Compacted DRI Fragmentation for Faster Arc Furnace Melting

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Solution Overview

Problem

The melting of compacted DRI, such as HBI and HCI, in arc furnaces is limited by the time it takes for briquettes to melt, which affects the rate of addition and productivity, and increasing energy output to accelerate melting can have unfavorable effects.

Innovation Solution

Comminuting HBI and HCI prior to melting into smaller fragments, preferably between 3.35 mm to 31.5 mm, to enhance the melting rate without increasing energy input.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If HBI and/or HCI are supplied to the melting process without comminution, then the device complexity is reduced, but the melting time increases and productivity decreases

Engineering Contradiction:

Improverate of addition to melting processVSAvoidcomminution step addition

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by comminuting HBI and/or HCI before supplying them to the melting process. This pre-processing step breaks down the compacted DRI into smaller fragments, which then melt faster in the arc furnace, enabling a higher rate of addition and improving productivity without requiring increased energy output.

Inventive Principle:

Principle #10Preliminary action

2Speed

If energy output to the melting process is increased to accelerate melting, then the melting rate improves, but productivity is adversely affected

Engineering Contradiction:

Improvemelting rateVSAvoidproductivity of melting process

Core Design Contradiction:

SpeedVSProductivity

Solution Approach 1:

The patent applies parameter changes by altering the physical state and size of the HBI and/or HCI material through comminution before melting. By changing the particle size parameter, the melting rate is accelerated without requiring an increase in energy output, thus improving productivity while maintaining energy efficiency.

Inventive Principle:

Principle #35Parameter changes

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

Enables a higher rate of addition to the melting process, improving productivity while maintaining energy efficiency.

Implementation Method 1

the hot-briquetted sponge iron (HBI) and/or hot-compacted sponge iron (HCI) are comminuted prior to supply to the melting process

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 2

for melting sponge iron (DRI) consisting at least partly of hot-briquetted sponge iron (HBI) and/or hot-compacted sponge iron (HCI) by means of a melting process

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20260043103A1Optimized melting of compacted dri

Publication Date: 2026.02.12 PRIMETALS TECH AUSTRIA GMBH

AI summary

A method for melting DRI consisting at least partly of HBI and/or HCI using a melting process, wherein the HBI and/or the HCI is comminuted before being supplied to the melting process, and HBI or HCI fragments obtained during the comminuting process are supplied to the melting process.