produce a multitude of steel brands. Drastic reduction of the technological generation of polluting gases (e.g., NOx, CO, CO2, SO2, SO3 or H2S). The use of some of the already existing technological equipment. Examples: Continuous casting, rolling mills, granulation separators, etc. Almost all of the resulting products (heat and metallurgical products) represent recoverable materials. In addition, the alloys resulting from the processing of slags and / or from the processing of reaction gases contain more than 70% a- AI2O3 and because of this they can be used as abrasive and / or heat-resistant materials.

[0042] 11. The use of caloric energy, released according to the CBI solutions, can have many applications, but, outside of the traditional applications, the possibility of obtaining ecological thermoelectric energy is emerging, through the retrofitting of thermal power plants that used / use fossil fuels or even the construction of a new type of thermal power plants. Electrometallurgical power plants which, releasing less gaseous waste, become capable of producing complementary metals / alloys and non-metals (abrasive and / or heat-resistant materials).

[0043] As a result, it can be proposed, as an industrial application, to replace the old furnaces of thermal power plants (which use fossil fuels) with electrometallurgical metallothermic converters, with sequential or multi-sequential operation with continuous serial unfolding and which, using “metallothermic fuels” constituted from powdered mixtures of thermite reactants, and reaction moderators (including fluxes), produce by cogeneration metals, alloys, refractory / abrasive materials, heat and / or electricity.

[0044] The conceptual block diagram of the Patent Application is presented in figure 2.

[0045] The objective technical problem that the invention solves is the cheap production of “cleaner” thermoelectric energy, complementary to the sequential or to the serial continuous multisequential obtaining of some steel / metallurgical products, by using the potential chemical energy existing at the atomic level in the metallothermic mixtures, for the simultaneous obtaining of two different types of products (energy and metallurgical products).

[0046] 1.1 - The CBI Process

[0047] 1.1.0 - Overview

[0048] The CBI presentation mainly uses the DEX definitions of the terms used (e.g., metallothermic / aluminothermic, thermites, continuous / discontinuous, sequential, phase, stage, etc.) or, in the absence of these, defining clarifications are proposed (e.g., metallothermic fuels / metallothermic reactants, sorts of thermite powders, multisequential processes with continuous serial development, etc.). The CBI process proposes theoretical and practical ways to streamline the production of cleaner electricity, complementary to obtaining metallurgical products.

[0049] The CBI process involves thermite reactants (metal oxides and reductants), plus reaction moderators consisting of alloying materials, reaction inhibitors and fluxes.

[0050] The technological processes specific to the CBI process take place predominantly by gravity and with a minimal presence of atmospheric air.

[0051] From a metallurgical point of view, the CBI Process is a multi-sequential, continuous DRI type.

[0052] The processed raw materials can have different characteristics even when they are of the same type and for this reason, the technological processes applied must be adapted, in real time / sequentially, to the batch processed at that moment. This is done by using a P program, loaded in a controller (Ctrl) shown in figure 4.

[0053] Consequently, the metallothermic process proposed by CBI is defined, according to DEX, as a sequential process that unfolds over time, through an ordered sequence of distinct physical-chemical processes.

[0054] The sequential process proposed by CBI allows obtaining the programmed reaction products, through the serial and / or parallel processing of certain types of raw materials and reactants, plus the reaction moderators resulting from them.

[0055] The CBI proposes the use of batches of raw materials, regardless of their size. The batches of raw materials consist of:

[0056] 1 . Oxidative precursors made of: metal ores (e.g., iron ores without pyrites) and / or from oxidic waste (e.g., steel dross).

[0057] 2. Precursors of metal reducers consist of: loose powders of aluminium, magnesium or processed waste of such products;

[0058] 3. Precursors of reaction moderators consist of: alloying materials (e.g., ferroalloys), reaction inhibitors (nail chips, metallic shavings - e.g., steel) and fluxes (e.g., CaC03).

[0059] Through processing, the batches of raw materials become batches of: a. Thermite reactants consisting of: metal oxides (e.g., FeO, Fe2O3, FesO4, CuO, CU2O, etc.) and metal reducing agents (e.g., aluminium, magnesium powders or shredded waste of such materials); b. Reaction moderators consisting of: alloying materials (e.g., ferroalloys, shavings or powders of pure metals), reaction inhibitors (e.g., steel shavings) and fluxes (e.g., dry CaC03 powders).

[0060] Batches of processed raw materials (reducers and / or reaction moderators), are characterized by chemical and granulometric compositions that together define the “sorts” of the respective materials (e.g.,

[0061] The ensemble formed by the assortments of reactants and reaction moderators, dosed in percentages, mixed and homogenized, according to certain “thermite recipes”, constitute the metallothermic / aluminothermic mixtures, also called “thermite mixtures” which, for the CBI, represent the “metallothermic fuels” used.

[0062] The serial / parallel processing of various batches of raw materials constitute sequences of processes that lead to the release of caloric energy and to obtaining complementary metallurgical products.

[0063] Consequently, the metallurgical processes targeted by the CBI are sequential or multi-sequential processes with continuous serial unfolding.

[0064] The great diversity of chemical compositions of oxidic raw materials leads to the production of a diversity of oxidic thermite reactants, which requires the proportional generation of a diversity of thermite recipes, capable of leading to certain reaction products.

[0065] The programmed thermite recipes (according to the P program) materialize in a homogenizing mixer (AM), identified in figure 3.

[0066] The materialization of thermite recipes uses the percentage dosing, using the dispensers (D), of thermite reactants and reaction moderators produced in Module A and collected in the bunkers of module B, shown in figure 3.

[0067] The materials in the bunkers, after characterization by diffractometry and after percentage dosing, are directed by gravity to the mixer (AM) where, through homogenization, the thermite recipe of the moment materializes, i.e. the "metallothermic fuel" used. This, after homogenization, it is characterized from a diffractometric point of view and dosed according to program P, after which it is sent by gravity to the metallothermic crucible (CM).

[0068] The transition from one thermite recipe to another represents / marks a new sequence of the metallothermic process. The sequences, in their multitude, can have different durations, depending on the size of the batch of raw materials with similar properties, processed at a given time.

[0069] The CBI process uses reaction inhibitors both to control the reaction rate and to stop the process in case of failure.

[0070] Stopping the process can be achieved by stopping the supply of reactants to the metallothermic crucible and / or flooding it with reaction inhibitors.

[0071] The CBI process allows a permanent exchange of mass and energy with the outside of the considered system.

[0072] The CBI process proposes cooling the reaction crucible using metal melts.

[0073] The CBI process uses primary chemical potential energy released by a metallothermic process.

[0074] Chemical potential energy is due to the electrical forces that arise from the rearrangement of the electrical charges of electrons and protons in the process of forming the new chemical bonds that lead to the reaction products.

[0075] As it is known, any chemical or metallurgical process proceeds in the direction of decreasing the internal energy of the system, which causes the released energy to be transferred to the environment in the form of heat (usable energy).

[0076] The amount of caloric energy released through the metallothermic reactions considered is dependent on the type of oxides and reducing agents used, but for quick estimates, an average of about 850 kcal / kg of reacted thermite can be accepted, which can generate temperatures of over 2600°C in the crucible. Because of this, it is necessary to cool the crucible, because its operating temperature must not exceed 2300°C.

[0077] The CBI process treats the specific reactions of metallothermy (e.g., - aluminothermy) as theoretically having two complementary components: an exergonic energy component and an endergonic component.

[0078] The oxidic components of the dross and / or ores, along with the reducing metals, are used for their potentially exergonic properties.

[0079] The other materials that are introduced into the metallothermic crucible (reaction moderators) can be endergonic (e.g., FeMn, reaction inhibitors, etc.) and others can be exergonic (e.g., Mg, Ti, Zr, etc.), which makes, from an energy point of view, that the operation of the crucible should present a surplus energy balance. The specificity of the CBI process continuously ensures, in the metallothermic converter, a molar balancing of the flow of reactants with the flow of reaction products. This fact simultaneously leads to a balancing of the speed with which the reactants are consumed, compared to the speed with which the reaction products are formed.

[0080] The exergonic component manifests itself after overcoming the transient initiation stage of the metallothermic reaction, which is initially endergonic.

[0081] The exergonic component can appear when the free enthalpy of reaction is negative

[0082] (AG°< 0).

[0083] The exergonic component is dependent both on the temperature / rate of metallothermic redox reactions, expressed in kilograms of metallothermic mixture (thermite) consumed in one second, and on the chosen production capacity.

[0084] The chosen production capacity starts from the molar expression of reactions of type (3), defining for the metallothermic processes that take place in the metallothermic crucible (CM).

[0085] 3FeO + 2AI -> AI2O3 + 3Fe + 693 Kcal / 1000 grams of thermite;

[0086] Fe2O3 + 2AI —> AI2O3 + 2Fe + 848 Kcal / 1000 grams of thermite;

[0087] (3)

[0088] 3FesO4 + 8AI 4AI2O3 + 9Fe + 1289,58 Kcal / 1000 grams of thermite.

[0089] The exergonic component causes the controlled development of reactions of type (3) to evolve in the sense of the reduction of oxides if negative reaction free enthalpy is generated.

[0090] The reducing component of the metallothermic reactants must be as cheap as possible and sufficient to support a continuous, efficient process at the chosen production capacity.

[0091] Depending on the type of predominant metal oxides (e.g., Fe or Cu), the effective reducing agent can be aluminium supplied from various sources (e.g., atomized aluminium or recovered from aluminium waste). The moderating component can only start if it has the necessary energy, provided by the exergonic component, and because of this there is initially a time gap between the two components.

[0092] The CBI proposes the use of thermite reactants that significantly reduce the use of carbon and sulphur, simultaneously with the reduction of the presence of atmospheric air in the metallothermic crucible, which also leads to the significant reduction of the presence of NOx type gases in the reaction gases. This makes the CBI process not generate significant amounts of CO2, NOx and sulphur compounds (e.g., SO2, SO3, H2S, etc.) and thus become a “cleaner” technological process of metallothermic release of thermal energy and conversion of them in electricity, complementary to the sequential metallothermic production of some metallic (e.g., steels, cast irons, ferroalloys) or non-metallic materials (e.g., slag with a minimum of 70% AI2O3).

[0093] The CBI presents, according to figure 3, the use of some inventive subassemblies (e.g., the metallothermic crucible cooled with metal melts) alongside the non-obvious use of some known means (e.g., granulometric separators), for another purpose and with obtaining new and surprising effects. Thus, starting from the release of the potential chemical energy existing in the metallothermic mixtures (metallothermic fuels), through cogeneration, thermoelectric energy is produced by the metallothermic process, simultaneously and complementary with metals / alloys or non- metals.

[0094] Also, the CBI process inventively proposes the unitary use of dross and / or oxidic metal ores of the type hematite (69.9% Fe), magnetite (72.4% Fe), goethite (FeO (OH) - 62.9% Fe ) and limonite (FeO (OH) ■ n (H2O) - 55% Fe) to be transformed into similar oxide thermite components.

[0095] Upon exiting the metallothermic crucible, the resulting metal / alloy is compositionally characterized. Characterization is done sequentially, using analysers (R) that perform XRF-type analysis.

[0096] Any change in the chemical composition of the metallothermic fuels causes changes in the chemical composition of the reaction products.

[0097] The identification of the newly emerging situation after any modification of the thermic recipe is done using the spectral analysers (R) in figure 3. These, starting after 15 s from the modification of the recipe, analyse 5 times (at 10s intervals) the evolution of the chemical composition of the metals / alloys resulting from the crucible (CM), which allows recording the new chemical composition of the metals / alloys produced.

[0098] The controller, through a program P, registers the new composition, compares it with the programmed composition and, if necessary, commands its improvement.

[0099] The improvement of the chemical composition of the resulting steel is done by adding in the homogenizer (OM), in doses, the reaction moderators located in a set of hoppers located above the homogenizer. The assembly consisting of the rotary homogenizer (OM) and the casting-timing recipient (VTT) replaces traditional steel mills and ensures the desired steel grades are obtained.

[0100] The rotary homogenizer (OM) takes the steel produced in the crucible (CM) for 15 minutes, mixes it with the necessary moderators (additional) and directs it to the casting-timing recipient (VTT).

[0101] . The casting-timing recipient allows the separation of the secondary slag, settled on the surface of the metal in this recipient. At the same time, the casting-timing recipient allows the accumulation of the metal produced in one hour and its natural cooling, up to the continuous casting temperature.

[0102] The innovative technical elements and those known in the “state of the art” contribute to the elimination of the technical, ecological and financial difficulties in the way of the metallothermic production of electricity, complementary to the cheap production of metals / alloys or non-metals.

[0103] At the same time, through the use of homogenizers and casting-timing recipients, the composition of the desired steel brands can be finalized.

[0104] The CBI process, shown schematically in figure 3, inventively proposes both the operation with a minimum of atmospheric air (remaining after the vacuum at 0.1 mbar) of the metallothermic crucible (CM), as well as its cooling with the help of metallic melts at temperatures between 1100°C and 1200°C and thus between the melting and boiling temperatures of the coolant metal.

[0105] Among the metals whose melts can functionally fall (without generating large amounts of vapor) between the melting-boiling temperatures necessary for both heat transfer and cooling of the reaction crucible, copper can be chosen. It can be used at temperatures between 1085°C and 1150°C.

[0106] Such a metallurgical crucible cooling solution provides safety because it does not generate large amounts of vapor even if, accidentally, the cooling melt comes into direct contact with the molten steel.

[0107] The presentation of the CBI modularly follows the stages and phases through which the proposed process allows the processing of batches of raw materials and leads to obtaining useful reaction products (thermoelectric energy, metals / alloys, slags and reaction gases. All utilizable. The CBI presentation is structured according to the block diagram in Figure 2. It covers the CBI Process and Installation, highlighted on 2 stages and 8 technological phases.

[0108] Stage 1 - Presents the process and installation for processing raw materials and transforming them into thermite reactants, reaction moderators and usable fluxes.

[0109] Stage 1 takes place on 3 phases of the procedure that lead to the justification of the creation of 3 complementary technological lines A1 , A2 and A3, respectively). These correspond to the 3 types of raw materials used: oxidizing, reducing and moderating.

[0110] Phase A1- presents the process and the complementary installation for the processing of oxidic precursors, respectively Line A1 .

[0111] Phase A2 - presents the process and the complementary installation for processing the precursors of reducers, respectively Line A2.

[0112] Phase A3 - presents the process and the complementary installation for processing precursors of reaction moderators and fluxes, respectively Line A3.

[0113] Stage 2 - Presents the process and installation for the metallurgical processing of thermite reactants, reaction moderators and fluxes and their transformation into usable reaction products (thermoelectric energy, metals / alloys, slags and metallic or non-metallic powders).

[0114] Stage 2 - Takes place on 5 phases / technological lines, corresponding to the 5 types of processes that exploit the results of Stage 1 in a metallothermic process. The 5 phases of Stage 2 are:

[0115] Phase B1 - presents the process and the complementary metallothermic processing installation of the thermite components resulting in Stage 1 , in order for them to become thermites and, respectively, usable reaction products.

