Iron Making Waste Material Drying Using Sinter Plant Exhaust Gas
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Solution Overview
Problem
Existing iron making processes using carbon-containing waste materials face variability issues due to differences in waste material characteristics, leading to inconsistent calorific power and potential pollutant emissions, as existing methods fail to account for these variations and lack efficient pollutant removal systems.
Innovation Solution
A method and installation that involves drying waste materials using sinter plant exhaust gas, roasting them to produce coal, and recycling roasting exhaust gas, ensuring consistent energy supply and pollutant removal through a specific treatment step, with the dried and milled coal being injected into a blast furnace, and utilizing sinter plant exhaust gas for drying, which maintains consistent heat levels regardless of waste material characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If waste materials are used as carbon-containing material in iron making, then carbon balance is improved and external energy supply is reduced, but variability in waste material characteristics causes inconsistent calorific power and potential pollutant emissions
Solution Approach 1:
The patent applies preliminary action by implementing a drying step before the carbonization step. The waste material is dried to a moisture content of 10-30% using drying gas (combustion gas or top gas) before being carbonized. This preliminary drying action standardizes the material state and ensures consistent calorific power during subsequent carbonization, resolving the variability issue while maintaining the benefits of using waste materials.
2Use of energy by moving object
If waste materials with high volatile compounds are used, then carbon balance is improved, but pollutant emissions increase
Solution Approach 1:
The patent converts the harmful volatile compounds into beneficial resources through the carbonization process. The volatile compounds are thermally decomposed and converted into combustible gases (CO, H2, CH4) that are captured and utilized as fuel for heating the carbonization process and generating electricity. This transforms the harmful emissions into useful energy, maintaining carbon balance while eliminating pollutant releases.
Solution Approach 2:
The patent introduces an intermediary system comprising gas cleaning equipment and gas utilization systems. The exhaust gases from carbonization pass through cleaning equipment (scrubbers, filters) that remove pollutants, and the cleaned gases are then utilized as fuel or injected into the blast furnace. This intermediary treatment step enables the use of waste materials with high volatile compounds while preventing direct pollutant emissions.
3Reliability
If external energy supply is used to compensate for insufficient calorific power, then process stability is maintained, but energy self-sufficiency is reduced
Solution Approach 1:
The patent implements self-service by creating a closed-loop energy system where the carbonization process generates its own heating energy. The combustible gases produced during carbonization are captured and used to heat the carbonization chamber, eliminating the need for external fuel. Additionally, the system generates electricity from the same gases, achieving energy self-sufficiency while maintaining process stability through consistent thermal input.
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 ensures consistent operation of the iron making process independent of waste material variability, reduces the need for external energy, and effectively prevents pollutant emissions into the atmosphere by utilizing recycled and treated gases, thereby improving carbon balance and environmental sustainability.
Implementation Method 1
drying waste material using a drying gas, the drying gas comprising an exhaust gas from a sinter plant
Implementation Method 2
roasting the dried waste material using a roasting gas, so as to produce coal and a roasting exhaust gas
Implementation Method 3
recycling roasting exhaust gas, ensuring consistent energy supply
Data Source
AI summary
A method of operating an iron making installation is provided, in which waste material is dried using a drying gas, the drying gas including an exhaust gas from a sinter plant, and the dried material is roasted a roasting gas, so as to produce coal and a roasting exhaust gas. An associated installation is also provided.