Continuous Desulphurisation Reactors Using Communicating-Vessel Flow
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Solution Overview
Problem
Existing steelmaking processes face challenges in achieving continuous and consistent desulphurization of liquid iron with reduced risks of spillage, personnel hazards, and process disturbances, particularly in the HIsarna process where sulphur levels are higher and raw material variability leads to inconsistent sulphur content.
Innovation Solution
A device comprising a desulphurization reactor or series of reactors with an entry section and reaction section, utilizing a communicating-vessel principle and airlift phenomenon, combined with a submerged lance for reagent introduction, to enhance sulphur removal through increased residence time and controlled flow, minimizing the need for mechanical stirring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-wise desulphurisation in ladles is used, then sulphur removal can be achieved, but the process is discontinuous and leads to production losses and transport risks
Solution Approach 1:
The patent implements a continuous desulphurisation process where liquid iron flows continuously through the reactor system, eliminating batch-wise processing. The communicating vessels configuration allows continuous flow from the first reactor through the second reactor to the converter, maintaining uninterrupted production and eliminating ladle transport operations.
Solution Approach 2:
The desulphurisation process is divided into multiple reactors (first and second reactors) connected in series, each contributing to the overall sulphur removal. This segmentation allows the continuous process to be managed in discrete stages while maintaining overall continuity, with each reactor handling a portion of the desulphurisation task.
2Productivity
If mechanical stirring is used to enhance reagent mixing, then desulphurisation efficiency improves, but energy consumption and device complexity increase
Solution Approach 1:
The patent replaces mechanical stirring systems with a natural flow-based mixing mechanism. Liquid iron flows through the reactors due to gravity and pressure differences between communicating vessels, creating sufficient mixing action without mechanical agitators, thereby eliminating the energy consumption and complexity associated with mechanical stirring equipment.
Solution Approach 2:
The system uses the inherent flow characteristics of liquid iron and the communicating vessels configuration to achieve self-mixing and self-propulsion through the reactor system. The process relies on natural convection and flow dynamics rather than external mechanical energy input, allowing the system to serve itself without additional energy-consuming components.
3Manufacturing precision
If residence time is increased to improve sulphur removal, then desulphurisation quality improves, but production speed decreases
Solution Approach 1:
The patent divides the total residence time requirement across multiple reactors in series. Each reactor provides a portion of the necessary residence time for sulphur removal, allowing the system to achieve the required sulphur content consistency while maintaining continuous flow and production speed. The segmented approach prevents bottlenecks that would occur if a single reactor attempted to provide all residence time.
Solution Approach 2:
Multiple reactors perform the same desulphurisation function simultaneously in parallel streams, with each reactor contributing to the overall sulphur removal. This multi-functional arrangement allows the system to achieve both extended residence time and continuous production by distributing the processing load across multiple identical units operating concurrently.
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 solution enables continuous production of desulphurized liquid iron with a consistent sulphur content, reduced risk of spillage and process disturbances, and lower energy consumption, while accommodating varying sulphur levels in raw materials.
Implementation Method 1
wherein the entry section (3) and the reaction section (4) in the desulphurisation reactors act as communicating vessels
Implementation Method 2
the bubbles reduce the specific weight of the liquid iron in the reaction section (4), while simultaneously desulphurising the liquid iron
Implementation Method 3
the means (11) for introducing reagents into the liquid iron comprise a submerged lance
Data Source
AI summary
A device and a method for continuous desulphurisation of liquid iron provided by a blast furnace process or a direct reduction process. The device including a desulphurisation reactor or a plurality of consecutive desulphurisation reactors. The desulphurisation reactor or reactors each include an entry section for receiving liquid iron from liquid iron production means or from the desulphurisation reactor immediately preceding the subsequent desulphurisation reactor, and a reaction section for removing the sulphur from the liquid iron.