[0116] Phase B2 - presents the process that allows the processing of materials resulting from phase B1 and which leads to the complementary installation, respectively to Line B2.

[0117] Phase B3 - refers to the process of processing the metallothermic slags resulting in the crucible (CM) and which leads to the complementary installation for processing these slags, respectively to Line B3.

[0118] Phase B4 - presents the process used to process the reaction gases resulting from the metallothermic processes in the crucible (CM) and which leads to the complementary installation for processing these gases, respectively to Line B4. Phase B5 - presents the process used for the continuous cooling of the crucible (CM) and for the recovery of the thermal energy released in the crucible (CM) through the metallothermic process, by transforming it into thermoelectric energy that can be used both to meet the energy needs of the CBI installation and to create an available quantity deliverable in the national electricity distribution network.

[0119] At the same time, the process carried out in Phase B5 justifies the creation of the complementary installation that materializes this process, namely Line B5.

[0120] 1.1.0.1 - Defining particularities of the CBI process

[0121] For the CBI process, the reference metallothermic reactions are of type (3):

[0122] Compared to this system of equations, it is found that the development of metallothermic reactions also leads to the release of caloric energy.

[0123] Part of this energy is useful for the self-maintenance of the process and implicitly the generation of reaction metallurgical products, and the rest of the energy is taken over and transformed into thermoelectric energy, so that thermites in reaction can be considered “metallothermic fuels” capable of leading to the functioning of a new type of thermal power plants. Metallurgical thermal power plants, capable of additionally generating metallurgical products.

[0124] The CBI admits that the conversion efficiency of caloric energy into electrical energy is 32-35%.

[0125] The CBI does not propose to patent a specific thermite recipe, but instead proposes a flexible way to generate a set of thermite recipes capable of leading to the required reaction products.

[0126] From a metallurgical point of view, the CBI proposes continuous sequential DRI solutions capable of leading to similar reaction products, even if the batches of raw materials processed have different characteristics. For this reason, the applied technological processes must be adapted, in real time / sequentially, to the batch of raw materials processed at that moment. The adaptation of the technological processes is made out by carrying out 2 stages and 8 distinct phases of raw material processing and their transformation into useful materials, controlled by an informational program. Program P.

[0127] The CBI does not propose to patent Program P, because it is a classic informational program, but which, together with the other components of the “Process” proposed for patenting, contributes to obtaining new and surprising effects. Inexpensive production of thermoelectric energy simultaneously and complementary to obtaining metallurgical products.

[0128] Stage 1- is the stage of transformation of raw materials into thermite reactants and reaction moderators. This takes place in module A and comprises 3 phases.

[0129] Stage 2 - is the stage of processing / transforming the thermite reactants and reaction moderators into metallothermic fuels and then, through metallothermic reactions, into useful reaction products. This stage takes place in module B and comprises 5 phases.

[0130] The presentation, as a conceptual block diagram, of the two stages is done modularly and is highlighted in figure 2, and the functional block diagram is presented in figure 3.

[0131] The unfolding of the defining phases is controlled by using the “Program P”, loaded into a controller (Ctrl) shown in figure 4, complementary to figure 3.

[0132] The development of the technological stages specific to CBI is mainly organized by gravity.

[0133] Following the chemical and granulometric diversity of the batches of raw materials, the metallothermic process proposed by CBI takes place sequentially through a continuous succession of distinct physical-chemical processes that, together, form a unitary whole.

[0134] The sequential processes proposed by the CBI allow the continuous obtaining of the programmed reaction products.

[0135] The CBI proposes the continuous metallothermic production of thermal energy convertible into electricity, complementary to the sequential production of metals / alloys, slags and reaction gases, without the use of carbon, carbon monoxide or hydrogen as reductants.

[0136] The diversity of the chemical and granulometric compositions of the oxidizing and reducing raw materials leads to the production of a diversity of thermite reactants (assortments of reactants) which, together with the sorts of reaction moderators, allows the proportional generation of a diversity of metallothermic fuels, capable of leading to certain reaction products.

[0137] The programmed thermite recipes (according to a P program), materialize in the mixer (AM) shown in figure 3.

[0138] The materialization of assortment thermite recipes (generation of thermite mixtures) uses the percentage dosing and homogenization of the components that together lead to obtaining the metallothermic fuel used at a given time.

[0139] The continuous transition from the use of a certain metallothermic fuel to another, materializes a new sequence of the multi-sequential process with continuous serial unfolding.

[0140] Dosing of the types of thermic reactants and reaction moderators, stored in pairs of specialized bunkers (e.g., bunkers Bmod, Bred and Box of module B, from figure 3) is carried out using dispensers (e.g., with auger), marked with (D) in figure 3.

[0141] The materials in the bunkers, after characterization by diffractometry and after dosing, are directed by gravity to the mixer (AM) where, through mixing and homogenization, they materialize the thermite recipe / mixture, i.e., the metallothermic fuel used at a given time.

[0142] The metallothermic fuel is characterized from a diffractometric point of view, dosed and sent by gravity to the metallothermic crucible (CM).

[0143] Dosing is controlled through Program P.

[0144] The sequences run serially, without interrupting the process. The sequences can have different durations, depending on the size of the batches of raw materials processed at a given time.

[0145] The CBI proposes the use of reaction inhibitors both to control the reaction rate and to stop the process in case of failure.

[0146] Stopping the process can be achieved by stopping the supply of reactants to the metallothermic crucible (CM) or / and by flooding it with reaction inhibitors.

[0147] The CBI process, being a continuous sequential process, allows a permanent exchange of mass and energy with the outside of the considered system.

[0148] The amount of caloric energy released, through the considered metallothermic reactions, is dependent on the types of reactants used. For indicative estimates, an average of about 850 kcal / kg of reacted thermite can be accepted, which can generate temperatures of over 2600°C in the metallothermic crucible. This fact must be avoided and for this reason the cooling of the crucible (CM) or / and the use of thermite mixtures generating temperatures chosen according to diagrams of the type shown in figure 3b are also required.

[0149] The specificity of the CBI continuously ensures, in the metallothermic crucible, by dosing a molar balancing of the flow of reactants with the flow of reaction products. This fact simultaneously leads to a balancing of the speed by which the reactants are consumed, with the speed by which the reaction products are formed.

[0150] The sizing of the CBI installation is done in accordance with the chosen production capacity.

[0151] The production capacity is chosen respecting the biunivocal molar relations presented in the systems of equations of the type (3).

[0152] 1.1.1 - Command and control of the electro-metallurgical process, promoted through CBI

[0153] It is done using a P informational program loaded into a controller (Ctrl).

[0154] Program P generates “thermite diagrams”, of the type shown in figure 3b. The diagrams result from the graphic-analytical interpretation of the biunivocal relations resulting from the systems of equations of the type (3). They relate the chemical compositions of the metallothermic fuels to the defining parameters of the reaction products.

[0155] Thermite diagrams are made in real time, for the flow of thermite reactants from the raw materials undergoing processing at a given time.

[0156] The characterization of the flow of raw materials and reactants obtained is done using diffractometers or XRF-type spectral analysers that also validate the data from the quality certificates that accompany the purchased materials.

[0157] Diffractometric analyses allow, through the P program, the rapid identification of molar equations, of type (3), specific as a reference for a certain batch of reactants and which, along with the other components, also materialize the chosen production capacity.

[0158] NOTE: For practical procedural exemplification, the thermite diagram in figure 3b shows a simplified metallothermic process that does not highlight the energy exchanged for phase changes. The graphical representation of the conditions revealed by the system of equations of type (3) indicates the direct / linear / biunivocal links between the reaction parameters, which allows the choice of one parameter to identify the others as well. This installation transforms “thermite diagrams”, of the type shown in figure 3b, into a command and control tool of the CBI Process.

[0159] Thus, the temperature of the metallothermic process is identified as the necessary and sufficient parameter for the molar / parametric definition of the metallothermic recipes leading to a certain metallothermic fuel processed at a given time.

[0160] And reciprocally, the reaction temperatures can be estimated compositionally, according to diagrams of the type shown in figure 3b, corresponding to the thermite mixture (metallothermic fuels) processed at a given time.

[0161] Depending on the characteristics of the assortment of thermite mixtures, the speeds of metallothermic reactions can quickly take very high values, which make unnecessary the “post factum” attempts to control them, and because of this, the estimation of the temperature at which the reaction takes place is essential.

[0162] -Eg

[0163] At the same time, by the Arrhenius equation k = Ae^-r (4), it becomes apparent that reaction rates and temperatures are interdependent.

[0164] NOTE - In equation (4): k is the reaction rate constant, A is a pre-exponential factor, kB is Boltzmann's constant, T is the absolute temperature of the reaction, and Eais the activation energy of the reaction.

[0165] Such diagrams, built for each batch of thermite reactants, allow that by choosing a certain temperature for the thermite reaction, the reaction speed and the composition of the aluminothermic mixture that generates and guarantees it can be estimated.

[0166] The command and control of the CBI Process and Installation is done using the “thermite diagrams” embedded in the “P Program” which is loaded into the controller (Ctrl), the block diagram of which is shown in figure 4.

[0167] Through Program P, the controller (Ctrl) records the characteristics of the raw materials and the resulting thermal components (reactants and reaction moderators), provided in real time by the diffractometers or spectral analysers used, and corroborates them with the expected characteristics of the reaction products. Based on the systems of equations of type (3) and the correlations of the type shown in the Thermite Diagrams (figure 3b), related to the batch processed at that moment, Program P establishes the thermite recipe of the moment and orders its materialization (the appropriate metallothermic fuel).

[0168] The percentage performance of the current thermite recipe is obtained, mainly, by the command and control of the auger dispensers (D), highlighted in figure 3.

[0169] The P program, embedded in the controller (Ctrl), acts as a continuous control loop in which the values transmitted by the sensors are evaluated with a minimum frequency of 1 Hz.

[0170] The outputs of the P Program are represented by commands to the actuators (screw dispensers, solenoid valves, etc.), thus ordering both the percentage materialization of the momentary metallothermic fuels and the obtaining of the desired reaction products.

[0171] The controller, through the P program, interprets the necessary analogic measurements and transforms them into digital format to be able to use them in the specific mathematical formulas that take into account the real-time variation of the characteristics of the raw materials, reactants and reaction moderators.

[0172] The operation of the controller (Ctrl) is shown in figure 4. From this figure it can be seen that the command and control loop of the CBI process and related installation starts from the characterization of the raw materials, followed by the command of the actuators that condition the processing and characterization of the thermite reactants and reaction moderators. These, under the command of the controller (Ctrl and the P program), are transformed into usable reaction products (heat, slag, alloys and reaction gases).

[0173] In this context, both the characteristics of the metals / alloys reaching the recipient (VTT) and the collection and evacuation of secondary slag resulting in this recipient are controlled and improved.

[0174] For this, the metals / alloys resulting from the crucible (CM) are evaluated with analysers (R), XRF type and discharged into the rotating and tilting homogenizer (OM) and from there into the recipient (VTT).

[0175] The recipient inlet and outlet temperature (VTT) and pouring timing are continuously monitored by the controller (Ctrl). This, upon reaching the optimal temperature value of the metal in the recipient (VTT) (about 1600°C), commands its inclination with the angle (a) and thus determines the controlled discharge of its contents, in the continuous casting installation (ITT).

[0176] Also, the controller (Ctrl) commands the opening of the proportional solenoid valves for the evacuation of both the secondary slag and the metal prepared for continuous casting, shown in figure 16, complementary to figures 2 and 3.

[0177] The efficiency of the CBI process results from the “Metallothermic Processes Moment Sheet”, collected in real time and presented, as a type, in table 2.

[0178] In this regard, sequentially, for each thermite batch processed, the P program compiles a comparative sheet of the defining characteristics of the exergonic component of the process and the resulting reaction products. Thus, through program P, a “thermite module” of 10 Kg of oxidic reactants is chosen in real time, as a theoretical reference, to which the necessary reducing agents are added and based on the outputs of the reactions, the “Metallothermic Processes Moment Sheet” is drawn up.

[0179] The “Metallothermic Processes Moment Sheet” is of the type presented in Table 2. This highlights parametrically (quantitatively and by percentage) the sequential, momentary situation of the inputs and outputs of the respective reactions (e.g., aluminothermic).

[0180] TABLE 2 - Metallothermic Processes Moment Sheet otal thermites 13.113 [Kg]

[0181] THE REACTION PR IODUCTS CORRESPONDING TO THE THERMITE MODULE

[0182] REACTION LOSSES

[0183] YIELDS / RATIOS

[0184] Both the transition of raw materials from one technological phase to another, as well as the stages of production and utilization of the resulting reaction products are monitored (controlled and validated electronically by the controller (Ctrl) which, through its sensors (stopwatches, diffractometers, XRF analysers and thermometers) uses the Program P.

[0185] 1.1.0.1.2 - Green thermite recipes

[0186] The CBI process proposes the use of batches of thermite reactants and reaction moderators dosed in percentage and homogenized, aiming at the significant reduction of the presence of carbon and sulphur.

[0187] At the same time, the aim is to reduce the presence of atmospheric air in the crucible (CM), which means that the CBI process and installation do not generate significant amounts of CO2, NOx and sulphur compounds (e.g., SO2, SO3, H2S, etc.) and thus become a “cleaner” technological process.

[0188] Thermite recipes are molar constituted, according to some thermic diagrams of the type shown in figure 3b, resulting from the interconnections resulting from the systems of equations of type (3), related to a certain thermite mixture (metallothermic fuel), processed at a given time.

[0189] The systems of equations of type (3) show how a certain metallothermic composition leads to the metallothermic release of thermal energy, complementary to the multi-sequential production with continuous serial running of some metallic (e.g., steels, cast irons, ferroalloys) or non-metallic materials (e.g., slag with a minimum of 70% AI2O3) and reaction gases.

[0190] Thermite recipes drawn up according to molar systems of type (3) use oxidic reactants obtained by processing ores (e.g., iron) and / or from oxidic dross waste (e.g., steel). Metal reducers are also used in addition, (e.g., Al, Mg, chemical compounds with Na, Ca, etc.).

[0191] For the composition of thermite recipes, the CBI process inventively proposes the unitary processing of oxidic raw materials such as dross and / or metal ores. Regarding the ferrous oxide ores, it is proposed to use only hematite (69.9% Fe), magnetite (72.4% Fe), goethite (FeO (OH) - 62.9% Fe) and limonite (FeO (OH) • n (H2O) - 55% Fe).

[0192] Through processing, the slag and oxide ores are converted into similar thermite reactants. Thermite recipes are drawn up starting from the quantities and qualities of the intended reaction products. They must correspond to the biunivocal relations shown graphically in figure 3b.

[0193] The percentage granulometric distribution, by type of reactants, is exemplified in table 1.

[0194] Table 1

[0195] 1.1.0.1.3 - General features of the installation presented in the CBI

[0196] The CBI presents, according to the block diagram in figure 3, the functional interconnection of the inventive and non-inventive subassemblies used to constitute the Installation that materializes the invented process.

