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Novel Flash Ironmaking Process

Novel flash making process..

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55 views2 pages

Novel Flash Ironmaking Process

Novel flash making process..

Uploaded by

gabhalemak
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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A Novel Flash

Ironmaking Process
Steel is used in a wide variety of
manufactured products, such as
skyscrapers, automobiles, and
bridges. The coke oven/blast furnace
process that produces pig iron for
steelmaking requires additional
Large-scale bench reactor facility layout
energy to prepare the raw iron ore Photo credit Berry Metal Company
as sinter and pellets, and consumes
A major advantage of flash ironmaking Applications in Our Nation’s
large amounts of carbon which is
over powder-based processes that use
emitted as the greenhouse gas Industry
shaft or fluidized-bed furnaces is the
carbon dioxide. Alternative processes elimination of sticking and particle The flash ironmaking process could
fusion at high temperatures. The provide steel plants with significantly
can avoid some of these issues, but
ability to use ore fines provides a cost more energy efficient and customized
are limited by low production capaci- iron production facilities than that of
advantage over processes that require
ties and raw material restrictions. ore to be agglomerated into pellets for competing processes.
Therefore, the U.S. steel industry ironmaking. The fine particles also cut
would benefit from the development the furnace’s processing time to seconds. Project Description
This translates to a smaller system for The project objective was to conduct
of a low capital cost process, scal-
the same output, reducing both capital a comprehensive bench-scale testing
able to large capacities that can costs and operating costs. Other potential campaign for the flash ironmaking
take advantage of the availability of benefits include improved refractory life, process concept to:
inexpensive iron ore concentrate, and and ease of feeding raw materials into the
vessel. • Validate the design concept of the flash
can use fuels that significantly reduce
ironmaking reactor in terms of heat
potentially harmful greenhouse gas supply and metallization degree.
emissions. Potential Benefits for Our
Industry and Our Nation • Determine optimum operating
The novel, high-intensity flash conditions in terms of reaction
The flash ironmaking process would
ironmaking process is a viable alternative temperature, reducing gas composition,
reduce energy consumption up to
that uses iron ore concentrates that and particle residence time.
15% over competitive processes by
are plentiful in the United States. The
eliminating pelletizing, briquetting, or
process would use inexpensive, abundant • Identify and address potential technical
sintering.
natural gas (or hydrogen) to both heat hurdles, such as refractory lining and
the ore in the furnace and to remove Greenhouse gas emissions could be iron powder collection.
oxygen, converting the ore to iron metal. significantly reduced by using natural gas
Although similar to Direct Reduced Iron, or hydrogen as the reducing agent instead • Identify and address potential safety
this advance would process fine powder of coke. Preliminary estimates show that challenges, including emergency shut-
ore, eliminating the briquetting process. the use of natural gas would emit 39% off procedures.
The product could be added to Electric less carbon dioxide than with a blast • Design an industrial-scale pilot plant.
Arc Furnaces or Basic Oxygen Furnaces furnace-based process.
for cleaner steelmaking. • Estimate costs for the industrial-scale
pilot system.

ADVANCED MANUFACTURING OFFICE


ADVANCED MANUFACTURING OFFICE

Barriers Milestones Project Partners


• Achieving 1300°C–1600°C by This project began in 2012 and was American Iron and Steel Institute
reducing heat loss completed in August 2018. Washington, D.C.
Project Director: Michael Sortwell
• Achieving required particle residence • Completed system design, Email: msortwell@steel.org
time by optimizing the gas flow in the specifications, and build requirements
system to avoid “short circuit” paths for a 1 kg/hr bench reactor at University University of Utah
of Utah, compliant with all safety and (Lead Research Organization)
• Identifying suitable refractory lining environmental regulations Salt Lake City, UT
for extended service Principal Investigator: H. Y. Sohn Email:
• Built the system and commissioned the h.y.sohn@utah.edu
Pathways reactor, confirming temperatures to be
greater than 1400°C, ore feed rate to be Berry Metal Company
Researchers designed and constructed
greater than 1 kg/hr, and operation time Harmony, PA
a large-scale bench reactor, addressing
to be greater than six hours
administration, safety, and operation ArcelorMittal USA
issues. The reactor was commissioned • Achieved greater than 95%metallization East Chicago, IN
in 2015 and validation tests were then with 1.5 times the theoretical minimum
performed for two years. The amount of reducing gas The Timken Company
experiments were focused on achieving Canton, Ohio
metallization targets (how much oxide • Determined optimum conditions for the
was converted to metal) and production flash ironmaking process United States Steel Corporation
rates. Pittsburgh, PA
• Provided detailed cost estimates and
Large bench reactor testing explored design for industrial pilot plant
a wide range of operating parameters
For additional information,
including temperature, gas velocity, please contact
supplemental heating, and refractory Bill Prymak
Technology Transition Technical Project Officer
types. Optimum operating parameters
were established through a series of Options regarding the pilot plant were U.S. Department of Energy
designed experiments. provided and considered by the industrial Advanced Manufacturing Office
steel participants. The American Iron Phone: (720) 356-1754
The design team also used a physics- and Steel Institute (AISI) developed a E-mail: Bill.Prymak@ee.doe.gov 
based computer simulation with reactive commercialization plan and, at the end of
flow combustion, fluid dynamics and the project, was actively seeking funding The final report is available at: www.osti.
heat transfer to assist in the design of a for construction of a pilot plant. AISI will gov/scitech: OSTI Identifier: 1485414
next generation pilot facility. also maintain and coordinate intellectual
property activities regarding patents.
In the final phase of the project, the team Initial entry into the mainstream market
developed an advanced design concept will likely be via steel manufacturing
with construction and operating cost facilities looking for a more cost-efficient
estimates for a 3000 tonne/year pilot- alternative ironmaking process with
plant. reduced carbon emissions.

For more information, visit:


energy.gov/eere/amo
DOE/EE-1869 • March 2019

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