Exploring possibility of exploiting old known

processes to create a new process process

Jayant Sathaye

Exploring possibility of exploiting old known

processes to create a new process process

Jayant Sathaye

History

� Self reducing composites known for a long time. Earliest trial in mid 1950’s. Even India in late sixties

� Started in attempt to utilise fines coalcoal

� Rotary Hearth processes -� submerged arc furnaces –� Shaft furnaces – OxyCup, Tecnored� Others without composites

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Self reducing composites known for a long time. Earliest trial in mid 1950’s. Even India in late sixties

Started in attempt to utilise fines – both iron ore and

Maumee, Fastmet, ITmK3– Redsmelt

OxyCup, TecnoredOthers without composites – Hismelt, Romelt, Ausmelt

Exploring possibility of exploiting old known processes to

create a new process 2

Rotary Hearth Furnaces

� Quick reduction

� Heat transfer – one or two layers only

� re-oxidation – has to be matched to melting vessel

� Sulphur from coal goes into product

� Phosphorus also retained

� cooling/melting after reduction

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Rotary Hearth Furnaces

one or two layers only

has to be matched to melting vessel

Sulphur from coal goes into product

cooling/melting after reduction

Exploring possibility of exploiting old known processes to

create a new process 3

Submerged Arc Furnaces

� Electric energy consumption

� matching rotary hearth output to SAF input

� slag handling

� DRI also can be melted

� still being used for Ti and V bearing ores

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Submerged Arc Furnaces

Electric energy consumption – cost of energy

matching rotary hearth output to SAF input

still being used for Ti and V bearing ores

Exploring possibility of exploiting old known processes to

create a new process 4

Direct use of Iron ore and coal

� Incomplete reduction

� FeO content in slag

� refractory life – corrosive slag

� Top lance and life

� waste energy utilisation - at 1700 Deg C

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Direct use of Iron ore and coal

corrosive slag – campaign life

at 1700 Deg C – sensible and fuel

Exploring possibility of exploiting old known processes to

create a new process 5

Shaft furnaces

� Size of composite brick, pellet, briquette is a requirement

� Reduction degradation – tall shaft is not suitable

� permeability

� heat transfer

� waste gas energy utilisation

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Size of composite brick, pellet, briquette is a requirement

tall shaft is not suitable

Exploring possibility of exploiting old known processes to

create a new process 6

Raw material possibilities in India ore

� High grade ore fines limited, low grade needs beneficiation

� need to grind to beneficiate to 63.5%

� size – 20 to 80 microns - superfines

� need to agglomerate

� hot agglomeration

� cold bonding

� slag design for after melting the reduced composite

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Raw material possibilities in India – Iron

High grade ore fines limited, low grade needs beneficiation

need to grind to beneficiate to 63.5%

superfines

slag design for after melting the reduced composite

Exploring possibility of exploiting old known processes to

create a new process 7

Raw material possibilities in India

� High carbon low ash preferred

� reactivity – temperature

� melting of ash – temperature

� size restriction for fixed bed

� generation of coal fines and possibilities of utilisation

� what is better? – electric power or chemical reduction

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Raw material possibilities in India - Coal

High carbon low ash preferred

temperature

generation of coal fines and possibilities of utilisation

electric power or chemical reduction

Exploring possibility of exploiting old known processes to

create a new process 8

Suggestion – Shaft Furnace

� good heat transfer

� reduction degradation requirement

� permeability – paramount importance

� multiple injection points – combusted gas

� discharge – without reoxidation

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Shaft Furnace

reduction degradation requirement

paramount importance

combusted gas

without reoxidation

Exploring possibility of exploiting old known processes to

create a new process 9

Suggestion - melter

� need for permeability

� need to complete reduction

� slag composition – fluidity/temperature

� refractory for vessel

� handling of sulphur/phosphorus

� permeable coke/slightly caking coal bed

� Fuel generation for shaft

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

fluidity/temperature

handling of sulphur/phosphorus

permeable coke/slightly caking coal bed

Exploring possibility of exploiting old known processes to

create a new process 10

Suggestion – Utilisation of wastes

� slag to be suitable for cement making

� gas to be suitable for thermo

� gas to be suitable for direct use without need for enrichment – in IC engines, reheat furnaces, gas turbines, enrichment – in IC engines, reheat furnaces, gas turbines, fuel cells (?)

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Utilisation of wastes

slag to be suitable for cement making

gas to be suitable for thermo-electric power generation

gas to be suitable for direct use without need for in IC engines, reheat furnaces, gas turbines, in IC engines, reheat furnaces, gas turbines,

Exploring possibility of exploiting old known processes to

create a new process 11

Possibility – Flowsheet 1

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Flowsheet 1

Exploring possibility of exploiting old known processes to

create a new process 12

Possibility – Flowsheet 2

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

Flowsheet 2

Exploring possibility of exploiting old known processes to

create a new process 13

Possibility ?

� utilisation of superfine iron ores and coals

� simple agglomeration with lime fines as binder

� viable unit processes

� possible overall process� possible overall process

�Thank you for your patience

2/1/2016Exploring possibility of exploiting old known processes to

create a new process

utilisation of superfine iron ores and coals

simple agglomeration with lime fines as binder

Exploring possibility of exploiting old known processes to

create a new process 14