[0197] As an installation, CBI proposes the use of both known sub-assemblies (e.g., rotary kilns, magnetic separators, granular separators, hoppers, dispensers, mixers, crucibles, etc.) and known materials (e.g., metal oxides, metal reducers, ferroalloys, etc), as well as the use of new / inventive technological components. These are: the metallothermic crucible (CM) with partial suction, double-walled and cooled with metal melts, the tilting and rotating homogenizer (OM), used to improve the chemical compositions of the materials resulting from (CM), and the tilting recipient (VTT), for timing of casting and finishing of melts obtained from the metallothermic process.

[0198] The set of components known as “State of the Art”, along with those newly proposed by the CBI, contribute inventively to obtaining new and unexpected effects such as the metallothermic production of thermoelectric energy, simultaneously and complementary to the obtaining of metallurgical products (metals, alloys, slags and gases of reaction), all usable. The metallothermic crucible (CM) in figure 3 has initially partial suction. It has double walls and it is cooled with metal melts (e.g., copper melts).

[0199] Upon exiting the metallothermic crucible, the resulting metal / alloy is compositionally characterized. Characterization is done sequentially, using analysers (R) that perform XRF-type analysis.

[0200] Any change in the thermic recipe can cause changes in the chemical composition of the metallurgical reaction products.

[0201] The identification of the new situation after any modification of the thermite recipe is done using the spectral analysers (R) in figure 3 (complementary to figure 2). These, starting after 5 s from the modification of the recipe, analyse 5 times (at intervals of 10 s) the evolution of the chemical composition of the metals / alloys resulting from the crucible (CM), which, through Program P, allows to identify, record and possibly improve it.

[0202] The improvement of the chemical composition of the resulting steel is done by adding, in doses, into the homogenizer (OM), the reaction moderators available in a set of hoppers related to the homogenizer, located above a funnel feeding it.

[0203] The assembly consisting of the rotary homogenizer (OM), its associated hoppers and the casting timing recipient (VTT) replaces traditional steel mills and ensures the desired grades of metals / alloys (e.g., steel).

[0204] The rotary homogenizer (OM) can be tilted. It continuously takes the steel produced in the crucible (CM) for 15 minutes, mixes it with the additional necessary moderators and directs it by gravity to the casting timing recipient (VTT).

[0205] The casting timing recipient (VTT) allows the separation of the secondary slag, settled on the surface of the metal in this recipient. At the same time, the casting timing recipient allows the accumulation of the metal produced in one hour and its natural cooling, up to the continuous casting temperature.

[0206] From the casting timing recipient, the metal / alloy is poured, at a temperature of about 1600°C (in the case of steels), into the continuous casting installation (ITT) and from here, solidified, it reaches the rolling mill (L).

[0207] The innovative technical elements and those known in the “state of the art” contribute to the elimination of technical, ecological and financial difficulties in the way of the metallothermic production of electricity, complementary to the metallothermic production of metals / alloys or non-metals. At the same time, by using homogenizers and casting timing recipients, the desired steel grades can also be determined compositionally.

[0208] From a practical point of view, the CBI installation proposes a set of technological solutions necessary for the metallothermic and ecological processing and valorisation of the raw materials used.

[0209] Among the metals whose melts can functionally fall (without generating large amounts of vapor) between the melting and boiling temperatures required for both heat transfer and cooling of the reaction crucible, copper can be chosen. It can be used at temperatures between 1085°C and 1175°C.

[0210] Such a metallothermic crucible cooling solution provides safety because it does not generate large amounts of vapours even if, accidentally, the copper melt comes into direct contact with the steel melt, produced trough the metallothermic process in the crucible (CM).

[0211] 1.2 PRESENTATION OF THE CBI STAGES

[0212] 1.2.1 - STAGE 1 - takes place in the Raw Materials Preparation Plant - Module A

[0213] Stage 1 presents the procedure and installation for the sequential processing of batches of raw materials, regardless of the granulometric class to which they belong, aiming at their transformation into components of thermite recipes (further - thermite components).

[0214] There are three types of raw materials processed in Stage 1 / Module:

[0215] - metal oxides, regardless of whether they come from ores (magnetite, hematite, limonite, goethite) or from oxidic metal waste (dross).

[0216] - metal reducers, regardless of whether they are supplied as finished products or represent processed metal waste

[0217] - precursor materials of reaction moderators (alloying materials, reaction inhibitors and fluxes).

[0218] Stage 1 proposes the sequential processing of raw materials both to remove waste and moisture, and to bring them to a powdery state with chemical and granulometric compositions suitable for metallothermic processing (150-5000 p). Following the existence of the three types of raw materials, Stage 1 takes place in three phases and on three technological lines that materialize the distinct processing phases of those 3 types of raw materials.

[0219] Therefore:

[0220] 1.2.1.1 - Phase A.1 - carried out on Line 1 which is shown in figure 11

[0221] Phase A.1 proposes the sequential transformation of metal oxides, found in ores and / or in dross, into similar thermic reactants, regardless of the chemical and granulometric compositional weight of the constituents of these raw materials.

[0222] Thus, after the supply of oxidic raw materials (dross or ores), they are primarily processed on technological flows specific to the type of raw material, after which, by raising to the higher levels of module A, the technological flows are reunited, continuing on a common route (figure 11 ).

[0223] The oxidic materials that have reached the upper level of module A, gravitate through a technological route (primary sieving, crushing, granulometric or magnetic separations, etc.) necessary in order to become oxidic thermite reactants, with granulations between 200 and 1600 p and with predominant weights of oxides higher (Fe2O3 plus FeaO4) of at least 60%, the rest is FeO).

[0224] The processing technology of oxidic raw materials (ores and / or dross) is also dependent on the quantities involved.

[0225] If the processing of large quantities of metal oxides (millions of tons) is intended, homogenizations similar to those practiced for limited quantities (e.g., up to 50 tons) cannot be effectively used and therefore continuous / dynamic compositional characterization is required, on the entire technological flow, both of the raw materials and of the resulting thermite reactants.

[0226] Under these conditions, the CBI process proposes a flexible, multi-sequential technological flow with continuous serial operation, dependent on the compositional variations inherent in the use of dross (technological waste) and / or ores.

[0227] The chemical compositional variations refer both to the weight of carbon and to the weight of the different types of oxides contained in the mixtures (oxides of iron, silicon, calcium, manganese, etc.).

[0228] Chemical compositional characterizations are done by diffractometry or XRF analysers.

[0229] The diffractometers, item (2) and item (2.2) respectively - fig. 11 , deliver the data obtained to Program P which generates the thermite recipes (metallothermic fuels) according to the chemical compositions of the reactants and according to the requirements imposed on the reaction products.

[0230] The compositional and granulometric characterizations and corrections are made using classic methods and machines (sieving, crushing, magnetic separation, pelletizing, dosing, etc.).

[0231] The useful granulations go into the recipes, the granulations larger than those required by the recipes are reintroduced into the rotary crushers and the smaller ones are directed to the pelletizers or are removed by storage.

[0232] In the case of the processing of oxidic batches (ores and / or dross) of less than 50 t, after the homogenization follows their characterization and then their processing in order to transform them into thermite reactants (module A - line 1 ).

[0233] After the obtaining, the oxidic reactants are stored in module B (the electrometallurgical converter), by granulometric classes, in pairs of alternately filled, suctioned and emptied hoppers.

[0234] The entire process is controlled and driven by the Controller (Ctrl) using the Program P.

[0235] 1.2.1.2 - Phase A2, carried out on Line 2

[0236] Phase A.2 proposes the processing of metallothermic reducing agents (e.g., Al, Mg, compounds with Na, etc.).

[0237] Theoretically, the metals to the left of the iron in the Beketov-Volta series can be usable reducing agents.

[0238] Practically, metal reducers can effectively result both from the processing of consecrated ores (e.g., bauxite) and their purchase as finished products (e.g., atomized Al powder), as well as from the recycling of reducing of metal waste (examples - aluminium metal waste or aluminium powders, aluminium recovered from oily slurries).

[0239] Aluminium-type metal reducers are purchased by granulometric classes or (in the case of waste recoveries) are separated by granulation into classes between 150- 500 p.

[0240] After the granulometric separation, the supplied metallic reducing agents become reducing reactants and are stored in module B (the electrometallurgical converter), by granulometric classes, in pairs of alternately filled, suctioned and emptied hoppers. Figure 12. In order to make the Process more efficient, the CBI also creatively proposes the processing of oily aluminium slurries, which involves: collecting the slurries, decanting them, washing them with clean wire drawing emulsions, in polyhedral sieves, sifting the obtained powders and collecting the resulting moist granulometric fractions. Figure 13.

[0241] OBSERVATIONS

[0242] The oily aluminium slurries result during the wire-drawing operations of aluminium cables or during the rolling operations of various aluminium profiles.

[0243] The recovery of aluminium powders from slurries is done by decanting of the metal component, followed by washes with clean wire-drawing emulsion and winnowing of the stripped metal component.

[0244] For safety reasons, the metal part of the aluminium slurries (wet aluminium powders) is not force-dried / heat dried, centrifuged or mechanically agitated.

[0245] The separation by granulometric classes is done by processing the powders in a wet state (max. 15%).

[0246] The resulting wet powders lead to wet, particularly active thermic recipes.

[0247] The processing of oily aluminium slurries is not done in the Raw Materials Preparation Plant, but in isolated locations, far from the rest of the facilities.

[0248] 1.2.1.3 - Phase A.3 - carried out on Line 3

[0249] Phase A.3, shown in figure 14, proposes the gravitational and sequential processing of the precursors of reaction moderators represented by alloying materials (e.g., carbon, ferroalloys, etc.), reaction inhibitors (e.g., steel shavings) and fluxes (e.g., calcium carbonate).

[0250] The precursors of reaction moderators are purchased according to accompanying quality certificates specifying their chemical composition and particle size class.

[0251] After purchase, if applicable, the precursors are crushed in order to bring them to the required grain size (e.g., 3-5 mm - for ferroalloys or metal shavings).

[0252] After crushing and bringing to the necessary granulation, the precursors became “reaction moderators” and are stored in pairs of hoppers equipped with dispensers, dedicated to each type of moderator.

[0253] Doubling the number of bunkers is necessary for their alternate filling, suction and emptying. The thermite reactants and reaction moderators obtained in Module (A) are transferred to the upper levels of the electrometallurgical converter presented in Module B - figure 2.

[0254] 1.2.2 - STAGE 2 - takes place in Module B

[0255] The Stage 2 of the process aims at the ecological transformation of thermite reactants and reaction moderators into reaction products (energy and metallurgical products).

[0256] The process and the installation related to the 2nd stage are embodied in an installation that represents a metallothermic electrometallurgical converter.

[0257] The operation of Stage 2 is presented as a block diagram, in figure 5, complementary to figures 2 and 3.

[0258] The Stage 2 of the CBI process highlights the concept that allows the metallothermic processing of metallothermic fuels (homogenized mixtures of oxidizing, reducing and moderating assortments) to be transformed into usable reaction products.

[0259] The metallothermic processing of batches of reactants and reaction moderators proceeds by gravity and leads to obtaining 4 types of reaction products.

[0260] The 4 types of reaction products are: metals / alloys, mainly non-metallic slags, reaction gases and heat.

[0261] Corresponding to the 4 types of reaction products, the 2nd Stage takes place on 5 eco-technological phases of obtaining and capitalizing on the reaction products, materialized on 5 technological lines.

[0262] All processes are controlled and directed by the controller (Ctrl) using the program P.

[0263] Therefore:

[0264] 1.2.2.1 - Phase B.1 -

[0265] Phase B.1 - presents the gravitational process that allows the using of the reactants, reaction moderators and fluxes obtained in Stage 1 and that justifies the complementary processing installation of thermite components, in order to become thermites / metallothermic fuels and later reaction products.

[0266] Gravitational processing is sequential, continuous and organized on three levels, according to Figure 6 (complementary to Figures 2, 3 and 5). The development of Phase B.1 is carried out conceptually according to those shown in figure 6, corresponding to level 1 .

[0267] The materials obtained in stage 1 (thermite components) are stored on level 1 in pairs of bunkers dedicated to each type of reactant / moderator, depending on the chemical composition and the granulometric class to which they belong.

[0268] The hoppers also serve as homogenizers because they are built as rotating drums for continuous homogenization of the contents.

[0269] Thus, in the system of paired bunkers (Box) the necessary oxide assortments are stored.

[0270] In the paired hopper system (Bred) the reaction reducer assortments are stored and in the paired hopper system (Bmod) the reaction moderators are stored.

[0271] The pairs of bunkers can be filled, suctioned and emptied alternately according to the technological needs pursued by the Program P.

[0272] The Program P, through the diffractometers (RD), ascertains and records the chemical composition resulting in the bunkers after the homogenization of their contents. These, after dosing, also go through the other phases of Stage 2.

[0273] Thus, the thermite components are sent by percentage to Level 2, in the mixer (AM) where, after mixing / homogenization, they become thermites / metallothermic fuels capable of metallothermic reaction.

[0274] Metallothermic reactions take place at Level 3, in the crucible (CM). This is where the programmed reaction products (heat, metallurgical products and reaction gases) appear.

[0275] The crucible (CM), having to withstand the programmed temperatures (about 2200°C) of the metallothermic reactions, must be cooled. Cooling is done with metal melts (e.g., copper).

[0276] In the crucible (CM), the slag and the metals being in a molten state and having different densities, are separated by gravity, generating 3 functional volumes.

[0277] VOL 1 - the volume of metals produced (marked in figure 6 with “a”) .

[0278] VOL 2 - the reaction volume, in which the metals and reaction slag appear (noted in figure 6 with “b”).

[0279] VOL 3 - the volume of slag produced (noted in figure 6 with “c”).

[0280] The size of the volumes is variable depending on the reaction rate, the crucible geometry (CM) and the chosen production capacity. In the crucible (CM) the metallothermic fuels enter with the flow rate commanded by the controller (Ctrl), able to ensure permanent balancing both with the discharge flow rates of the reaction products (metals / alloys, slags and reaction gases) and with the amount of heat discharged.

[0281] Flow balancing is achieved by permanently maintaining the flow of the slag through the device (EzG) for its evacuation.

[0282] Before the initiation of the metallothermic reaction, the vacuum pumps (PV) create a depression of 0.1 mbar throughout the technological process related to phase B.1.

[0283] After the initiation of the metallothermic reaction, the reaction gases appear in the crucible (CM) which create a counter pressure against the atmospheric air pressure and close the flow valves (CLS). Thus, the reaction in the crucible takes place only in the presence of atmospheric air remaining after the partial suction, which significantly reduces the presence of NOx in the reaction gases.

[0284] After overcoming the transient stage of the metallothermic reaction and stabilizing the reaction rates, the CBI Process aims to balance, in real time, the rates of oxidation-reduction reactions (V1 ) and the rates (V2) of the formation of reaction products.

[0285] For the CBI Process, the reaction rates represent technological, quantifiable and controllable parameters during the metallurgical process.

[0286] The balancing of the reaction rates and implicitly the stabilization of the reaction temperature (according to Arrhenius) materializes, in the metallothermic crucible, the three levels / volume intervals (V1 ), (V2) and (V3), relatively stabilized, of the existing melts:

[0287] - The volume corresponding to level “a” represents the volume of the metal melt (VOL 1 ) that is formed by the metallothermic reaction;

[0288] - The volume (V2) corresponding to level “b” represents the “reaction volume”, in which the metallothermic reduction reactions mainly take place. The intermediate volume (V2) represents the volume in which the two types of materials (slag and metal products) are being separated.

