Phosphorus-Containing Pig Iron Production via Organic Additives

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Solution Overview

Problem

The existing methods for phosphorus recovery and utilization in steel production are complex, expensive, and contribute to CO2 emissions, with limited alternatives for closing phosphorus cycles and reducing reliance on natural phosphorus resources.

Innovation Solution

A method involving the production of phosphorus-containing pig iron melt by melting iron carriers and additives in an electric melter, using organic substances with phosphorus and/or phosphate content to adjust the phosphorus content between 0.150 and 5.0 wt.%, which reduces carbon content and lowers the melting point, facilitating logistics and potentially reducing CO2 emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional methods are used for phosphorus recovery from sewage sludge through mono-incineration, then phosphorus can be extracted and recovered, but the process becomes complex and expensive

Engineering Contradiction:

Improvephosphorus recoveryVSAvoidprocess complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention changes the chemical composition parameters of the pig iron melt by adding organic substances with phosphorus content, transforming the approach from complex extraction processes to a simpler compositional adjustment method that achieves phosphorus recovery while simplifying the overall process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention extracts phosphorus from organic substances and directly incorporates it into the pig iron melt, bypassing the complex mono-incineration and extraction processes while achieving the same phosphorus recovery objective

Inventive Principle:

Principle #2Taking out (Extraction)

2Temperature

If phosphorus is added to pig iron melt to adjust content between 0.150 and 5.0 wt.%, then the melting point is lowered and logistics are improved, but the phosphorus content must be precisely controlled

Engineering Contradiction:

Improvemelting pointVSAvoidphosphorus content control

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The invention performs preliminary action by pre-calculating and pre-mixing the required amount of phosphorus-containing organic substances into the pig iron melt before final processing, ensuring the phosphorus content is already optimized for the desired melting point reduction, thereby simplifying subsequent precision control

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention implements feedback control by monitoring the phosphorus content during the melting process and adjusting the addition of organic substances accordingly, ensuring the phosphorus content remains within the optimal range of 0.150-5.0 wt.% while achieving the desired melting point reduction

Inventive Principle:

Principle #23Feedback

3Quantity of substance

If phosphorus-rich ores are used to produce Thomas slag, then phosphorus-containing slag can be obtained for fertilizer use, but natural phosphorus resources are depleted

Engineering Contradiction:

Improvephosphorus-containing slagVSAvoidnatural phosphorus resources

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The invention recovers phosphorus from organic substances that would otherwise be discarded or underutilized, transforming waste organic material into a valuable phosphorus source for pig iron production and subsequent fertilizer generation, thereby eliminating the need to deplete natural phosphorus resources

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The invention converts organic substances containing phosphorus, which may be considered waste or harmful if improperly disposed, into a beneficial phosphorus source for steel production and fertilizer manufacturing, turning a potential environmental problem into a resource recovery opportunity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 phosphorus recovery, reduces decarburization work, decreases CO2 production, and allows for the production of phosphorus-containing converter slag that can be further processed into fertilizer, thus closing the phosphorus cycle and minimizing environmental impact.

Implementation Method 1

iron carriers and additives are melted in an electric melter to form a smelter slag covering the pig iron melt

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

Phosphorus in a pig iron melt increases the entropy of the system and can thus have a positive influence on lowering the melting point of a phosphorus-rich pig iron melt

Methodology Applied

Scientific EffectEntropy increase and melting point depression: Phase Change

Implementation Method 3

iron carriers and additives are melted in an electric melter

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentEP4644574A1Method for producing a phosphorus-containing pig iron melt

Publication Date: 2025.11.05 THYSSENKRUPP STEEL EUROPE AG PATENTE PATENT DEPARTMENT

Figure 1

AI summary

The invention relates to a method for producing a phosphorus-containing pig iron melt (11).