Manganese Ore Preheating via Inert CO2 Atmosphere
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Solution Overview
Problem
The existing methods for smelting manganese ore sinter are inefficient in terms of energy usage and can lead to uncontrolled temperature increases and potential explosions due to reactions between carbon and oxygen, limiting the preheating temperature to around 600-700°C.
Innovation Solution
A method involving preheating a feed mixture containing manganese ore sinter and a reducing agent in a pre-treatment silo using carbon dioxide gas, generated by combusting carbon monoxide from the smelting process, to a temperature between 400-700°C, while controlling oxygen and hydrogen content to prevent carbon oxidation, thereby reducing energy consumption and preventing explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the preheating temperature is increased to save electrical energy and improve productivity, then energy efficiency and production improve, but carbon oxidation reactions occur causing uncontrolled temperature increases and potential explosions
Solution Approach 1:
The patent applies the inert atmosphere principle by creating an oxygen-deficient environment in the preheating zone using a sealed silo structure with controlled gas composition. The atmosphere is maintained with low oxygen content (below 5%) and controlled hydrogen content (below 10%) to prevent carbon oxidation reactions while allowing temperature increase to 400-700°C. This resolves the contradiction by enabling higher preheating temperatures for energy efficiency without compromising safety through carbon combustion.
Solution Approach 2:
The patent uses gas composition control as an intermediary mechanism between temperature control and safety. By carefully regulating the partial pressures of oxygen, hydrogen, and carbon monoxide in the preheating atmosphere, the system mediates between the need for high temperature (energy efficiency) and prevention of exothermic reactions (safety). The controlled atmosphere acts as a buffer that allows thermal energy transfer without enabling harmful chemical reactions.
2Reliability
If the preheating temperature is limited to 600-700°C to prevent carbon oxidation, then process safety is maintained, but energy efficiency and productivity are reduced
Solution Approach 1:
The sealed silo structure with controlled atmosphere composition enables extended preheating temperature range up to 700-800°C by maintaining oxygen content below 5% and hydrogen below 10%. This inert environment prevents carbon oxidation while allowing higher temperatures that improve feed mixture reactivity and reduce smelting time, thereby increasing productivity without compromising safety.
Solution Approach 2:
The patent changes the atmospheric parameters (oxygen partial pressure, hydrogen partial pressure, carbon monoxide concentration) to enable higher preheating temperatures. By adjusting these chemical parameters rather than relying solely on temperature control, the system achieves both safety and productivity improvements through enhanced thermal processing of the feed mixture.
3Temperature
If carbon oxidation reactions occur during preheating, then additional heat is generated, but uncontrolled temperature increases and explosions may occur
Solution Approach 1:
The patent creates an inert preheating atmosphere with controlled low oxygen content (below 5%) and limited hydrogen content (below 10%) to prevent exothermic carbon oxidation reactions. This controlled environment allows systematic temperature increase to 400-700°C through external heating without the risk of runaway thermal reactions, eliminating the harmful effect of uncontrolled temperature increases while maintaining effective preheating.
Solution Approach 2:
The system applies preliminary anti-action by pre-establishing oxygen-deficient conditions before heating begins. The sealed silo structure and controlled gas composition are prepared in advance to counteract the potential for carbon oxidation, preventing the harmful effect before it can occur during the preheating process.
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 enhances energy efficiency, prevents uncontrolled temperature rises, and ensures safer operation by preheating the feed mixture to optimal temperatures without burning or losing carbon, improving the smelting process in submerged electric arc furnaces.
Implementation Method 1
heating said feed mixture (1) with said carbon dioxide containing carbonaceous gas (9) formed in the combusting step (7) in a pre-treatment silo (8)
Implementation Method 2
heating said feed mixture (1) with said carbon dioxide containing carbonaceous gas (9) formed in the combusting step (7) in a pre-treatment silo (8)
Implementation Method 3
combusting carbon monoxide containing carbonaceous gas (6) discharged in the first discharging step (5) from the submerged electric arc furnace (5) in presence of oxygen such as air in a burner (7) to form carbon dioxide containing carbonaceous gas (9)
Implementation Method 4
preheating the feed mixture containing at least manganese ore sinter and reducing agent in order to eliminate the moisture from the feed mixture
Data Source
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AI summary
Described is a method and an apparatus for preheating and smelting manganese ore sinter. The method comprises feeding feed mixture (1) containing manganese ore sinter (2), reducing agent (3), and fluxing agent (4) into an submerged electric arc furnace (5), smelting feed mixture (1) to form a layer containing liquid manganese alloy and a layer containing slag, withdrawing liquid manganese and, discharging carbon monoxide containing carbonaceous gas (6), combusting carbon monoxide containing carbonaceous gas (6) in presence of oxygen such as air in a burner (7) to form carbon dioxide containing carbonaceous gas (9), and heating said feed mixture (1) in a pre-treatment silo (8) prior feeding said feed mixture (1) into the submerged electric arc furnace (5) with said carbon dioxide containing carbonaceous gas (9).