Briquette Production from DRI By-Products Using Low-Temperature Curing
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Solution Overview
Problem
Current methods for producing briquettes from steel industry by-products like pellet fines, DRI sludge, and DRI dusts are inefficient in reusing these materials in Direct Reduction iron production, as they require high-temperature curing and specific binders, limiting their reuse and contributing to material inventory buildup.
Innovation Solution
A process involving grinding and sieving of pellet fines and DRI sludge, sieving of DRI fines, storing DRI dusts, briquetting with liquid sodium silicate and bentonite or composite Portland cement as binders, and curing at room temperature to enhance physical properties, allowing the briquettes to be used directly in Direct Reduction reactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature curing is used to produce briquettes from steel industry by-products, then the briquettes achieve sufficient strength for handling, but the process complexity and energy consumption increase
Solution Approach 1:
The patent changes the curing temperature parameter from high-temperature (1200-1380°C) to room temperature or low-temperature drying (80-100°C), fundamentally simplifying the curing process while achieving sufficient briquette strength through optimized binder formulations
Solution Approach 2:
The patent replaces complex high-temperature curing processes with simpler alternative processes using organic binders that cure at room temperature, creating a copy of the desired outcome (strong briquettes) through a different, simpler pathway
2Strength
If high-temperature curing is used to produce briquettes, then the briquettes achieve adequate strength, but the energy consumption increases
Solution Approach 1:
The patent fundamentally changes the temperature parameter of the curing process from high-temperature (1200-1380°C) to room temperature or low-temperature drying (80-100°C), dramatically reducing energy consumption while maintaining briquette strength through optimized binder systems
Solution Approach 2:
The patent uses organic binders that cure quickly at low temperatures, replacing expensive and energy-intensive high-temperature curing processes, accepting that the binders are consumed in the process but achieving overall cost and energy efficiency
3Strength
If specific inorganic binders are used in roller presses, then the briquettes achieve required strength, but the adaptability to different by-product materials decreases
Solution Approach 1:
The patent develops organic binder formulations that can effectively bind multiple different types of steel industry by-products (pellet fines, DRI sludge, DRI fines, and dusts), making the briquetting process universally applicable to various material compositions rather than requiring specific inorganic binders for each material type
Solution Approach 2:
The patent uses composite organic binder systems that combine multiple binding mechanisms and components, creating a versatile binding solution that adapts to different by-product materials while maintaining consistent briquette strength quality
4Device complexity
If by-products are not reincorporated into production processes, then the production process remains simple, but material inventory builds up causing environmental harm
Solution Approach 1:
The patent recovers steel industry by-products (pellet fines, DRI sludge, DRI fines, and dusts) that would otherwise be discarded or stored as hazardous materials, transforming them into valuable feedstock for briquette production and eliminating environmental harm associated with material accumulation
Solution Approach 2:
The patent converts potentially harmful by-product materials that cause environmental problems when accumulated into beneficial feedstock for briquette production, transforming an environmental liability into a production asset
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 process effectively reincorporates by-products into steel production, minimizing inventory and improving environmental sustainability by producing briquettes with enhanced strength and porosity, achieving metallization rates greater than 92.5% in Direct Reduction reactors.
Implementation Method 1
The briquetting process consists in agglomerating the materials by compression using roller presses
Implementation Method 2
the use of binders will be necessary to help form a briquette that meets the characteristics of strength needed for handling
Implementation Method 3
curing in closed warehouses at room temperature and optionally in drying furnaces operating at 80-100° C.
Data Source
AI summary
A method for producing briquettes from pellet fines, DRI sludge, DRI fines and dust from DRI dedusting systems and, in this way, reincorporating same into steel production processes, thereby contributing to the re-use of the by-products of these processes, as well as minimizing the stocks of these types of materials and, consequently, helping to improve the environment. The invention comprises: grinding and sieving the pellet fines and the DRI sludge; sieving the DRI fines; storing the dust from DRI dedusting systems; briquetting with roller presses, using liquid sodium silicate and bentonite or composite Portland cement as binders; sieving the briquettes; shredding the edges and waste of the fresh briquettes; and curing in order to improve the physical properties thereof, such as strength. Once cured, the fresh briquette can be stored or sent directly to direct-reduced iron production processes for use as part of the feedstock for reduction ovens or reactors.