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Smelting reduction process based on ore fines with high gas utilization

Ziel

The aim of this project is the further development of the KRUPP COIN process (Coal Oxygen Injection) for direct reduction. This process also uses the blowing-in of coal and oxygen into a metal bath to produce a reducing gas. Following the cooling of this gas, the ore reduction takes place in a circulating fluidizing bed. The particular feature of this process is that ore fines can be used. This process would also make the coking and sintering plants superfluous, which would be of ecological interest as well as of economic advantage. The general disadvantage of all smelting reduction processes is the production of a considerable excess of reducing gases, for which a use must be found outside the reduction process. One of the major aims of this pilot project is, therefore, to improve the overall heat balance.

To this end, an attempt will be made to provide for:
a) Carbon removal from the exhaust gas. Iron and iron oxides have a catalytic effect on the decomposition of CO gas into C and CO2 in the temperature range around 500C. The carbon precipitates out in the form of graphite on to the fine ore particles, and can thus be reintroduced into the process. An improvement of the gas utilization from 45 to 74% is expected. The carbon should also ensure that the fine ore particles do not stick;
b) Low temperature carbonization of the coal for injection in the COIN gas. When coal and oxygen are injected into the metal bath a gas with a temperature of 1,500-1,600C arises. This must be cooled to 800-900C before it enters the reduction vessel. The heat discharge can thus be used as part of the process, namely for the semi-coking of the coal to be injected.

The project will be divided into the following, partly overlapping, stages: - carbon recuperation from the exhaust gas; - semi-coking of the volatile coal fines; - reduction tests; - optimum running of the pilot plant and development of detailed specifications for the plant.

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Krupp Forschungsinstitut GmbH
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Münchener Straße 100
45145 Essen
Deutschland

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