[0289] The slag, without metallic constituents, due to its density, has an upward movement towards level (c), forming (VOL 3) where it accumulates.

[0290] Similarly, the metal produced, having a density higher than the density of the slag, has a downward movement, towards the volume (VOL 1 ), where it accumulates. The size of the volumes (VOL 1), (VOL 2) and (VOL 3) is dependent on the chemical, physical and technological characteristics of the reactants and reaction products.

[0291] The three volumes of melts in the crucible appear gravitationally and are maintained both due to the flow rate of the thermite introduced into the crucible and due to the density differences (dependent on the chemical compositions and the reaction temperature) existing between the metals / alloys and the resulting slags (e.g., p_slag « 3.3 kg / dm3, and p_steel « 6.8 kg / dm3).

[0292] According to the CBI process, the stabilization of the hydraulic levels and implicitly of the two reaction rates (V1 for the consumption of reactants and respectively V2 for the formation of the reaction products) is obtained by correlating the flow of controlled metallothermic fuel into the crucible, corroborated with the flow of metals / alloys and of slag continuously discharged from the same crucible.

[0293] Flow control / equalization is done by permanently maintaining the flow of slag only through the first two holes of the slag evacuation system (EzG) from the crucible (CM).

[0294] The flow of slag through the third hole of the system (EzG) requires the reduction of the metallothermic combustible flow, and the lack of flow through the 2nd hole requires the increase of the metallothermic fuel flow.

[0295] The flow of slag through hole 4 of (EzG), requires stopping the process.

[0296] The temperatures generated by metallothermic reactions can be particularly high (they can even exceed 3000°C) and because of this, the reaction temperature must be compositionally limited and the metallothermic crucible (CM) must be cooled. For this, a cooling fluid is used, which is recirculated between the double walls of the metallothermic crucible (CM) and led outside it to a heat exchanger.

[0297] The cooling fluid also has the role of taking the excess heat from the crucible and taking it out of it, for recovery.

[0298] The cooling fluid of the metallothermic crucible (CM) can be a metal melt (e.g., Cu), at a temperature of about 1150°C

[0299] The flow rate of the cooling fluid, combined with the reaction temperature, must ensure inside the crucible a global temperature between 2100°C and 2300°C and an outlet temperature of the reaction products of about 2200°C. From the metallothermic crucible (CM), the resulting metals / alloys are transferred by gravity to the homogenizer (OM), shown in figure 15, complementary to figure 3.

[0300] All functional correlations are made through the controller (Ctrl) using Program P.

[0301] 1.2.2.2. Phase B.2

[0302] Phase B.2 presents the process that allows the processing of the materials resulting from phase B1 and which leads to the installation presented in Line B2.

[0303] The development of process Phase B.2 is shown schematically in figure 7 (complementary to figure 2 and figure 3).

[0304] As a result of the metallothermic reaction of the thermite mixtures, sequentially introduced into the crucible (CM), metals or alloys flow into the rotary homogenizer (OM) and from there into the casting-timing recipient (VTT) (figure 7 complementary to figures 2, 3 and 6 ).

[0305] The CBI process proposes that upon exiting the crucible (CM), the produced metal / alloy is compositionally tested using an XRF type analyser (R).

[0306] If the resulting composition does not correspond to the programmed one, through Program P, compositional corrections are made.

[0307] Compositional corrections are made in the homogenizer (OM). The necessary reaction moderators (alloying materials) can be added here by percentage.

[0308] The reaction moderators produced in step 1 are available in a hopper assembly (BOD) intended to store the required alloying materials.

[0309] Hoppers (BOD) allow percentage corrections by means of dispensers (D).

[0310] In Phase B.2 metals or alloys with common chemical compositions can be generated.

[0311] In order to achieve / ensure a homogeneous chemical composition of the metals / alloys produced, the homogenizer (OM) must be able to store and improve the production of metals / alloys made for 15 minutes by the crucible (CM).

[0312] The real-time change in the chemical composition of the metals / alloys delivered by the crucible (CM) makes the operation of the homogenizer (OM) sequential and continuous.

[0313] For compositional checks, samples are taken from the metal entering the homogenizer (OM), which are quickly cooled and analysed spectrally with XRF type analysers (R). The detected information is accumulated by the controller (Ctrl) in figure 2 which, through the program P, compares it with the programmed composition and orders the necessary corrections.

[0314] If the correction of the chemical composition is required, from the hoppers (BOM) equipped with the dispensers (D), through the controller (Ctrl), the percentage addition of the necessary alloying materials is ordered.

[0315] At the exit from the homogenizer (OM), the chemical composition of the resulting alloys is controlled by another XRF-type analyser (RV) that allows the validation of the resulting composition.

[0316] After validation, the resulting metals / alloys are poured into the casting timing recipient (VTT), through which they travel within an hour.

[0317] During this period, "secondary slag" can accumulate on the surface of the metal in the (VTT) recipient which may contain various impurities (e.g., oxides, carbides, etc.).

[0318] In phase 2.2, the casting timing recipient (VTT) provides two facilities:

[0319] 1 - Continuous transport and natural cooling of accumulated metals / alloys for one hour.

[0320] In order to ensure this timing, the recipient (VTT) must have a geometry (volume, surface and longitudinal section) capable of accumulating and transporting continuously, without turbulence, the metals / alloys produced during one hour.

[0321] During this time the recipient (VTT), by its dimensions, must allow the natural cooling by convection, conduction and radiation of the accumulated metal / alloy, from about 2200°C to about 1600°C (for steel).

[0322] 2 - Separation and removal of secondary slag that forms / accumulates on top of the metal in the vessel (VTT).

[0323] The secondary slag, which flows together with the alloy in the recipient, is directed geometrically (through the narrowed shape of the recipient) towards the discharge device (EZ) which leads it into a collecting pot (OZ).

[0324] The flow velocity of the molten metal passing through the recipient (VTT) depends on its geometry and its adjustable inclination, with an angle (a).

[0325] The flow rate is controlled by the controller (Ctrl), . This corroborates it with the cooling rate of the metal / alloy traveling the length of the recipient (VTT), shown schematically in figure 16. The variation of the temperature in the recipient is indicated by an assembly consisting of a thermometer, placed at the entrance of the metal into the recipient (VTT) and by 2 thermocouples that measure the temperature of the metal at the exit from the recipient.

[0326] The assembly consisting of thermometer and thermocouple, also makes it possible to determine the cooling rate of the metal / alloy intended for casting.

[0327] The required cooling speed needs, through the P program, the optimal choice of the angle (a) of the tilt of the recipient (VTT).

[0328] The judicious choice of the angle (a) makes it possible for the produced metal / alloy to travel the length of the recipient (VTT) and cool naturally by about 600 C in one hour.

[0329] The evacuation of the cooled metal / alloy, at the casting temperature, is done through evacuators with variable flow rates (proportional solenoid valves) that allow controlling the flow rates.

[0330] After compositional finishing, in the homogenizer (OM) and after cooling to the casting temperature, in the recipient (VTT), the molten metal / alloy passes by gravity into the continuous casting plant (ITT) and from there, solidified, it reaches the rolling mill (L) which completes the processing of metal materials.

[0331] 1.2.2.3 - Phase B.3

[0332] Phase B.3 refers to the process of processing the metallothermic slag resulting in the crucible (CM) and leading to the installation / Line B3 for processing the metallothermic generated slag.

[0333] The development of Phase B.3 is shown in figure 8 (complementary to figure 2 and figure 3).

[0334] The slags appear in the crucible (CM), as a result of the metallothermic reactions taking place in that enclosure. Metallothermic slags consist of at least 70% aluminium trioxide, with the formula AI2O3.

[0335] The remaining percentage is represented by metal pellets and / or non- metallothermic reacted metal oxides.

[0336] The methodology for processing metallothermic slags involves their evacuation from the crucible (CM) to an atomizer (AZ) where they are transformed into pellets (spheroidal bodies) of different sizes. For atomization, the slags at temperatures of around 2200°C are dispersed with an air-water mixture jet, directed perpendicular to the molten slag jet.

[0337] The pressure with which the air-water mixture disperses the slag jet is 0.25 MPa.

[0338] Through atomization, predominantly metallic and / or oxidic spheroidal pellets appear, with granulations ranging from submicron to millimetre (3-5 mm).

[0339] The resulting pellets are collected in the decanter pair (DEC). The decanters (DEC) have an alternative operation, being filled or emptied after an alternative cooling with water from the cooler (RA).

[0340] The cooling temperature of the blades is around 40°C.

[0341] The water in the decanters is alternatively cooled using a large capacity cooler (RA).

[0342] After cooling, the pellets are passed by gravity into a rotary dryer (UR).

[0343] The dryer (UR) uses air at ambient temperature, supplied by a fan system (VE) that creates a pressure of about 1 .25 bar.

[0344] From the dryer (UR), both metallic and non-metallic alloys pass into a magnetic separator (SM) which separates the predominantly metallic alloys from the predominantly non-metallic alloys (corundum - aA Os).

[0345] After the magnetic separation, the two types of pellets reach the grain separators (SG) that detect the granulometric classes of interest.

[0346] The pellets separated by granulometric classes with sizes varying between micron and millimetre, are then stored in bunker systems dedicated to the two types of pellets.

[0347] The whole process is controlled and directed by the program P, loaded into the controller (Ctrl).

[0348] 1.2.2.4 - Phase B.4

[0349] Phase B.4 - represents the part of the CBI process of neutralization - using of reaction gases.

[0350] Phase B.4 is presented conceptually, as a block diagram, in Figure 9 (complementary to Figure 2 and Figure 3).

[0351] Following the specificities of the CBI process, the reaction gases contain only traces of CO2, NOXand gaseous sulphur compounds. The reaction gases mainly contain metallic and non-metallic vapours. They result at temperatures of about 2300°C and they are evacuated from the crucible (CM) at temperatures of about 2200°C.

[0352] The reaction gases are collected by a fume cupboard (H) which sends them to a chimney (CG) for their evacuation.

[0353] The chimney (CG), through a heat recovery unit (RCP), allows the partial recovery of the heat carried by the reaction gases.

[0354] The reaction gases, after a wet filtration, carried out with a nebulizer (NB), are passed through a system of electro-filters (EF), after which they are analysed with a gas analyser (AG) and, if they match, they are released into the atmosphere. Exceeding the allowed norms automatically leads to the stop of the process.

[0355] Wet filtration, carried out in phase 2.4, involves passing the flue gases through a wet mist that condenses them and transforms them into metallic and non-metallic powders. The resulting powders are collected in a pair of decanters (DP).

[0356] The decanters are filled and emptied alternately (sequentially), with pellets or with water, at a temperature of about 20°C.

[0357] The water in the decanters is cooled using an industrial cooler (RAP).

[0358] The CBI process aims for the wet filtering of the flue gases to be done when they have temperatures lower than 1700°C (to avoid the thermolysis of water).

[0359] From the decanters (DP), the resulting powders are sequentially introduced into a rotary drying drum (TRU) which operates with pressurized air (1.1 bar) at a temperature of around 50°C.

[0360] The hot air is supplied by the fan (VP) which circulates atmospheric air through the heat recovery unit (RCP).

[0361] After drying, the powders must be magnetically separated with a separator (SMP), in order to separate the metallic (magnetic) component from the non-metallic (non-magnetic) component, predominantly - aAI2O3.

[0362] Each type of powder, magnetically identified, is directed by gravity to the particle size separators (SGP) that facilitate the collection and separation of the particle size classes of interest in dedicated bunkers. The size of the granulometric classes ranges from micron to millimetre.

[0363] The entire process is monitored by the controller (Ctrl), through the program P. 1.2.2.5 - Phase B5 / the thermo-energetic phase.

[0364] Phase B5 - Presents the process of using the excess caloric energy in the crucible (CM).

[0365] The block diagram of phase B5 is shown in figure 10 (complementary to figure 2 and figure 3).

[0366] The exothermic reactions that occur in the metallothermic crucible (CM) are exergonic reactions, and because of this, a significant amount of usable heat appears.

[0367] The CBI process proposes taking over the excess heat, located in the metallothermic crucible (CM), followed by its removal and recovery outside it.

[0368] Taking over the excess heat is done using the crucible cooling fluid (CM), which thus also becomes a heat transfer agent.

[0369] The cooling / heat transfer fluid is recirculated through the double walls of the metallothermic (CM) crucible and is directed to a heat exchanger / steam generator.

[0370] The amount of heat available depends on the current thermal recipe and the chosen production capacity. Globally, the amount of heat released is at least 700 kcal / kg of termite.

[0371] The cooling / thermal transfer fluid of the metallothermic crucible is a metallic melt (Ex. Cu), at temperatures no higher than 1200°C (about 1150°C).

[0372] Outside the metallothermic crucible (CM), the heat transfer I cooling fluid (MT) is circulated through a refractory tube and a transfer pump (PTHR), resistant to temperatures higher than 1200°C.

[0373] In order to control the temperature of the heat transfer fluid, the refractory tubing can be cooled using the heat sink (SR).

[0374] The refractory tubing leads the cooling / heat transfer fluid to a recovery type heat exchanger (SC), a component of a steam generator (GA).

[0375] The tubing is made also of heat-resistant materials (e.g., sintered molybdenum, ultra- high density graphite, etc.).

[0376] Low, medium or high pressure steam is produced in steam generators with capacities dependent on the size of the intended production (thousands of kg / h - steam). The steam produced can be used for various heating purposes or can be expanded in classic turbines (TA), currently used in thermal power plants. They drive electric generators (GE) of alternating electric current.

[0377] The conversion efficiency of thermal energy into electrical energy is around 32- 35%.

[0378] The alternating electric current, produced at 6000 V / 50 Hz is sent to the transformer system (TrE) which brings it to usable parameters. Thus, part of this availability is transformed into three-phase electric current (380 V / 50 Hz / 100 kW) which is intended to satisfy the energy needs of the installation presented in the CBI, and the rest is brought to the necessary parameters in order to be transferred to the national energy system (National Network).

[0379] 2.1 - THE CBI INSTALLATION

[0380] 2.1.0 - Overview

[0381] The CBI installation - is used to materialize the sequential process claimed by the CBI.

[0382] The CBI installation is bimodular and works according to the basic block diagram shown in figure 2, complementary to figure 3.

[0383] The CBI installation is sized according to the chosen production capacity.

[0384] The CBI installation is mainly composed of subassemblies known in the state of the art, but it also contains inventive subassemblies that together lead to new and unexpected effects (e.g., metallothermic production of thermoelectric energy).

[0385] The CBI installation is controlled electronically by the controller (Ctrl) using the Program P.

[0386] The sensors used are XRF type analysers, diffractometers, timers, screw dispensers, thermometers, etc.

[0387] The CBI installation has as its main inventive sub-assembly, a metallothermic electrometallurgical converter, represented by Module B. It also contains subassemblies unknown in the state of the art, such as: a partially suctioned metallothermic crucible (CM), a homogenizer (CM) and a casting timing recipient (VTT). The installation of the electrometallurgical converter is made around the doublewalled metallurgical crucible (CM), between which a cooling and heat transfer fluid circulates.

