Method for removing phosphorus from phosphorus-containing substance, method for manufacturing raw material for metal smelting or raw material for metal refining, and method for manufacturing metal

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Solution Overview

Problem

Conventional methods for removing phosphorus from phosphorus-containing substances used in metal smelting or refining are energy-intensive, costly, and inefficient, particularly due to high treatment temperatures and wet treatments, and they do not effectively address the issue of phosphorus absorption into valuable components like iron and manganese.

Innovation Solution

A method involving a reduction treatment at a controlled temperature range followed by nitriding with a nitrogen-containing gas to remove phosphorus as a gas phase mononitride, using a reducing agent to control oxygen partial pressure and maintain an unmolten state, thereby reducing phosphorus content in phosphorus-containing substances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional dephosphorization treatment is performed at high temperatures, then phosphorus removal effectiveness is improved, but energy consumption increases and treatment cost increases

Engineering Contradiction:

Improvephosphorus removal effectivenessVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The invention changes the temperature parameter from conventional high temperatures (above melting point of iron ore) to a controlled range below the melting point (300-1300°C), thereby reducing energy consumption while maintaining phosphorus removal effectiveness through optimized chemical reactions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention introduces a reducing agent as an intermediary substance that facilitates phosphorus removal by controlling oxygen partial pressure and creating favorable conditions for phosphorus oxidation and transfer to slag, enabling effective dephosphorization at lower temperatures

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If conventional wet treatment methods are used, then phosphorus removal is achieved, but treatment cost increases and efficiency decreases

Engineering Contradiction:

Improvephosphorus removal effectivenessVSAvoidtreatment cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention replaces conventional wet treatment methods with a thermal/chemical process using reducing agents and controlled atmosphere, eliminating the need for complex wet treatment infrastructure and reducing operational costs while maintaining phosphorus removal effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If high treatment temperatures are used, then phosphorus removal is effective, but phosphorus absorption into valuable components increases

Engineering Contradiction:

Improvephosphorus removal effectivenessVSAvoidphosphorus absorption into iron and manganese

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The reducing agent acts as an intermediary that controls oxygen partial pressure and creates a controlled chemical environment, enabling phosphorus removal through oxidation to slag while preventing phosphorus absorption into iron and manganese by maintaining appropriate oxygen activity levels

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By precisely controlling the temperature parameter within the range of 300-1300°C (below melting point) and using reducing agents to control oxygen partial pressure, the invention creates optimal conditions for phosphorus removal while minimizing phosphorus absorption into valuable metal components

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

This approach allows for efficient phosphorus removal at lower temperatures, reducing the load on dephosphorization treatments and enabling the reuse of by-products, thus lowering costs and increasing the availability of inexpensive raw materials for metal smelting or refining.

Implementation Method 1

a reduction treatment is performed in which the phosphorus-containing substance is heated to an unmolten state temperature range so as to react with a reducing agent, thereby reducing at least a part of metal oxide in the phosphorus-containing substance

Methodology Applied

Scientific EffectReduction: Reduction

Implementation Method 2

the phosphorus-containing substance is reacted with a nitrogen-containing gas so that phosphorus in the phosphorus-containing substance is removed through nitriding

Methodology Applied

Scientific EffectNitriding: Nitriding

Data Source

PatentUS12584187B2Method for removing phosphorus from phosphorus-containing substance, method for manufacturing raw material for metal smelting or raw material for metal refining, and method for manufacturing metal

Publication Date: 2026.03.24 JFE STEEL CORP

AI summary

A method removes phosphorus from a phosphorus-containing substance. In the method, the phosphorus-containing substance that is used as a raw material for metal smelting or refining is reacted with a nitrogen-containing gas so that phosphorus in the phosphorus-containing substance is removed through nitriding. Prior to a treatment of a nitriding removal of phosphorus from the phosphorus-containing substance, a treatment is performed in which the phosphorus-containing substance is heated to an unmolten state temperature range so as to react with a reducing agent, thereby reducing at least a part of metal oxide in the phosphorus-containing substance.