Blast Furnace Syngas Injection via Catalytic Partial Oxidation
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Solution Overview
Problem
Current methods for utilizing blast furnace gas in steel production, such as PSA/VPSA installations and dry/steam reforming, are expensive, complex, and inefficient, with high CO2 emissions and coke consumption.
Innovation Solution
A method involving a catalytic partial oxidation reactor that processes a mixture of steam-enriched oxygen and natural gas with recycled blast furnace gas to produce syngas, which is then injected into the blast furnace, reducing CO2 production and coke usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If PSA/VPSA installations are used to reduce CO2 content in blast furnace gas, then CO2 content is reduced from about 35% to about 5%, but the equipment becomes very expensive to acquire, maintain and operate and requires a lot of space
Solution Approach 1:
The invention extracts and removes CO2 from blast furnace gas through a dedicated removal unit, separating the harmful component from the useful gas stream. This allows the cleaned gas to be recycled back to the blast furnace while the CO2 is disposed of separately, avoiding the need for complex PSA/VPSA systems
Solution Approach 2:
The invention employs a simpler, more cost-effective CO2 removal unit that can be easily maintained and operated, replacing the expensive and space-consuming PSA/VPSA installations. The removed CO2 is disposed of rather than being processed further, accepting the disposability of the harmful component
2Quantity of substance
If dry reforming reaction is used to produce synthesis gas from blast furnace gas and hydrocarbons, then H2 and CO concentration is significantly increased, but expensive and technically complex equipment is required
Solution Approach 1:
The invention continuously recycles blast furnace gas back to the blast furnace after CO2 removal, maintaining a continuous useful action rather than requiring batch processing or complex reforming equipment. The syngas production occurs continuously within the blast furnace itself through the interaction of recycled gas with the iron ore
Solution Approach 2:
The blast furnace itself serves as the reactor for producing synthesis gas, utilizing the recycled blast furnace gas and incoming hydrocarbons to generate H2 and CO in situ. This eliminates the need for separate, expensive reforming equipment as the blast furnace performs the syngas production function
3Quantity of substance
If steam reforming reaction is used to produce synthesis gas from blast furnace gas and hydrocarbons, then H2 and CO concentration is significantly increased, but expensive and technically complex equipment is required
Solution Approach 1:
The invention implements continuous steam reforming within the blast furnace by injecting steam along with the recycled blast furnace gas. The high temperature environment of the blast furnace provides continuous thermal energy for the endothermic steam reforming reaction, eliminating the need for separate reforming units
Solution Approach 2:
The invention merges the steam reforming function with the blast furnace operation itself, combining multiple functions (heating, reforming, reduction) into a single integrated system. This eliminates the need for separate, complex reforming equipment by utilizing the existing blast furnace infrastructure
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 significantly reduces CO2 emissions, lowers coke consumption, and simplifies the process with reduced equipment complexity and energy consumption, while producing syngas suitable for efficient blast furnace operation.
Implementation Method 1
A method involving a catalytic partial oxidation reactor that processes a mixture of steam-enriched oxygen and natural gas with recycled blast furnace gas to produce syngas
Implementation Method 2
heating a first stream of steam in a first heater, before or after having been mixed with an oxygen source selected from oxygen (O2) and oxygen-enriched air, to provide a first heated stream of oxygen-enriched steam
Data Source
AI summary
A method for operating a blast furnace for producing of pig iron, includes the following stepsheating a first stream of steam in a first heater, before or after having been mixed with an oxygen source selected from oxygen and oxygen-enriched air, to provide a first heated stream of oxygen-enriched steam;heating a first stream of blast furnace gas from the blast furnace and a first stream of natural gas in a second heater, before or after being mixed together, to provide a heated carbon feed stream;feeding the first heated stream of oxygen-enriched steam and the heated carbon feed stream either as a combined stream or separately to a catalytic partial oxidation reactor to produce a stream of syngas; andfeeding the stream of syngas to the shaft of the blast furnace.