[0388] The electrometallurgical converter installation works with atmospheric air remaining after producing vacuum (at 0.1 mbar) for the subassemblies between the vacuum pumps (Pvid) and the metallothermic crucible (CM).

[0389] As an installation, the metallothermic electrometallurgical converter has a continuous sequential or multi-sequential operation because it allows, in real time, the materialization and continuous use of a multitude of thermite recipes, provided by the Program P.

[0390] As part of the CBI installation, the rotating and tilting homogenizer (OM) allows the correction of the chemical and structural composition of the metals / alloys resulting from the metallothermic reactions in the crucible (CM).

[0391] Similarly, the casting timing recipient (VTT) can be tilted and allows both the collection and controlled cooling of metals / alloys released, for one hour, from the homogenizer (OM) and the removal of secondary slag, resulting from compositional corrections, carried out after the exit of metals / alloys from the crucible (CM).

[0392] The homogenizer (OM) and the recipient (VTT) simplify the technologies that define traditional steelworks.

[0393] The CBI installation consists of two modules:

[0394] 2.1.1- Module A - is the module / installation that ensures the sequential processing of the purchased raw materials (ores and / or dross, alloying materials and fluxes) and their transformation into thermite reactants and / or reaction moderators, usable for the metallothermic process. and

[0395] 2.1.2 - Module B - which represents the composition of the metallothermic electrometallurgical converter.

[0396] Module B contains, apart from the metallothermic crucible (CM), the homogenizer (OM) and the casting timing recipient (VTT), subassemblies known in the state of the art. These are sub-assemblies that through CBI, are potentiated to produce new and surprising effects.

[0397] Module B is that part of the CBI Installation that allows the transformation of thermite reactants and reaction moderators into reaction products (heat and metallurgical products). In this regard, it is the metallothermic production of electricity, complementary to the production of metallic and non-metallic materials).

[0398] 2.1.1.0 - Presentation of the CBI Installation, related to module A

[0399] The installation related to Module A includes three technological lines (A1 , A2 and A3) used for the materialization of the three phases that make up Stage 1 of the CBI process.

[0400] The CBI Installation is dimensioned according to the chosen production capacity.

[0401] The raw materials processed are: oxidic materials represented by dross and / or metal ores (without pyrites), metal reducers (e.g., Al, Na, K, Ca, Mg, etc.) and reaction moderators (ferroalloys, metal shavings) and fluxes.

[0402] After the loading of raw materials (ores or dross, precursors of reducers and precursors of reaction moderators) of the Raw Materials Warehouse (from module A), the technological lines of the CBI Installation operate continuously sequentially and mainly by gravity.

[0403] As part of the CBI Installation, Module A sequentially processes different grades and quantities of dross and / or ores, reducing metals and reaction moderators (alloying materials, reaction inhibitors) and fluxes, delivering them to Module B.

[0404] Module A and module B must be sized according to the chosen production capacity. They process distinct batches of raw materials and respectively components of thermite recipes (thermite components).

[0405] 2.1.1.1 - Module A is mainly made up of machines known in the state of the art, but there are also new subassemblies, unknown in the state of the art. Together, these lead to new and surprising results (e.g., unitary transformation of metal ores and dross into oxidic thermite reactants, in order to obtain thermoelectric energy, simultaneously with metals or non-metals).

[0406] As a result of the processing of the three types of raw materials (oxidizing, reducing and moderating), Module A is composed of three technological lines.

[0407] 2.1.1.0.1 - Line A1 - for the sequential processing of metal ores and / or dross that are part of the category of oxide precursors.

[0408] Line A1 targets the production of oxidic thermite reactants. The technological Line A1 , whose block diagram is presented in figure 11 (complementary to figures 2 and 3), is composed in its first part, of two separate circuits which initially allow the sequential processing of the two main types of raw materials (ores or dross).

[0409] After completing the specific circuits, the two types of raw materials are technologically reunited onto a common route.

[0410] The two specific circuits are:

[0411] Circuit 1 - for the processing of ores, until they are taken onto the circuit of the elevator (e);

[0412] Circuit 2 - for the processing of dross, until they are taken onto the circuit of the elevator (e).

[0413] On circuit 1 , the primary elevator (E), item (1 ) - fig. 11 , takes the ores from the dump and after characterization with the diffractometer (RD), item (2) - fig. 11 , upload them to the Raw Materials Preparation Plant.

[0414] Here the ores are crushed, separated by granule size and transferred to the primary magnetic separation system (3).

[0415] The magnetic separator has the possibility of separating magnetic components (metal oxides) from non-magnetic (tailings) ones.

[0416] The tailings are directed by gravity to the tailings dump (8), and the useful materials are sent, also by gravity, to the jaw crusher (5) and then to the rotary crusher (6). Both crushers are series products, electrically driven. They have operational elements made of manganese steel (Mn 14-16%).

[0417] The jaw crusher (5) crushes the ore pieces to sizes smaller than 20 mm, and the rotary crusher (6) brings them to sizes smaller than 5 mm.

[0418] Crushers (5) and (6) have production capacities dependent on the overall production capacity of the CBI Installation.

[0419] The useful fraction, resulting from the crusher (6), reaches the magnetic separator (7) by gravity, from where the tailings end up in the tailings dump (8), and the useful fraction is picked up by the elevator (e).

[0420] Similarly, on Circuit 2, the dross is taken from the dross dump, by the elevator (1.2) and the dispenser (D), they are chemically characterized with the help of the diffractometer (2.2) and sent by gravity to a granulation separator and from there to a magnetic separator that separates tailings from useful dross. The tailings are sent to the tailings dump (8), and the useful materials arrive by gravity in the rotary crusher (6.2), similar to the crusher (6), which brings them to granules smaller than 5 mm.

[0421] The materials resulting from the crusher (6.2) reach the elevator (e) by gravity.

[0422] The elevator (e) is a screw elevator, electrically operated and electronically controlled by the controller (Ctrl).

[0423] The elevator (e) picks up the crushed ores / dross, passes them through the diffractometer (13) and sends them to the rotary calciner (9).

[0424] The rotary kiln (9) removes the moisture and by calcination in an oxidizing atmosphere, influences the proportion of oxides.

[0425] The rotary kiln (9) operates with hot air supplied electrically, by an air heater

[0426] (19) placed laterally, at 15° from the axis of the furnace.

[0427] The oxidizing atmosphere is created at 1250°C and at a pressure of 1.25 bar, provided by the fan (V) of the air heater, capable of providing a flow of hot air depending on the dimensions of the furnace.

[0428] The rotary kiln (9) rests on a roller system (17) with an adjustable inclination of 6-10° and rotates at 5-10 rpm using a pinion-gear system (18) driven by an electric motor (16).

[0429] The operation of the rotary kiln is sequentially commanded and controlled by the controller (Ctrl).

[0430] The rotary kiln (9) has a length of 5m and a diameter of 800 mm. It consists of a metal jacket (10 mm thick welded pipe) protected on the inside with aluminium refractory brick, resistant to temperatures above 1250°C. On the outside, the rotary kiln is thermally insulated with a layer of ceramic fibre, with a minimum thickness of 25 mm.

[0431] After drying / calcining, the oxide powders reach the rotary cooler (10) by gravity. It is structurally similar to the furnace (9), but it is not lined with refractory materials.

[0432] The cooler (10) has an inclination and rotation speed similar to the rotary kiln (9) and forcibly cools the oxidic materials by blowing atmospheric air at a pressure of 1.25 - 1 .5 bar.

[0433] Cooling air is blown into the furnace by the fan (20). The pressure created by the fan

[0434] (20) is 1.25 - 1.5 bar.

[0435] The cooler (10) is controlled by the controller (Ctrl), to bring the oxidic materials to a maximum temperature of 50°C. After the primary cooling, the oxidic materials reach the secondary granulation separator (11) by gravity, which separates them into five granulometric intervals (< 200 p, 200-500 p, 500-1000 p and 1000-1500 p, >1500 p). At the exit from the separator, the oxide powders are characterized spectrally with the analysers (13) and are homogenized in the rotating drums (14).

[0436] The rotating drums (14) are made of metal pipes, with a diameter of 700 mm and a length of 6 m. They rotate at 10-20 rpm, and are also inclined at 4-7°. They contribute to the cooling of oxide powders (up to max. 50°C) and their homogenization.

[0437] The rotating drums are electronically controlled by the controller (Ctrl) to ensure homogenization and cooling of the separated oxide components.

[0438] The oxidic powders thus cooled and homogenized by granule size reach the hoppers (15) equipped with the dispensers (21 ) which are also controlled by the same controller (Ctrl).

[0439] The bunkers (15) are made of sheet steel with a minimum thickness of 5 mm and have capacities of at least 10 tons.

[0440] The oxidic powders in the bunkers (15), with grain sizes of 200-500 p, 500-1000 p and 1000-1500 p, constitute the oxidic reactants used in the CBI-specific metallothermic reactions.

[0441] The oxidic reactants obtained are ready to be transferred to the pairs of specialized bunkers (Boxes), existing in Module B.

[0442] The fractions smaller than 200 p, resulting from the separator (11), are pelletized.

[0443] Pelletization is shown schematically in figure 11. Pelletization is done continuously, by mixing the metal powders with bentonite 5% and 15% water, in a mixer with continuous operation (M), after which the mixture reaches the rotary kiln (CR) by gravity , electrically heated to 1200 C with the air heater (A).

[0444] The feed to the mixer (M), with the granulometric fraction smaller than 200 p, is made from the separator (11 ).

[0445] A screw dispenser, type (21 ), is used for dosing. Simultaneously, controlled amounts of water (15%) are added from the reservoir (12) and bentonite - 5% - is taken from the hopper (B).

[0446] The materials resulting from the rotary kiln (CR) reach by gravity in the rotary cooler (cr) and from there in the rotary crusher (CP) which brings them to sizes smaller than 2 mm, after which, with the help of an elevator (E), they are reintroduced into the the granulometric separator (11 ) and the cycle repeats.

[0447] The pelletizing furnace (CR) and cooler (cr) are made of 4 mm thick refractory stainless steel pipe.

[0448] The pelletizing furnace (CR) and the cooler (cr) have a diameter of 500 mm and a length of 4 m. They are inclined at 5° and rotate at 5 - 10 revolutions / minute.

[0449] 2.1.1.1.2 - Line A2 - It is used for the processing of precursors / raw materials capable of leading to the obtaining of the metal reducers used.

[0450] The block diagram of the A2 line is shown in figure 12 (complementary to figures 2 and 11 )

[0451] The precursors used in CBI are:

[0452] 1. Atomized aluminium powders, purchased from established suppliers;

[0453] 2. Aluminium powders resulting from the shredding of aluminium waste (e.g., thin aluminium sheets);

[0454] 3. Oily aluminium slurries.

[0455] Appropriate technologies are used to process each type of reductant precursor.

[0456] The A2 line aims to obtain reducing reactants and for this it mainly uses equipment known in the state of the art, organized on distinct technological circuits.

[0457] The technological steps related to line 2 are carried out by the precursors of the purchased metal reducers (e.g., aluminium powders with granulations between ISOSOO p).

[0458] The grain sizes of the aluminium powders resulting from the recoveries must also be between 150-500 p.

[0459] The grain size classes of metallothermic interest are: 100-200 p, 200-300 p, 300-500 p.

[0460] The technological circuit related to the processing of oily aluminium slurries begins after their separate collection and storage, in the Depot of Precursors of Reducers. From here, the oily slurries reach the decanter (2e) where the metallic part of the slurries is separated from their liquid part.

[0461] The liquid part (used emulsion) is recovered in the recipient (2f) and is prepared for sale or recycling.

[0462] The solid part of the oily slurries (wet aluminium powders) is introduced by gravity into the “washer-separator” (2g), shown in figure 13. The “washer-separator” (2g) has the shape of a hexagonal polyhedron with a length of 5 m, made of a round steel pipe with a diameter of 2”, having a polyhedral side of 600 mm and 5 working areas, corresponding to the 5 granulometric ranges of interest ( <100 p , 100-200 p, 200-300 p, 300 - 500 p and > 500 p).

[0463] The metallic construction of the hexagonal polyhedron is covered with stainless steel mesh, having on each working area meshes of distinct sizes (respectively: 150 p, 200 p, 300 p and respectively 500 p).

[0464] The capacity of the “washer-separator” depends on the chosen production capacity, but it is at least 500 kg / h aluminium powders.

[0465] The operation of the “washer-separator” addresses the metal part of the oily aluminium slurries.

[0466] The block diagram of the washer-separator is presented in figure 13, complementary to figure 12.

[0467] The hexagonal sieving polyhedron (2r) rotates at 10 rpm and is inclined at 6° to the level of the clean liquid emulsion bath in the basin (2h).

[0468] The rotating and inclined sieving polyhedron is partially immersed (minimum 100mm) in the emulsion bath of the type used for wire drawing, located into the basin (2h), supported by the system (2s).

[0469] The emulsion in the basin (2h), shown in figure 13, is filtered and recirculated with the help of the pump (2n), which lifts it above the sieving polyhedron (2r) and which, through the distributor (2p), sends it back to the washing - sieving polyhedron.

[0470] The washing-sieving polyhedron is supported by supports (2k) provided with rotating bearings (2t).

[0471] The rotary motion is provided by the electric motor (ME) which drives the pinion / gear system (2I).

[0472] The supply of the decanter-separator, with the metallic materials from the decanter (2e), mentioned in figure 12, and respectively the evacuation of the wet aluminium powders is done through the stationary drums (2i), from figure 13. These direct the wet powders to the decanter hoppers (2v). From here, with the help of the pumping-filtration system (2o), the residual emulsion is removed and sent back to the basin (2h), and the metallic part, after removing the residual emulsion, is sent by gravity to the storage bunkers (2J) and (2x) respectively - for useful granulations.

[0473] Granulations < 150 p and those > 500 p are sent by gravity (according to figure 13), to the bunkers (2J). From here, according to figure 12, the dispensers (2c) and the elevators (2d) send them to the bunkers (2u) and (2q), respectively, where they await commercialization or special applications (e.g., special recipes and respectively melting).

[0474] After removing the residual emulsion, the useful granulations are sent by gravity to the hoppers (2x), from where the dispensers (2c) send them by gravity to the elevators (2d) which, through the direction valves (2y), direct them to the corresponding pair of hoppers (Bred) of Module B.

[0475] The technological circuits related to the processing of atomized aluminium powders or those originating from the shredding of aluminium waste are similar and are shown in figure 12.

[0476] These circuits work alternately with the processing circuits of aluminium slurries and start with the supply of the respective precursor materials, accompanied by quality certificates.

[0477] After supply, the purchased reducer precursors (atomized powders and / or powders from aluminium waste recycling) are separated into the three particle size ranges of interest: 150 - 200 p, 200 - 300 p and 300 - 500 p.

[0478] The granulation separator (2a) is used.

[0479] After separation, the precursors become reducing reactants and are stored in the 3 bunkers (2b), equipped with type (2c) dispensers.

