Direct smelting and alternative processes for the production of iron and steel

Zervas, T.; McMullan, J. T.; Williams, B. C.

doi:10.1002/(sici)1099-114x(199612)20:12<1103::aid-er270>3.0.co;2-m

Cited by 10 publications

(3 citation statements)

References 7 publications

(8 reference statements)

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“…4) This requires a continuous supply of high quality raw materials such as iron ore pellets, sinter and coke. Since blast furnaces can not be shut down and restarted easily this continuous high capacity production takes place even under depressed market conditions.…”

Section: Flexible Processmentioning

confidence: 99%

The Microstructure of the Pig Iron Nuggets

Anameric

Kawatra

2007

ISIJ Int.

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The pig iron nugget process (referred to as the Iron Technology Mark 3, or ITmk3, process by Kobe Steel) was developed as an alternative to the traditional blast furnace process. Throughout this process self reducing-fluxing dried greenballs are reduced and smelted in to nuggets of metal. The objective of this research was to produce pig iron nuggets at laboratory scale, then characterize and compare them with the blast furnace pig iron. Pig iron nuggets were characterized utilizing apparent density measurements, optical microscopy, scanning electron microscopy with energy dispersive spectroscopy, and bulk chemical analysis. It was determined that pig iron nuggets had high apparent density (6.7-7 g/cm 3 ); had a high iron content (95-97 %); and exhibited microstructures similar to white cast iron, which is essentially the same as pig iron from a blast furnace.KEY WORDS: pig iron nuggets; iron smelting; self reducing-fluxing dried greenballs. 53© 2007 ISIJ Table 1. The comparison of some of the basic process properties of the blast furnace and pig iron nugget process.where they are reheated in the blast furnace. The pig iron nugget process aims to save energy by making it possible to produce pig iron from self reducing-fluxing dried greenballs with just one heating step. Self reducing-fluxing dried greenballs will be heat treated directly without any induration or sintering steps. This will enable the elimination of the energy used by heating, cooling and reheating of the pellets and sinters.iii. Reduced Residence Time in the Reactor For the pig iron nugget process the kinetics of the reduction and carburization reactions are enhanced by agglomeration of an iron ore source, flux, and reducing-carburizing agent together. The close contact of the reacting materials and availability of a large number of reacting sites enhances the solid-solid reduction and slag forming reactions. Also, the internal gas generation, and small diffusion distances in the sample enhances the solid-gas reduction reactions, reducing gas regeneration, slag forming and carburization reactions. [10][11][12][13][14][15] iv. Impurity (Gangue) Separation with Formation of Fusible Slag For the blast furnace process and pig iron nugget process, the impurities are separated from the metal by the formation of slag. Flux materials such as limestone, dolomite, and magnesia are added to lower fusion temperatures to enable the slag formation. The slag can only be separated from the metal when metal and slag are in liquid state. This requires metal (pure iron fusion temperature of 1 535°C) and slag (slag fusion temperature around 1 200°C) to be heated above their fusion temperatures. The blast furnace process operates at temperatures above the fusion temperature of iron and produces liquid metal (pig iron) and slag. On the other hand, throughout the pig iron nugget process, it is intended to have carburization of pure iron, lowering its fusion temperature (this effect takes place until the eutectic carbon composition is reached). This should allow the pi...

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Section: Flexible Processmentioning

confidence: 99%

The Microstructure of the Pig Iron Nuggets

Anameric

Kawatra

2007

ISIJ Int.

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“…These characteristics implied that the carbides could be employed for the direct upgrading of vegetable oils in a trend similar to metal-supported oxide catalysts. In fact, carbides, heteropoly acids, and related catalysts have shown good stability, reactivity, and regeneration properties in many catalytic reactions [195][196][197][198][199].…”

Section: And O Murazamentioning

confidence: 99%

Hydroisomerization of sustainable feedstock in biomass-to-fuel conversion: a critical review

Galadima

Muraza

2014

Int. J. Energy Res.

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Summary The production of diesel and gasoline range paraffins from both solid and liquid biomass is one of the promising alternatives being considered for ensuring sustainable fuel supply. Solid biomass gasification produces synthetic gas, which via subsequent Fischer–Tropsch reaction is converted into useful liquid hydrocarbon fuels. Similarly, pyrolysis generates oxygenated and bio‐oil products with comparable fuel potentials. The liquid biomass such as vegetable oils, on the other hand can be upgraded by serial hydrogenation, cracking, deoxygenation, and decarboxylation. We have critically reviewed substantial literature on the various conversion processes and the hydroisomerization of the linear bioparaffins into isomerized products with enhanced fuel properties. Emphasis was given to the heterogeneous catalyst systems, operational parameters, reaction mechanisms, and identified challenges. The scope was extended to cover different porous catalysts with prospects in biomass‐to‐fuel conversion. Copyright © 2014 John Wiley & Sons, Ltd.

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“…Clearly, a significant reduction in CO 2 emission is possible when the amount of coke used is decreased. In this regard, some coke-free iron-making methods, in which composites of iron oxides and carbon are utilized, have been studied. − Close contact between iron oxide and carbon is important; Kashiwaya et al revealed that direct reduction occurred at the interface between iron oxide and carbon at low temperature …”

Section: Introductionmentioning

confidence: 99%

Ultrafast Iron-Making Method: Carbon Combustion Synthesis from Carbon-Infiltrated Goethite Ore

et al. 2018

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Carbon-infiltrated iron ores were prepared from a coal-tar solution and selected calcined iron sources (i.e., goethite (FeOOH) ore, high-grade hematite ore, and Fe 2 O 3 reagent grain). A several hundred micrometer thick carbon layer was deposited on the surface of all iron sources. Because the tar solution successfully penetrated into its nanopores, only goethite ore possessed a significant amount of carbon in its interior nanopores. The carbon-infiltrated ores were heated rapidly in an oxygen atmosphere in the combustion synthesis experiments. Carbon combustion occurred at the ore surface, with the ore temperature increasing suddenly during the experiments. Fast reduction to metallic iron was observed only in the carbon-infiltrated goethite ore, regardless of the oxygen atmosphere. Close contact between the goethite ore and the carbon in its nanoporous interior facilitated the fast reduction. The apparent reduction reaction of goethite ore is akin to a direct reduction reaction (i.e., FeO x + C → FeO x –1 + CO).

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Direct smelting and alternative processes for the production of iron and steel

Abstract: SUMMARYProcesses for the direct smelting of iron and steel are presented together with a discussion of alternatives based on plasmas and the direct production of iron carbide. The advantages and disadvantages of each technology are presented and their energy efficiencies are discussed.

Cited by 10 publications

References 7 publications

The Microstructure of the Pig Iron Nuggets

The Microstructure of the Pig Iron Nuggets

Hydroisomerization of sustainable feedstock in biomass-to-fuel conversion: a critical review

Ultrafast Iron-Making Method: Carbon Combustion Synthesis from Carbon-Infiltrated Goethite Ore

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