Carbon-Coated Granules for Sintered Ore Production
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Solution Overview
Problem
Existing methods for producing sintered ore in blast furnaces face challenges such as poor wettability of carbon materials, high production costs due to oxidation treatments, and restricted production volume, as well as issues with the strength and stability of carbon material-containing agglomerated ores when using metallic iron-containing iron oxide powders.
Innovation Solution
The use of carbon material-containing granulated particles with a small lump coke core and an outer layer of iron ore powder and CaO-containing material, where the iron ore powder has a particle size of 10-1000 µm and a melting point between 1200°C and 1500°C, allowing for stable production of sintered ore without the need for metallic iron-containing iron oxide powders and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metallic iron-containing iron oxide powders are used to coat carbon material cores, then the carbon material can be closely arranged with iron-containing material, but the production cost increases due to oxidation treatments and production volume is restricted
Solution Approach 1:
The invention changes the material parameters by replacing metallic iron-containing iron oxide powders with ordinary iron ore powders having specific particle size (10-1000 µm) and melting point (1200-1500°C) characteristics. This parameter change eliminates the need for oxidation treatments while maintaining the functional requirements for carbon material arrangement and sintering performance.
Solution Approach 2:
The invention substitutes expensive metallic iron-containing powders with cheaper ordinary iron ore powders. The iron ore powder serves as a disposable coating material that fulfills its function during sintering and does not require recovery or reuse, thereby reducing production costs while maintaining productivity.
2Productivity
If iron ore powder with small particle size is used to coat carbon material, then the carbon material and iron-containing material are closely arranged, but the outer layer strength decreases
Solution Approach 1:
The invention optimizes the particle size parameter of iron ore powder to the specific range of 10-1000 µm. This parameter range achieves an optimal balance between close arrangement for high reaction rates and sufficient outer layer strength to maintain particle integrity during handling and charging.
Solution Approach 2:
The invention creates a composite structure consisting of a carbon material core coated with iron ore powder outer layer. This composite granulated particle combines the reactive carbon core with the protective and structurally sound iron ore coating, achieving both high reaction rates and adequate strength.
3Ease of manufacture
If the iron ore powder melting point is below 1200°C, then the coating process is easier, but the granulated particles lack strength and powder excessively during charging
Solution Approach 1:
The invention sets the melting point parameter of iron ore powder within the specific range of 1200-1500°C. This parameter ensures that the outer layer maintains sufficient strength during charging operations while still being compatible with the sintering process, preventing excessive powdering.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of sintered ore with improved strength and efficiency, allowing for increased iron-making reaction rates, reduced furnace temperatures, and lower production costs, while avoiding the limitations of previous methods.
Implementation Method 1
adding CaO-containing material of a melting point conditioner
Implementation Method 2
burning the carbon material contained in the quasi particles to perform sintering
Implementation Method 3
burning the carbon material contained in the quasi particles to perform sintering
Implementation Method 4
reduction reaction (exothermic reaction) at the side of the iron source
Implementation Method 5
gasification reaction (endothermic reaction) at the side of the carbon material
Data Source
Figure 1~2(b)
Figure 3(a)~4
Figure 5~6
AI summary
Small lump coke having a particle size of 3-15 mm as a carbon material core, iron ore powder having a particle size of not more than 250 µm to be an outer layer and CaO-containing raw material are charged into a pelletizer and mixed and granulated therein to obtain quasi particles formed by coating the carbon material core with the outer layer (carbon material-containing granulated particles). Also, a sintering raw material obtained by mixing the carbon material-containing granulated particles with normal granulated particles is charged onto a pallet of a sintering machine to form a charged layer, and a sintered ore (carbon material-containing sintered ore) is produced by sintering heat of a carbon material included in the normal granulated particles. Thus, the carbon material-containing sintered ore having the iron-containing raw material and the carbon material arranged close to each other is obtained without using metallic iron-containing iron oxide powder such as iron-making dust, mill scale or the like and without restricting production volume.