[0480] After storage in the bunkers (2b), if needed, the reducing reactants are transferred, with the elevators (2d), to the pairs of bunkers (Bred) of the module (B) - figure 11.

[0481] The bunkers (2b) have a capacity of 500 kg each and are made of 2 mm thick steel sheet.

[0482] The dispensers (2c) are electrically actuated and are industrial anti-ex type, (e.g. they can be with auger, with cups, etc.).

[0483] OBSERVATIONS

[0484] The oily aluminium slurries result during the wire drawing operations of aluminium cables or during the rolling operations of various aluminium profiles.

[0485] The recovery of aluminium powders from slurries is made by decanting the solid component, followed by its washing and crushing.

[0486] For safety reasons, the metal part of the aluminium slurries (wet aluminium powders) is not forced dried / heat dried and it is not centrifuged. The separation by granulometric classes is done by processing the powders in a wet state (max. 15%).

[0487] The resulting wet powders lead to wet, particularly active thermite recipes.

[0488] 2.1 .1 .1 .3 - Line A3 - for processing precursors of reaction moderators is part of Module A.

[0489] Line A3 is equipped with equipment known in the state of the art and it is shown schematically in figure 14.

[0490] For the CBI, the reaction moderators are of 3 kinds:

[0491] 1- alloying materials, i.e.: carbon, ferroalloys (e.g., FeMn, FeNi, FeCr, FeB, FeSiZr, FeTi, etc.) and possibly metal alloy shavings (e.g., Ni, Cu, etc.);

[0492] 2 - reaction inhibitors (e.g., steel shavings);

[0493] 3 - fluxes (ex. CaCC )

[0494] Corresponding to the three types of raw materials, there are three technological circuits for their processing.

[0495] Precursors of alloying materials are represented by coal / coke dust, ferroalloys or shavings of relatively pure metals.

[0496] The precursors of the reaction inhibitors are represented by the metal shavings that result as waste from mechanical processing (e.g., lathing / milling of profiles from OL37).

[0497] Fluxes (e.g., CaCOs) are purchased from established suppliers.

[0498] The technological stages related to the three circuits that make up Line 3 are covered by the precursors of the alloying materials (carbon, metal chips and ferroalloys type: FeMn, FeNi, FeCr, FeB, FeSiZr, FeTi, etc.), by the precursors of the reaction inhibitors (e.g., metal shavings purchased ad hoc) and by fluxes as follows:

[0499] The alloying materials are initially crushed (if applicable) in the jaw crusher (3a), after which the crushing continues in the rotary crusher (3b), which brings them to 1-5 mm granulations, after which they are stored, according to the chemical composition, in the bunker battery (3c). Thus they became reaction moderators.

[0500] The crushers have the active elements (e.g., the jaws) cast from manganese steel (Mn 16%). Crushers are driven by 4 kW three-phase electric motors.

[0501] The bunkers (3c) are dedicated to each type of moderator material used. The bunkers are made of steel sheet with a minimum thickness of 3 mm. They have volumes dependent on the production capacity of the facility (e.g., minimum 2 tons each).

[0502] The hoppers (3c) are equipped with industrial-type auger dispensers (3d).

[0503] After the XRF characterization, done with the analysers (3e), the alloying materials are transferred with the elevators (3f) into the corresponding battery of paired hoppers (8) of the B module.

[0504] The hopper battery in Module B consists of pairs of hoppers dedicated to each type of alloying material used.

[0505] The pairs of hoppers are alternately filled, suctioned and emptied to allow the partial vacuum start of the metallothermic process.

[0506] The initial suctioning is done with the pumps (5) at a depression of 0.1 mbar.

[0507] The reaction inhibitors - are metal shavings (e.g., of OL37), with dimensions of 3-5 mm (shavings, pellets, etc.).

[0508] In order to be brought to these dimensions, the shavings are crushed in the rotary crusher (3g) and dried in the rotary dryer (3h).

[0509] The drying temperature is around 400°C and can be obtained by various methods (e.g., by blowing hot air produced electrically with the air heater (3i)).

[0510] After processing, reaction inhibitors also become reaction moderators and are stored in the hoppers (3J) dedicated to each type of inhibitor.

[0511] The bunkers are made of steel sheet with a minimum thickness of 3 mm. From the hoppers, after the spectral characterization with the analysers (X), the materials are picked up with the auger elevators (3m) and stored in the pair of hoppers dedicated to them in the hopper battery (8) of the B module.

[0512] The pair of hoppers intended for reaction inhibitors allows the initial partial vacuum (0.1 mbar) operation of the metallothermic crucible (CM) in figure 2. The pair of hoppers allows alternate feeding, suctioning and emptying of each hopper, component of the pair.

[0513] The initial suctioning is done with the pumps (5) in figure 14 and in figure 2.

[0514] The fluxes - can be purchased in directly usable sizes (e.g., CaCO3).

[0515] In this case, the fluxes are introduced into the rotary dryer, with continuous operation (3n) and dried with the electric air heater (3s).

[0516] The air heater provides hot air at 200°C, blown in at a pressure of 1 .1 bar. The rotary dryer is 4 m long and made of 5 mm thick welded steel pipe. It has the appropriate diameter for the chosen production capacity (Ex. 500 mm. for a processing of 10 kg / s of fluxes).

[0517] The rotary dryer has an inclination of 6° and rotates at 15 rpm.

[0518] Upon exiting the dryer, the fluxes are spectrally characterized with the spectrometer (x) and then, with the elevator (3r), they are transferred to the battery of paired hoppers (8) dedicated to them, in Module B.

[0519] The data provided by the analysers are recorded and processed by the P program.

[0520] Similarly, in this case the paired bunkers ensure the priming in relative vacuum of the sequential metallothermic process.

[0521] The initial emptying is done at 0.1 mbar with the pumps (5) which have a flow rate of 1150 m3 / h (Ex. SOGEVAC A rotary pumps).

[0522] 2.1.2 - The Module B installation

[0523] The installation related to Module B takes the form of a metallothermic electrometallurgical converter, sized for the chosen production capacity.

[0524] The block diagram of the installation related to Module B / the electrometallurgical converter is presented in figure 5, complementary to figure 2.

[0525] The Module B installation sequentially processes the reactants and reaction moderators produced in Module A in a metallothermic process.

[0526] The installation related to module B leads to obtaining the reaction products: ferrous metals (e.g., steels, ferroalloys) or non-ferrous metals (e.g., copper), corundum slags convertible into metal or corundum pellets, fine metal powders (e.g., steel, copper, etc.) or non-metallic (a-AhOs) and heat convertible into electricity.

[0527] Corresponding to the 4 types of reaction products, there are 5 technological lines for obtaining them.

[0528] The main positioning of the 5 technological lines is presented in figure 5.

[0529] The installation related to Module B represents a cogeneration installation of metallurgical products together with heat convertible into electricity.

[0530] Module B is sized according to the production capacity chosen by the beneficiary.

[0531] The installation related to module B ensures the materialization of the process proposed by the CBI, for the transformation of termites into reaction products (thermoelectric energy and ferrous or non-ferrous metallurgical products, slags, and combustion gases).

[0532] Module B mainly consists of sub-assemblies known in the state of the art (series products), such as: hoppers, dispensers, XRF analysers, thermometers, vacuum pumps, mixers, fans, atomizers, auger dispensers, magnetic separators, granular separators, check valves, continuous casting plants, rolling mills, steam generators, turbines, electric generators, transformers, etc.

[0533] The inventive component of the installation related to module B is represented by the metallothermic electrometallurgical converter assembly, together with the specific sub-assemblies: the metallothermic crucible (CM) cooled with metal melts, the rotary homogenizer (OM) of the metallothermic resulting metal melts and the casting timing recipient (VTT).

[0534] 2.1.2.1 - The Line B1 installation - is the metallothermic and sequential processing facility of thermite components.

[0535] Line B1 is shown as a functional block diagram in figure 6.

[0536] Line B1 gravitationally processes the thermite components supplied by Module A. The processes are sequential, run continuously and are gravitationally organized on three levels, according to Figure 6.

[0537] It contains both sub-assemblies known in the state of the art and new / inventive sub-assemblies.

[0538] The Line B1 is organized by gravity, on 3 levels.

[0539] The materials provided by Module A (thermite components) are stored on level 1 (figure 6), in pairs of rotating / homogenizer hoppers dedicated to each type of reactant / moderator, depending on the granulometric class to which they belong (assortment). Figure 6.1.

[0540] The materials in the hoppers are dosed and evaluated spectrally or by diffraction, before being sent to the mixer (AM) on level 2 of the Line B1 .

[0541] The brief description of the subassemblies used is made according to figure 6.

[0542] Therefore:

[0543] 2.1.2.1.1 - The dispensers - are equipped with electrically operated augers and controlled by the controller (Ctrl) that manages the program P.

[0544] The analysers that quantify the chemical composition of the materials in the bunkers are XRF or diffractometric spectral analysers 2.1.2.1.2 - The pairs of hoppers (Box), (Bred) and (Bmoderators) are intended to take over the assortments of thermite reactants and, respectively, the assortments of reaction moderators, produced in Stage 1 .

[0545] These paired hoppers also serve to homogenize their contents. They can be alternately filled and suctioned before being connected to the homogenizing mixer (AM).

[0546] Their principal geometry is presented, as a partial section, in figure 6.1 , complementary to figure 6.

[0547] All paired hoppers are capable of rotating 5 - 20 rpm and tilting 5 - 15°.

[0548] The paired hoppers are made of sheet metal and steel profiles (thickness - minimum 3 mm). They have variable capacities, between 1 t and 20 t each (depending on the size of the Installation). The number of hoppers for oxide varieties is 3 x 3 = 9 pcs.

[0549] The “moderator hoppers”, related to the mixer (AM) in figure 6, correspond numerically to the assortments of moderators used. There are at least 10 of them.

[0550] The “moderator hoppers” have capacities of 1-5 tons and are made of steel profiles and sheets with a thickness of at least 3 mm. They correspond numerically to the assortments of moderators used and are in the number of at least 10 pcs.

[0551] The moderator hoppers are also tiltable 5-15° and can rotate at 10-20 rpm.

[0552] The reducer hoppers (Bred) are neither rotating nor can be tilted. They are cylindrical and in the number of 3x3x2 pieces, corresponding to the 3 granulometric classes used and the 3 possible sources of reducers (atomized aluminium, aluminium recovered by shredding solid oxidic waste and wet aluminium powders (moistened with wire-drawing emulsions) coming from slurries of aluminium).

[0553] The cylinders are made of sheet steel with a minimum thickness of 3 mm. They have a maximum capacity of 400 kg and are located at relative distances of at least 3 m.

[0554] 2.1.2.1.3 - The mixer (AM) is a tilting rotary drum type mixer.

[0555] The mixer (AM) is located according to level 2 in figure 6.

[0556] The mixer is made of welded pipe with a diameter of 600 mm and a thickness of 5 mm.

[0557] On the inside, along the length of the mixer, two strip metal segments are welded at intervals of 30 to 30° and diametrically opposite. The strip metal segments are offset on the cylinder generator by 100 mm. They have the dimensions 500x60x10 mm.

[0558] At the exit of the mixer (AM), the thermite mixture represents the metallothermic fuel used. It is dosed with the auger dispenser (D) and finally characterized with a diffractometer (DR), and then the thermite mixture is directed by gravity to the metallothermic crucible (CM).

[0559] The mixer is placed on a tilting chassis, hydraulically operated, similar to the one shown in figure 12.

[0560] The mixer is 5 m long. It can rotate at 4...20 rpm and tilt hydraulically at 1...100.

[0561] The rotation speed is controlled by the program P and is dependent on the homogenization of the mixture.

[0562] The rotation speed is provided by a mechanical reducer driven by a direct current electric motor.

[0563] 2.1.2.1.4 - The metallothermic crucible (CM) operates sequentially or multi- sequentially with continuous serial running, being able to process any thermite recipe (metallothermic fuel) leading to the required reaction products.

[0564] The crucible (CM) is located corresponding to level 3 of figure 6, complementary to figure 10.

[0565] The metallothermic crucible (CM) is made of high-refractory materials (e.g., molybdenum, graphite, etc.).

[0566] The ratio between the height and inner diameter of the metallothermic crucible is greater than 3 / 1 .

[0567] The metallothermic crucible is of the high type, because it must have a height capable of allowing the settling of metal slags, before the discharge of the produced slags.

[0568] In addition, the metallothermic crucible must be able to accumulate the slag and the metal / alloy produced for at least 15 s, depending on the recipe used, the production capacity and the chosen geometry.

[0569] The metallothermic crucible (CM) works with a minimum of atmospheric air and for this reason, before it is put into operation, the assembly consisting of the points (5) - (9), (R), (H), (13) - (15), (31 ) and (CM) is partially suctioned (0.1 mbar) with the pumps (Pvid), principally shown in figure 6. After starting the metallothermic processes, in the benchmarks listed above, the flue gases create a back pressure that prevents the atmospheric air from entering and thus the generation of NOx compounds is significantly reduced.

[0570] The metallothermic crucible has double walls made by using two coaxial cylinders, made of heat-resistant materials (e.g., graphite, molybdenum, etc.) marked in figure 6 with (C1 ) and (C2) respectively.

[0571] The space between the two heat-resistant cylinders (C1 ) and (C2) is ensured by the set of spacers (Di).

[0572] Among the usable heat-resistant materials, graphite has the lowest cost price, but also a relatively low resistance to thermal wear.

[0573] A metallic melt (MT) is circulated in the space between the double walls of the metallothermic crucible (e.g., molten copper at a temperature of about 1150°C).

[0574] The metal melt (MT) cools the reaction chamber and transfers the accumulated heat to the heat exchanger (SC).

[0575] 2.1.2.2 - Line B2 - corresponds to the block diagram in figure 7

[0576] The installation corresponding to Line B2 materializes the CBI process related to the production and processing of the metals produced in the crucible (CM).

[0577] The installation contains both sub-assemblies known in the state of the art and new / inventive sub-assemblies.

[0578] The sub-assemblies known in the state of the art are: Hoppers for alloying materials (MOD), powder hoppers (BPULB), auger feeders (D), spectrum analysers (R), continuous casting plant (ITT) and rolling mill (L).

[0579] The inventive / unknown subassemblies in the state of the art are: the homogenizer (OM) and the casting timing recipient (VTT).

[0580] 2.1.2.2.1 - The homogenizer (OM)

[0581] At the exit from the crucible (CM), the metal / metallothermic alloy having a temperature of about 2200°C is accumulated for 15 minutes in the homogenizer (OM) in figure 15, complementary to figure 3 and then it is accumulated, for one hour, in the “casting timing recipient” (VTT), from figure 16, complementary to figure 3.

[0582] Upon exiting the crucible, the molten metal flows through the chute (07) into the homogenizer (OM). The chemical composition of the molten metal continuously coming out of the crucible (CM) is checked and recorded using a spectrometer (R).

[0583] Also through this chute, any additional alloying materials necessary to obtain the chemical composition of the produced steel are introduced into the homogenizer. The alloying materials are taken and dosed, through the program P, from the “moderator hoppers (BMOD)” of the reaction.

