Fluidized-Bed Reduction Reactor Charging System for Iron Ore

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Solution Overview

Problem

The blast furnace process for producing molten iron faces challenges such as the need for accessory equipment, environmental pollution, and unstable operation due to blockages and stagnating layers in fluidized-bed reduction reactors, which affect the efficient charging and discharging of fine iron ore.

Innovation Solution

The implementation of a system comprising multiple fluidized-bed reduction reactors connected by fine iron ore charging and discharging lines, with a melter-gasifier and reducing gas supply, allows for direct and controlled charging and discharging of fine iron ore, preventing blockages and stabilizing the fluidized bed operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the fluidized-bed reduction reactor operates with multiple distribution nozzles to eject reducing gas at high speed, then the reduction efficiency is improved, but the dipleg portion becomes blocked due to backflowing fine iron and scattered fine ore

Engineering Contradiction:

Improvereduction efficiencyVSAvoidoperational stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The charging system is divided into multiple independent charging lines that can operate separately. Each charging line has its own control mechanism, allowing selective operation to prevent blockages while maintaining overall system productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary charging of fine iron ore into the reactor before full operation begins. This preliminary action establishes a stable fluidized bed and seals the dipleg portion before high-speed reducing gas ejection starts, preventing backflow blockages.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the dipleg portion is sealed by forming fluidized bed up to its height, then backflow of fine iron is reduced, but initial operation becomes unstable

Engineering Contradiction:

Improvebackflow preventionVSAvoidinitial operation stability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts operating parameters during different phases. During initial operation, parameters are optimized to stabilize the fluidized bed and seal the dipleg portion. During steady-state operation, parameters are adjusted to maximize reduction efficiency while maintaining seal integrity.

Inventive Principle:

Principle #15Dynamics

3Productivity

If fine iron ore is discharged quickly during emergency situations, then operational flexibility is improved, but blockages and stagnating layers occur in the fluidized bed

Engineering Contradiction:

Improvecharging and discharging speedVSAvoidfluidized bed stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates feedback mechanisms that monitor the fluidized bed state and adjust charging/discharging rates accordingly. When blockages or stagnating layers are detected, the system automatically reduces discharge speed or adjusts charging rates to maintain fluidized bed stability.

Inventive Principle:

Principle #23Feedback

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 enables stable and quick charging and discharging of fine iron ore, reducing blockages and stagnating layers, thereby improving operational stability and extending the operational period of the fluidized-bed reduction reactors.

Implementation Method 1

The fine iron is fluidized in a reducing gas flow and then reduced in the fluidized-bed reduction reactor

Methodology Applied

Scientific EffectFluidization: Fluidisation

Implementation Method 2

oxygen is injected through a plurality of tuyeres installed in an outer wall of the melter-gasifier, a coal-packed bed in the melter-gasifier is burned, and then molten iron is manufactured. The oxygen is converted into a hot reducing gas

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 3

the hot reducing gas reduces fine iron ore and is discharged outside

Methodology Applied

Scientific EffectReduction: Reduction

Data Source

PatentUS7850902B2Apparatus for manufacturing molten irons

Publication Date: 2010.12.14 PRIMETALS TECH AUSTRIA GMBH

AI summary

A method for manufacturing molten iron that improves charging and discharge of the fine iron ore, and an apparatus for manufacturing molten iron using the same. The apparatus for manufacturing molten iron includes i) at least one fluidized-bed reduction reactor that reduces fine iron ore and converts the fine iron ore into reduced iron, ii) a fine iron ore charging bin that supplies the fine iron ore to the fluidized-bed reduction reactor, iii) a fine iron ore charging line that directly connects the fine iron ore charging bin to each of the fluidized-bed reduction reactors, and directly charges the fine iron ore into each of the fluidized-bed reduction reactor, iv) a melter-gasifier into which lumped carbonaceous materials and the reduced iron are charged and oxygen is injected, the melter-gasifier manufacturing molten iron, and v) a reducing gas supply line that supplies a reducing gas discharged from the melter-gasifier to the fluidized-bed reduction reactor.