Cold-Pressed DRI Agglomerate Composition for Multi-Furnace Reuse
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Solution Overview
Problem
Existing agglomeration processes for DRI fines in the steel industry are limited in versatility and efficiency, preventing their use in various steel production processes due to limitations in fine granulometry, binder choice, and agglomerate geometry, leading to environmental waste disposal issues and reduced energy efficiency.
Innovation Solution
A cold-pressed solid agglomerate composed of 80-90% DRI fines, 5-10% binder (such as water, starch, phenolic resins, lime, molasses, or sodium silicate), and 5-10% charcoal, with optional additives like calcium oxide, is manufactured through controlled granulometry and cold-pressing, enabling reuse in blast furnaces, oxygen converters, and electric arc furnaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If DRI fines are agglomerated using conventional methods with limited binder choices and simple processes, then the agglomeration process is simple and cost-effective, but the product's physical-chemical and mechanical properties are limited, preventing versatile use in different steel production processes
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the agglomerate - specifically incorporating charcoal (5-15%) as a reducing agent and using multiple binder types (lime, molasses, sodium silicate) in specific proportions. These compositional parameter changes enable the agglomerate to be used in diverse steel production processes including BF-BOF, BF-EAF, and direct reduction routes, thereby achieving versatility without requiring complex processing equipment
Solution Approach 2:
The patent creates a composite agglomerate material combining DRI fines (80-90%), charcoal (5-15%), and binders (5-10%). This composite structure integrates multiple functional components: DRI fines provide iron content, charcoal provides reducing capability and carbon source, and binders provide structural integrity. The composite nature enables the single agglomerate product to serve multiple functions across different steelmaking processes, resolving the contradiction between versatility and process simplicity
2Ease of manufacture
If DRI fines are disposed of in landfills and dams, then waste disposal is simplified, but environmental impact becomes significant and natural resources are consumed
Solution Approach 1:
The patent converts the harmful waste product (DRI fines that would be disposed of in landfills) into a beneficial raw material for steel production. By incorporating 80-90% DRI fines into the agglomerate composition along with charcoal and binders, the waste material becomes a valuable resource that reduces the need for virgin iron ore, thereby eliminating environmental harm while maintaining simple disposal-like processing
Solution Approach 2:
Instead of discarding DRI fines in landfills, the patent recovers and reuses them in the steelmaking process. The agglomerated DRI fines are fed into BF-BOF, BF-EAF, or direct reduction processes where the iron is extracted and reused. This recovery approach eliminates environmental impact while the simple agglomeration process maintains ease of manufacture
3Productivity
If conventional agglomeration processes are used with limited granulometry control, then production is simpler and faster, but the agglomerate geometry and physical properties are limited, restricting use in various furnaces and converters
Solution Approach 1:
The patent applies granulometry control as a parameter change strategy, specifying that the DRI fines should have a particle size distribution where 60-80% passes through a 10 mesh sieve and 20-40% passes through a 20 mesh sieve. This controlled particle size distribution, combined with the charcoal and binder composition parameters, produces agglomerates with consistent geometry and physical properties suitable for various furnaces and converters, achieving manufacturing precision without sacrificing production efficiency through the simplicity of the agglomeration process
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
The agglomerate enhances the reuse of DRI fines across multiple steel production processes, reducing carbon emissions and increasing energy efficiency while minimizing waste, thus promoting a circular economy.
Implementation Method 1
5 to 10% by mass of at least one binder
Implementation Method 2
cold-pressing the mixture of DRI fines, at least one binder, and charcoal
Data Source
AI summary
The present invention pertains to a cold-pressed solid agglomerate comprising DRI fines or pre-reduced briquette fines. In this context, the invention presents a versatile agglomerate that can be used in blast furnaces, basic oxygen furnaces (BOF), and electric arc furnaces (EAF). For this purpose, the agglomerate of the invention comprises (i) 80 to 90% by mass of DRI fines or pre-reduced briquette fines, (ii) 5 to 10% by mass of at least one binder, and (iii) 5 to 10% by mass of charcoal. According to the invention, the process of manufacturing the cold-pressed solid agglomerate comprises the steps of: (i) mixing 80 to 90% by mass of DRI fines or pre-reduced briquette fines, 5 to 10% by mass of at least one binder, and 5 to 10% by mass of charcoal; and (ii) cold-pressing the mixture of DRI fines or pre-reduced briquette fines, at least one binder and charcoal.