Molten Iron Production via Fluidized and Packed-Bed Reduction
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Solution Overview
Problem
The existing methods for manufacturing molten iron, such as the blast furnace process and smelting reduction processes, face challenges in efficiently reducing iron ores with a wide range of grain sizes, leading to issues like uneven gas flow, scattering, and increased operational complexity in fluidized-bed reduction reactors.
Innovation Solution
A method involving the reduction of first iron ores in a fluidized-bed reactor, followed by compaction and subsequent reduction with larger second iron ores in a packed-bed reactor, then melting both in a melter-gasifier with controlled reducing gas and auxiliary fuel injection, to form molten iron, while managing gas temperatures and ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fine iron ores are reduced in a fluidized-bed reduction reactor with high velocity reducing gas, then reduction efficiency is improved, but scattering and adhesion occur leading to operational instability
Solution Approach 1:
The patent changes the velocity parameter of the reducing gas from high velocity (causing scattering) to controlled velocity (preventing scattering and adhesion). By adjusting this critical parameter, the system achieves both efficient reduction and operational stability without material loss.
2Adaptability or versatility
If iron ores with wide range of grain sizes are reduced in fluidized-bed reduction reactor, then adaptability to different ore sizes is improved, but uniform fluidized layer formation becomes difficult increasing operational complexity
Solution Approach 1:
The patent controls the velocity parameter of the reducing gas to maintain uniform fluidization across ores of varying grain sizes. By optimizing this parameter, the system can process a wide range of ore sizes while keeping operation simple and manageable.
3Productivity
If reducing gas velocity is increased to fluidize fine iron ores, then reduction of fine ores is improved, but fine iron ores are scattered outside causing material loss
Solution Approach 1:
The patent optimizes the reducing gas velocity parameter to a controlled level that is sufficient to fluidize and reduce fine iron ores but not so high as to cause scattering loss. This parameter optimization eliminates material loss while maintaining high reduction efficiency.
4Loss of substance
If reducing gas velocity is decreased to prevent scattering, then material loss is reduced, but fluidized-bed layer collapses stopping the process
Solution Approach 1:
The patent identifies and controls the critical velocity parameter of the reducing gas that maintains fluidized-bed layer stability. By keeping the velocity within an optimized range, the system prevents both scattering loss and layer collapse, ensuring continuous operation without material loss.
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 prevents scattering and adhesion in fluidized-bed reactors, increases molten iron production, reduces sludge loss, and ensures complete reduction of iron ores with improved gas flow and reduced operational complexity.
Implementation Method 1
reducing first iron ores by charging the first iron ores into a fluidized-bed reduction reactor
Implementation Method 2
reducing second iron ores together with the compacted irons by charging the second iron ores and the compacted irons into a packed-bed reduction reactor
Implementation Method 3
preparing lumped carbonaceous materials as a heating source for melting the reduced compacted irons and the second iron ores
Implementation Method 4
charging the lumped carbonaceous materials into the melter-gasifier and then forming a coal packed-bed; injecting oxygen through a tuyere installed in the melter-gasifier and then manufacturing molten iron
Implementation Method 5
fine iron ores are reduced to be fluidized using a reducing gas with a high velocity in the fluidized-bed reduction reactor
Data Source
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AI summary
The present invention relates to an apparatus for manufacturing molten irons and a method for manufacturing molten iron using the same. The method for manufacturing molten irons according to the present invention includes reducing first iron ores by charging the first iron ores into a fluidized-bed reduction reactor; manufacturing compacted irons by compacting the reduced first iron ores; reducing second iron ores together with the compacted irons by charging the second iron ores and the compacted irons into a packed-bed reduction reactor, a size of the second iron ores is greater than a size of the first iron ores; charging the reduced compacted irons and the second iron ores into a melter-gasifier connected to the packed-bed reduction reactor; preparing lumped carbonaceous materials as a heating source for melting the reduced compacted irons and the second iron ores; charging the lumped carbonaceous materials into the melter- gasifier and then forming a coal packed-bed; and injecting oxygen through a tuyere installed in the melter-gasifier and then manufacturing molten iron from the compacted irons and the second iron ores.