[0584] Similarly, if metallic or non-metallic powders are needed, they are taken and dosed from the “powder hoppers - BPULB” and through the same chute they are introduced into the homogenizer.

[0585] The homogenizer has a volume and geometry dependent on the production capacity of the installation, since the useful volume of the homogenizer must be able to take over and process the crucible production (CM) made in 15 minutes.

[0586] The homogenizer is a tilting “rotating drum” (03), placed on a metal chassis, equipped with a bearing (013) that allows the assembly to tilt.

[0587] Inside, the homogenizer is lined with profiled super-refractory ceramic materials (08), resistant to temperatures above 2000°C (e.g., ceramic type 35WA9546).

[0588] Ceramic materials (08) are profiled to facilitate homogenization.

[0589] The chassis can be tilted with the angle y (0 - 15°) with the help of a hydraulic cylinder (01), of 50 t. It is operated by the hydraulic pump (PH) - position (015), operated by the electric motor ME - position (014) .

[0590] The pressure in the pump is created with the help of a three-phase electric motor of 3 kW - position (014).

[0591] The rotating drum (03) rests on a system of bearing rollers (06), (09) and (010), located on a shaft (02) fixed to the homogenizer chassis.

[0592] The rotary drum rotates at 10-20 rpm using a 10 kW three-phase electric motor (04) via a pinion-gear assembly (05).

[0593] The homogenized metal in the homogenizer (OM) flows through the chute (011 ) into the recipient (VTT).

[0594] The composition of this metal is checked and recorded using the spectrometer (RV).

[0595] For this, 5 samples of the molten metal / alloy are taken every 10 seconds and rapidly solidified (with water) and then spectrally evaluated. Through the program P, the obtained spectral results are compared with the prescribed values and if the results are unsatisfactory, the compositional improvement continues.

[0596] 2.1.2.2.2 - The casting timing recipient (VTT) is intended both for the natural cooling of the metal accumulated in one hour and for its compositional control and finishing.

[0597] The block diagram of the casting timing recipient (VTT) is shown in figure 16, complementary to figures 2 and 3.

[0598] The recipient (VTT) is made on a metal structure, lined with highly refractory materials (e.g., aluminium bricks).

[0599] The recipient (VTT) can be tilted with the angle a which can take values between 30 and 15°.

[0600] The recipient is sized according to the chosen production capacity. It is geometrically defined both by the overall dimensions (L, I and H) and by its main functional dimensions (h, L1 , 11 , the opening 5 of the secondary slag evacuation solenoid valve and the angle (3, directing the materials to the solenoid valves angle has the value of 15°.

[0601] The filling of the recipient (VTT) with molten metal follows the hydrodynamics of indirect casting.

[0602] The metal flow speed through the recipient (VTT) is adjustable by tilting it, using a mobile support (V18) that allows adjustable tilts, with angles (a) that can vary between 0-15°.

[0603] At the start of the process, the angle a has a reference value of 6°.

[0604] Basically, according to figure (16), the recipient (VTT) has three functional areas:

[0605] 4. The filling zone (Z1 ) - has the role of mitigating the turbulence of the metal coming from the homogenizer (OM);

[0606] 5. Zone (Z2) is the final compositional finishing zone of the metal produced in the crucible (CM);

[0607] 6. Zone (Z3) - secondary slag and cooled metal discharge zone (up to casting temperature). 7. The interaction of the molten metal with the walls of the recipient (VTT), with the surrounding environment and with the alloying materials causes the formation of a secondary slag on the surface of the metal, consisting mainly of oxides and carbides.

[0608] The final compositional finishing of the metal produced in the crucible (CM) is done in the recipient (VTT), which allows the collection and evacuation of secondary slag.

[0609] The final chemical composition is checked with the probe (V5). It can sample metal in the upper half or lower half of the zone (Z3).

[0610] The samples taken are forced cooled and then chemically analysed with a spectrum analyser.

[0611] The chosen size of the angle (a) is dependent on the geometry of the vessel (VTT) and the temperature to which the molten metal reaches before discharge.

[0612] A hydraulic cylinder (V17), actuated by the hydraulic electro-pump (PH), is used as an actuator for tilting, controlled by the “program P”. The hydraulic cylinder is chosen to be able to raise / lower loads of 50 - 100 tons.

[0613] After the natural cooling of the metal / alloy to the casting temperature (about 1600°C for steel) and after its compositional finishing, it is discharged in a controlled manner, through the proportional solenoid valves (V14) and (V15), into the continuous casting plant (ITT).

[0614] The secondary slag is separated from the useful metal by discharge on the inclined chute (V9) and its collection in the vessel (OZ).

[0615] The angle of inclination of the chute is 15°.

[0616] The adjustable tilt of the recipient (VTT) also allows changing the secondary slag discharge speed. For this, the proportional solenoid valve (V16) is used, actuated by the electric motor (V11 ), commanded by the controller (Ctrl).

[0617] Similarly, the controller (Ctrl) commands, through the solenoid valve (V15), actuated by the electric motor (V10), the evacuation of the metal / alloy accumulated under the secondary slag.

[0618] Also, the “program P” , through the solenoid valve (V14), can command the evacuation of the metal accumulated on the bottom of the recipient (VTT). This is done by actuating the electric motor (V12) which opens the proportional solenoid valve (V14). The active elements of the proportional solenoid valves, in direct contact with the molten metal, are made of highly refractory materials (e.g., graphite, molybdenum, etc.) and have a minimum thickness of 150 mm.

[0619] The temperature evolution of the metal in the recipient (VTT) is permanently monitored by the controller (Ctrl) and the “program P”. These use (according to figure 16) non-contact thermometers (V3) and (V8), capable of measuring temperatures of 2200°C (e.g., type GM 2200 - Chinese production), plus thermocouples (V4), (V6) and (V7) , capable of measuring temperatures of 1800°C (e.g., type S41 -TC - produced by RUEGER, Switzerland)

[0620] The evacuation of the cooled metal, at the temperature of continuous casting and compositionally finished, from the casting delay vessel, is done through the lower exhauster (V13). It collects the metal / alloy discharged through solenoid valves (V15) and (V14) and directs it to the continuous casting plant (ITT).

[0621] From the continuous casting plant, the metal solidified and cooled to the rolling temperature is fed into the rolling mill (L) which completes the recovery of the produced metal.

[0622] The subassemblies (ITT) and the rolling mill (L) are standard products.

[0623] The continuous casting plant (ITT) and the rolling mill (L) have a production capacity consistent with the production capacity of the assembly.

[0624] 2.1.2.3 - Line B3 installation - is shown schematically in figure 8. This materializes the CBI process for processing corundum slag resulting from the metallothermic processes carried out in the crucible (CM).

[0625] Corundum slag (containing at least 70% AI2O3) passes by gravity from the crucible (CM), through the exhauster (EZG) into the atomizer (AZ) which breaks the slag jet, with a flow of air and water under pressure (about 2.5 bar).

[0626] Except for the slag extractor (EZG), the decanters (DEC) and the hoppers, the other components of the Line B3 are products known in the state of the art.

[0627] The evacuator (EZG) is made of highly refractory materials (e.g., graphite, sintered molybdenum, etc.).

[0628] The evacuator is placed at the top of the crucible (CM). Aluminium runs through its double walls.

[0629] The evacuator (EZG) has 4 slag evacuation holes. The slag discharge holes have dimensions dependent on the production capacity of the installation. Decanters (DEC) are a pair of conventional decanters with reciprocating operation. They are equipped with a distributor that allows their alternate filling, emptying and cooling, necessary to ensure the continuity of the process.

[0630] The hoppers are made of sheet steel with a minimum thickness of 3 mm. They store the resulting pellets separately and have capacities between 5000 and 10,000 kg.

[0631] The dryer (UR) is represented by a rotating drum with a diameter of 400 mm and a length of 4 m.

[0632] The rotary drum is made of 4 mm welded pipe and is placed on a metal chassis with a 5 degree tilt.

[0633] The rotating drum rotates at 10 revolutions per minute

[0634] The drying agent is represented by atmospheric air, with a pressure of 1 .25 bar. Atmospheric air (the drying agent) is circulated by an electric fan, with a power of 2 kW, which is a component of the dryer.

[0635] The other components of the Line B3 are standard products.

[0636] 2.1.2.4 - Line B4 installation - materializes the CBI process for collecting, processing and exhausting the reaction gases resulting from the metallothermic processes carried out in the crucible (CM).

[0637] The block diagram of the Line B4 installation is presented in figure 9.

[0638] The collection and evacuation of reaction gases is done through a hood (H), made of highly refractory materials (e.g., graphite, molybdenum, etc.).

[0639] The hood is placed above the crucible (CM) at a height of 1 m from it, the distance at which the temperature of the combustion gases drops below 2000 C.

[0640] The fume cupboard receives the reaction gases and through a refractory tube (e.g., graphite), with a diameter of 300 - 1000 mm and a thickness of at least 50 mm (depending on the production capacity of the installation), leads them to their exhaust chimney (CG).

[0641] The chimney for exhausting reaction gases is made of refractory steel with a minimum thickness of 3 mm and has a diameter of 300 - 800 mm

[0642] Apart from the chimney (CG), the other components of the Line B4 installation are standard products. The chimney (CG) is also equipped with a heat recovery unit (RCP) which partially cools the reaction gases and then directs them to the wet filtration zone and then to the electro-filter zone.

[0643] Wet filtration is done in a counter-current of dispersed water with the nebulizer (NB).

[0644] Wet filtration causes the condensation of metallic and non-metallic vapours from the reaction gases. These are converted into atomized powders that collect in paired decanters (DP).

[0645] The rest of the reaction gases are passed through the electro-filters (EF), are analysed with the analyser (AG) and, if they meet the environmental protection standards, are discharged into the atmosphere. If they do not match, the whole metallothermic process is stopped.

[0646] The nebulizer (NB) is of high capacity. It consumes between 20 and 50 I of water / min (depending on the capacity of the installation) and uses a fan that creates an overpressure of 0.25 bar in the chimney.

[0647] The electric motor that drives the nebulizer fan has a power between 1 kW and 5 kW, depending on the size of the chimney (CG).

[0648] The other components of Line B4 are:

[0649] 8. Fan (VP) - Driven by a 2 kW three-phase electric motor - standard product.

[0650] 9. The water cooler (RAP) has a cooling capacity dependent on the size of the Installation. It is a standard product.

[0651] 10. Decanters (DP) with alternating filling, cooling and emptying. They each have a storage capacity of 1 ton. They are made of steel profiles and sheet metal with a thickness of 2 mm.

[0652] 11 . The rotary powder dryer (RTU) is a known landmark in the state of the art. It works with warm air (at 50°C), supplied by the fan (VP).

[0653] 12. The rotary dryer is made of welded pipe with a diameter of 500 mm and a thickness of 5 mm. The rotary dryer has a length of 5 m, an inclination of 60 and a rotation speed of 10 rev / min.

[0654] - The magnetic separator (SMP) and granular separators (SGP) are standard products.

[0655] - The hoppers for collecting metallic or non-metallic powders are pairs that correspond to the granulometric classes of interest. They allow alternate filling and emptying. o The bunkers have a capacity of 1 - 2 tons and are made of steel sheet with a minimum thickness of 2 mm.

[0656] 2.1.2.5 - Line B5 installation (thermo-energetic line) - is presented as a block diagram, in figure 10.

[0657] The Line B5 installation materializes the CBI process of using the energy surplus released as a result of the metallothermic reactions in the crucible (CM).

[0658] The Line B5 installation transforms the caloric surplus into usable electricity both to ensure the energy independence of the installation proposed for patenting, and to inject the remaining available quantity into the national grid.

[0659] The Line B5 takes the excess heat from the crucible (CM) with the cooling / heat transfer fluid (MT) and takes it out of the crucible for processing outside of it.

[0660] The crucible (CM), having double walls, allows the recirculation of the heating / cooling agent (MT) through the created space.

[0661] The double walls (C1) and (C2) of the crucible (CM) are made of highly refractory materials (e.g., ultra-high density graphite).

[0662] The double walls create two coaxial enclosures.

[0663] The inner enclosure is intended to support metallothermic reactions, and the outer enclosure is intended to facilitate the recirculation of the cooling / heat transfer fluid.

[0664] The cooling / heat transfer fluid is molten copper (MT).

[0665] The walls (C1) and (C2) of the enclosures, respectively, have a minimum thickness of 100 mm and are separated by spacers (Di), shown in figure 10.

[0666] The spacers (Di) are made of refractory materials (e.g., high density graphite) and have dimensions that make them able to take the existing weight in the inner enclosure, without damaging the outer enclosure.

[0667] The spacers (Di) and the crucible enclosures (CM) have dimensions dependent on the production capacity chosen for the installation in the CBI.

[0668] In order not to release more heat than is sufficient both for metallurgical production and for energy needs, thermite mixtures (metallothermic fuels) are generated by the program P, in real time, according to the diagram shown in figure 3b. The compositional correlation is performed by the program P, depending on the momentary characteristics of the raw materials, reactants and reaction moderators. The cooling fluid, at temperatures of around 1150°C, after leaving the crucible (CM), is recirculated through a heat exchanger (SC) made of highly refractory materials (e.g., graphite or sintered molybdenum).

[0669] The heat exchanger is part of a steam generator (GA) capable of taking the controlled amount of heat produced in the crucible (CM) and delivering low, medium or high pressure steam at temperatures up to 450°C.

[0670] As a safety system against accidental exceeding of the operating temperatures of the technological subassemblies between the crucible (CM) and the steam generator (GA), a classic water cooling system (SR) is used. It is triggered by the controller (Ctrl), before the cooling fluid (MT) reaches the temperature of 1180°C, at the exit from the crucible.

[0671] The steam released in the classic turbine system (TA) drives the electric generator (GE) which produces three-phase electric current (e.g., 6 kV x 50Hz). The electric current produced is sent to the classic transformer system (TrE), capable of delivering both the three-phase electric current required by the CBI installation and injecting the rest available into the national grid.

[0672] 3. IMPLEMENTATION EXAMPLE

[0673] The implementation example refers to a complementary assembly consisting of an installation and an electrometallurgical process, of the type shown in figure 3.

[0674] The implementation example highlights a solution for the production of approximately 14,611 kcal / s, which, through adequate efficiencies, lead to obtaining approximately 5.76863 MWh of electricity, using “metallotherrriic fuels”. Complementarily, it results in about 136,000 tons of steel / year (about 5.4 kg steel / s) and about 159,000 tons of slag / year (about 6.3 kg slag / s), plus about 73 tons / year of reaction gases (about 2.5 kg / s), usable.

[0675] The quantities of expected products involve the processing of about 330,750 tons of termite / year (about 13.11 kg of termite / s).

[0676] The exemplification of the invented process and device highlights the processing of the supplied raw materials (dross and / or ores, aluminium powders, ferroalloys, metal shavings and fluxes) in order to become thermite reactants (metal oxides or reducing agents) and reaction moderators (alloying materials, inhibitors and fondants), which, through percentage mixing and homogenization, become “metallothermic fuels” capable of generating the desired reaction products (heat / electricity, alloys, slags, reaction gases / metallic and non-metallic powders).

