Iron Ore Reduction Apparatus with Magnetic Gangue Separation
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Solution Overview
Problem
The existing methods for manufacturing ingot iron using low-grade iron ore are inefficient due to high gangue content, leading to increased slag generation, reduced molten iron productivity, and higher manufacturing costs, as they require separate mineral dressing processes and have low gangue separation efficiency.
Innovation Solution
A reduction apparatus that simultaneously performs reduction and mineral dressing of fine iron ore, utilizing a granulated ore pre-reduction furnace, an ultra-fine ore pre-reduction furnace, intermediate reduction furnaces, and a final reduction furnace, with magnetic separation to remove gangue, allowing for the direct production of ingot iron and reduced iron without a separate mineral dressing step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If low grade ore is used without pre-mineral dressing treatment, then the gangue content in ore charge is high, but the generated amount of slag is greatly increased and melting heat of slag is required, leading to increased reducing agent ratio and manufacturing cost
Solution Approach 1:
The patent applies preliminary action by performing mineral dressing treatment before the reduction process to remove gangue components from low grade ore. This preliminary separation of gangue from iron ore particles enables the use of low grade ore without generating excessive slag during subsequent reduction and melting operations
Solution Approach 2:
The patent extracts and removes gangue components from the ore charge through mineral dressing treatment before reduction. By taking out the harmful gangue elements separately from the iron ore, the process eliminates the need for excessive reducing agents and minimizes slag generation while maintaining adaptability to low grade ore
2Productivity
If gangue separation is performed after reduction step, then the reduced iron and ingot iron include gangue, but the magnetic separation treatment amount is increased and separation efficiency is very low
Solution Approach 1:
The patent performs gangue separation through mineral dressing treatment before the reduction step rather than after. This preliminary separation action removes gangue from the ore charge, enabling efficient reduction process and eliminating the need for extensive magnetic separation treatment afterward, thus maintaining high productivity while reducing separation complexity
Solution Approach 2:
The patent segments the processing flow into distinct stages: mineral dressing for gangue removal, reduction for iron conversion, and melting for final product production. By segmenting the separation function from the reduction function and performing them in optimal sequences, the process achieves high productivity without requiring complex magnetic separation treatment
3Ease of manufacture
If large particles and ultra-minute particles are not divided, then the gangue is separated from entire particles, but the magnetic separation treatment amount is increased in proportion to charge amount
Solution Approach 1:
The patent segments particles into different size categories (large particles and ultra-minute particles) and applies appropriate separation methods to each segment. By dividing the particle population and treating each segment separately through mineral dressing, the process reduces the total amount of magnetic separation treatment required compared to treating all particles uniformly
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 increases the use of low-grade ore, enhances gangue separation efficiency, reduces the capacity and cost of magnetic separators, and decreases the reducing agent requirement, thereby lowering production costs and improving molten iron productivity.
Implementation Method 1
a first magnetic separator separating and then discharging a gangue component from the ultra-fine ore reduced in the ultra-fine ore pre-reduction furnace
Data Source
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AI summary
A reduction apparatus and a reduction method of a fine iron ore are disclosed. The reduction apparatus of the fine iron ore according to the present invention includes: a granulated ore pre-reduction furnace into which the fine iron ore is charged to be pre-reduced by a reduction gas; an ultra-fine ore pre-reduction furnace into which an ultra-fine ore scattered in the granulated ore pre-reduction furnace to be discharged is charged to be pre-reduced; a first magnetic separator separating a gangue component from the ultra-fine ore reduced in the ultra-fine ore pre-reduction furnace and then discharged; at least one intermediate reduction furnace into which the granulated ore reduced in the granulated ore pre-reduction furnace to be discharged and the ultra-fine ore from which the gangue component is separated are charged to be further reduced and thus increase a reduction ratio of the granulated ore and the ultra-fine ore; and a final reduction furnace finally reducing the granulated ore and the ultra-fine ore reduced in the intermediate reduction furnace to be discharged to manufacture a reduced iron.