[0677] The targeted processing takes place in two stages and 8 phases, organized by gravity.

[0678] Stage 1 is the stage of transformation of raw materials into thermite reactants and reaction moderators.

[0679] Stage 1 includes three phases of processing the three types of raw materials used (according to points 1.2.1 and 2.1.1) and their transformation into oxides, reducers and reaction moderators. The development of the 3 phases is simultaneous and takes place in a coordinated way in module A, on production lines that work in parallel.

[0680] Stage 2 is the stage in which the thermite reactants and reaction moderators are transformed into “metallothermic fuels” and which, through sequential or multisequential metallothermic reactions with continuous serial unfolding, lead to usable reaction products. According to points 2.1.1 and 2.1.2.

[0681] Stage 2 comprises 5 phases of transformation of thermic reactants and reaction moderators into “metallothermic fuels” and which then, reacting specifically, lead to the release of potential chemical energy, transformed into electrical energy, complementary to obtaining metallurgical products (alloys, slag and reaction gases). According to points 1.2.2 and 2.1.2.

[0682] Stage 2 takes place in module B which functions as a metallothermic electrometallurgical converter.

[0683] Stage 1 is the raw material processing stage. This starts with the supply of oxidic precursors, reducing precursors and moderator precursors of metallothermic reactions.

[0684] The oxidic raw materials (oxidic precursors) appear as lumps of iron ores (magnetite, goethite, limonite, hematite) or steel dross in the form of powders, chips or shells, with different chemical compositions (FeO, Fe2C>3, FesC , H2O, manganese oxides, chromium, etc.).

[0685] The reducing raw materials (reducing precursors) are represented as atomized aluminium powders or pulverulent chips, resulting from the recycling of aluminium waste. These powders have grain sizes between 150 and 500 p.

[0686] Precursor raw materials of reaction moderators are represented by ferroalloys, metal alloy shavings or powders and steel shavings. The raw material used to obtain the CaC03 flux is purchased in the form of powder which, for use, is passed through a rotary dryer.

[0687] The supplied raw materials are processed in module A of the CBI facility, in stage 1 , on the three processing lines (L1, L2 and L3) and thus become thermite reactants and reaction moderators that correspond to process phases 1.1 , 1.2 and

[0688] 1.3, presented at points 1.2.1.1, 1.2.1.2 and 1.2.1.3 respectively.

[0689] Reactants and reaction moderators, resulting in module A, are processed in module B by the metallothermic process, in the Stage 2 of the CBI process.

[0690] For this example, at an overall yield of about 55%, module A must annually process about 391 ,046 tons of iron ore or about 277,576 tons of dross (of which the useful part represents about 90%).

[0691] Similarly, the annual need for atomized aluminium or the result of aluminium waste processing is about 80,000 tons;

[0692] The need for reaction moderators (ferroalloys, metal shavings and fluxes) can reach 90,000 tons / year, (about 25% of the amount of oxidic raw materials used).

[0693] The need for raw materials is dependent both on their chemical composition, on the composition of the materials resulting from processing, and on the chemical composition and mechanical characteristics imposed on the reaction products.

[0694] The thermite reactants are of oxidic type (metal oxides) and reducing type (aluminium powders with grain sizes between 150 p and 500 p). They are obtained in Step 1 , on Line 1 and Line 2 of Module A, respectively.

[0695] The technological phases passed by the oxidic raw materials, on Line 1 , are presented both functionally, in point 1.2.1.1 , and structurally in point 2.1.1.1.1.

[0696] The technological route travelled by the reducing raw materials, on Line 2, is presented both functionally, in point 1.2.1.2, and structurally in point 2.1.1.1.2.

[0697] The reaction moderators are represented by ferroalloys crushed to 3-5 mm grain sizes and metal shavings of selected relatively pure metals, reaction inhibitors and fluxes.

[0698] The reaction moderators are produced according to the CBI process, on Line 3.

[0699] The technological route followed by the raw materials, generators of reaction moderators, is presented both functionally, in point 1.2.1.3, and structurally in point

[0700] 2.1.1.1.3. The Stage 2 of the CBI process is simultaneously traversed by thermite reactants and reaction moderators in process phase 2.1 , and then the reaction products appear in phases 2.2, 2.3, 2.4 and 2.5. This phasing involves the serial passage of the module B installation subassemblies, presented at points: 2.1.2.1 , 2.1.2.2, 2.1.2.3, 2.1.2.4 and 2.1.2.5 respectively.

[0701] Thus, the products resulting in Stage 1 , after diffractometric characterization with the analysers (RD) are stored in module B, in the systems of pairs of bunkers (Box), (Bred) and (Bmod) which allow storage, homogenization and alternative release (according to program P) of each kind of reactant or reaction moderator, so that the continuity of the process is ensured.

[0702] Also, the program P commands both the alternate partial suction of the paired hoppers and the mixer (AM) plus the double wall crucible (CM).

[0703] Similarly, according to Phase 2.1 , the materials in the bunkers of Module B are percentage-portioned with the help of auger dispensers (D), compositionally characterized with diffractometers (RD) and sent by gravity to the mixer with continuous operation (AM) that performs the metallothermic mixtures, i.e. “the metallothermic fuels” needed.

[0704] At the exit from the mixer, the metallothermic fuels are compositionally checked with the diffractometers (RD) and after the quantitative dosing, with the help of dispensers (D), they are sent by gravity to the suctioned crucible (CM) which, having double walls, is cooled with copper metal melts, at temperatures between 1100- 1200°C. These, through recirculation, materialize phase 2.1.2.5, of using the available thermal energy.

[0705] The command and control of the aluminothermic processes is done in real time, according to point 1.1.1. Thus, after the real-time characterization of the oxides involved, the real oxidation-reduction molar ratios are identified through the program P and the need for aluminium reducing powders, capable of leading to the desired reaction products, is estimated.

[0706] The quantification of the characteristics of the reaction products is done in real time starting from a “thermite module”, of the moment, of the type shown in Table 1. It is generated by the molar estimation of the results obtained during the aluminothermic processing of 10 kg of oxidic reactants.

[0707] The obtained results allow, through the program P, the sequential generation of momentary “thermite diagrams”, of the type shown in figure 3. The program P provides real-time generation of versatile thermite recipes, capable of tracking chemical and particle size changes of reactants and reaction moderators, so as to ensure similar reaction products are obtained.

[0708] The thermite recipes determine the characteristics of the reaction products and implicitly facilitate the completion in real time of the “Process Moment Sheet” of the type shown in Table 1 .

[0709] The sheet is specific to the sequence of raw materials being processed at a given time.

[0710] The thermite reactants and moderators used contain minimal amounts of carbon (only bound carbon), which makes the reactions in the metallothermic crucible generate reduced amounts of greenhouse gases.

[0711] The priming of the reactions in the crucible is done after exhausting the atmospheric air (up to a pressure of 0.1 mbar), which also significantly reduces the share of NOx in the reaction gases.

[0712] In addition, the lack of sulphur-containing ores (pyrites) ensures a significant reduction of gases containing SO2, SO3, and H2S.

[0713] The process yields, shown in Table 1 , highlight its efficiency.

[0714] For the chosen example, the thermite recipes determine the operation of the metallothermic crucible at a temperature of about 2300°C.

[0715] Due to the existing density differences at the temperature of 2300°C, between the steel (about 6.8 kg / dm3) and the slag (about 3.5 kg / dm3), the molten slag settles out, which allows the separate and simultaneous evacuation of all waste products of the reaction.

[0716] The crucible (CM) is made of ultra-high density graphite (minimum 1 .9 kg / dm3).

[0717] The tubing that allows the evacuation of the reaction products is made of sintered molybdenum or high density graphite.

[0718] For the separation of slag from steel, the dimensions of the metallothermic crucible allow, before evacuation, the accumulation of steel and slag produced for at least 15 s, which leads to the accumulation in the crucible of amounts of about 90 kg of steel and about 97.5 kg of slag. These quantities occupy about 13.1 dm3for steel and about 27.85 dm3for the slag.

[0719] The two estimated volumes lead together to a minimum volume of 41 dm3, necessary for the correct operation of the crucible. This implies a minimum height of about 1 m and an inner diameter of the reaction enclosure of at least 72 mm. The metallothermic crucible is built so that the ratio between height and diameter is about 10:1 and for this reason the inner diameter of the enclosure (C1) was chosen to be 150 mm.

[0720] For reasons of safety of the operating personnel, a thickness of the graphite walls of the reaction chamber of the crucible (C1) of 100 mm is chosen. These dimensions require an outer diameter of the reaction chamber of 350 mm.

[0721] Consequently, the inner diameter of the outer enclosure (C2) is chosen to be 750 mm, and its outer diameter is chosen to be 1000 mm.

[0722] The evacuation of steel and slag produced is done through graphite or molybdenum refractory pipes that connect the inner enclosure (C1) to the outside of the crucible and to the subassemblies involved in the recovery of the evacuated products.

[0723] Crucible operation (CM) allows the control of the overall reaction rate. This is done by balancing the rates of V1 (termite consumption) with V2 (rate of reaction product formation).

[0724] Balancing is achieved by ensuring the continuous flow of slag through holes 1 and 2 of the slag evacuator (EzG) in figure 6.

[0725] The flow of slag through hole 3 of (EzG) imposes a decrease in the flow of thermite introduced into the crucible, and the lack of flow of slag through hole 2 of (EzG) imposes an increase of the flow of thermite introduced into the crucible.

[0726] The flow of slag through hole 4 of (EzG) requires a quick stop of the process.

[0727] The collection and usage of the produced steel, according to the Implementation Example, is done according to Phase 2.2, using Line B2.

[0728] For the Implementation Example, the homogenizer (OM) has a useful volume of 2.3 m3, a length of 3 m and a diameter of 1 m. Initially, the inclination of the homogenizer is 6 degrees.

[0729] Similarly, the casting timing vessel (VTT), from figure 16, has a useful volume of 5.12 m3, and useful dimensions: L = 7 m, I = 1.5 m, H = 0.5 m, L1 = 1 m, 11 = 0.95 m.

[0730] The collection and usage of the produced slag (about 6.3 kg / s) is done in Phase 2.3, using Line B3.

[0731] Similarly, the collection, neutralization and recovery of reaction gases (mainly steel and slag vapours) is done according to Phase 2.4, using the Line B4. The recovery of the available caloric energy (about 14.6 kcal / s) and its transformation into electrical energy is done by recirculating the copper melt (MT), at temperatures lower than 1200 C, located between the two enclosures (C1) and (C2) and its passage through the recuperative heat exchanger (SC), a component of the steam generator (GA), from figure 10.

[0732] The development of the energy process corresponds to Phase 2.5 and is applied according to the description related to Line B5.

Claims

The CBI claims relate to:The metallothermic electrometallurgical process and installation that represents a new possibility of cleaner production of thermoelectric energy and / or thermal energy, simultaneously with the significant reduction of waste production.The metallothermic electrometallurgical process and installation effectively transforms some raw materials into metallothermic mixtures which, for this CBI, represent true “metallothermic fuels" used to release the potential chemical energy existing at the atomic level in them and use it to generate thermal and / or thermoelectric energy, complementary to the production and usage of metals / alloys, slags and reaction gases, also aiming at the drastic reduction of the generation of polluting gases such as CO2, NOx, H2S, SO2, SO3, etc.CLAIM 1The metallothermic electrometallurgical process is a modular process described in stages and phases for obtaining “cleaner” thermal or thermoelectric energy simultaneously with the obtaining of metallurgical products such as metals / alloys of slags and reaction gases is characterized by the fact that using the existing potential chemical energy in metallothermic fuels, generates simultaneously, in accordance with the chosen production capacity, two different types of products (heat and metallurgical products), presents in stages the specificities of the processing methodology of precursor raw materials of reducers and thermite moderators, alongside oxidic raw materials (without pyrites) originating from ores and / or metallic oxidic waste (dross), in order to transform them in phases, into powdery components of similar oxidic reactants, of metallic reducers and moderators of metallothermic reactions which, according to some assorted recipes that vary in real time, they dose them, mix them and homogenize them, then they use them as “metallothermic fuels” able to carry out sequential or multi-sequential metallothermic reactions with continuous serial unfolding in partially evacuated crucibles, at temperatures between 2100 and 2300°C, which requires both cooling them and taking over the heat generated in the crucible, in order to exploit it through established technologies for obtaining thermal energy or min. 32% electric energy, as well as by taking over the metallurgical products (metals / alloys, slags and reaction gases) appearingcomplementary in the crucible and their usage, both through new processes of thermal transfer, compositional correction and homogenization of the produced alloys and casting timing, as well as through established technologies of continuous casting, lamination, atomization, assortment separation, etc.CLAIM 2The metallothermic electrometallurgical installation aims at the materialization of the process specified in Claim 1 , of metallothermic production of thermoelectric energy simultaneously with obtaining metallurgical products such as metals / alloys, slags and reaction gases, without using coke ovens, furnaces and traditional steelworks and is intended for processing modulation, on distinct technological lines, of batches of precursors of thermite reactants and reaction moderators, for their transformation into metallothermic fuels, in order to obtain thermal or thermoelectric energy, simultaneously with the obtaining of metallurgical products, and is characterized by the fact that using a Raw Materials Preparation Plant, dimensioned in sub-assemblies according to the chosen production capacities, on 3 distinct processing lines (Module A), in order to unitarily process both oxidic ores and / or oxidic metal waste (dross) to transform them into similar oxidic reactants with granulations between 200-1600p, as well as reducing precursors such as atomized aluminium powders, shredded aluminium waste or wet aluminium powders from aluminium slurries, which they transform into reducing thermite reactants with granulations between 150-500p and in reaction moderators with granulations smaller than 4000p and which they then transfer by gravity to the fixed cylindrical hoppers and to the rotating and tilting homogenizing hoppers, with diameters of at least 1000 mm and lengths of at least 1500 mm, made of metal sheet with a minimum thickness of 4 mm, of the Electrometallurgical Metallothermic Converter, organized in Module B, followed, on the same production line, by a compositional characterization by diffractometry, which allows the P program, through the dispensers (D), to send to the mixer (AM), a minimum of 3 kg / s of oxidic reactants and 0.9 kg / s of metallic reducing agents, plus a minimum of 1 kg / s of moderators for metallothermic reactions which, after mixing and homogenization, become at least 4.9 kg / s of “metallothermic fuels” which are sent by gravity into the heat-resistant crucible (CM), partially evacuated at 0.1 mbar and having double walls between which recirculate (to a heat exchanger of a steamgenerator) copper metal melts (at temperatures between 1100 and 1200°C), used both for cooling the crucible (CM) and for transferring the heat generated in it (minimum 700 kcal / kg metallothermic fuel per second, 32% convertible into electricity), to an external technological line, for its thermoelectric recovery, simultaneously with the evacuation of a minimum of 1.7 kg / s of homogenized metals / alloys, finished and usable on a technological line of casting and rolling, simultaneously with obtaining a minimum of 1.8 kg of slag / s, usable on another technological line of atomization and magnetic separation, along with a minimum of 0.7 kg / s powdery components resulting from the reaction gases and recoverable separately after granulometric separations followed by magnetic separations.

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