U.S. patent application number 09/266989 was filed with the patent office on 2001-12-20 for iron production method of operation in a rotary hearth furnace and improved furnace apparatus.
Invention is credited to HOFFMAN, GLENN E., ITO, SHUZO, KIKUCHI, SHOICHI, KOBAYASHI, ISAO, MEISSNER, DAVID C., NEGAMI, TAKUYA, SHOOP, KYLE J., TANIGAKI, YASHUHIRO, TOKUDA, KOJI, TSUGE, OSAMU, URAGAMI, AKIRA.
Application Number | 20010052273 09/266989 |
Document ID | / |
Family ID | 26805466 |
Filed Date | 2001-12-20 |
United States Patent
Application |
20010052273 |
Kind Code |
A1 |
MEISSNER, DAVID C. ; et
al. |
December 20, 2001 |
IRON PRODUCTION METHOD OF OPERATION IN A ROTARY HEARTH FURNACE AND
IMPROVED FURNACE APPARATUS
Abstract
The present invention is an apparatus and method for the direct
reduction of iron oxide utilizing a rotary hearth furnace to form a
high purity carbon-containing iron metal button. The hearth layer
may be a refractory or a vitreous hearth layer of iron oxide,
carbon, and silica compounds. Additionally, coating materials may
be introduced onto the refractory or vitreous hearth layer before
iron oxide ore and carbon materials are added, with the coating
materials preventing attack of the molten iron on the hearth layer.
The coating materials may include compounds of carbon, iron oxide,
silicon oxide, magnesium oxide, and/or aluminum oxide. The coating
materials may be placed as a solid or a slurry on the hearth layer
and heated, which provides a protective layer onto which the iron
oxide ores and carbon materials are placed. The iron oxide is
reduced and forms molten globules of high purity iron and residual
carbon, which remain separate from the hearth layer. An improved
apparatus includes a cooling plate that is placed in close
proximity with the refractory or vitreous hearth layer, cooling the
molten globules to form iron metal buttons that are removed from
the hearth layer. The improvements due to the present apparatus and
method of operation provide high purity iron and carbon solid
buttons, which are separate from slag particulates, and discharged
without significant loss of iron product to the interior surfaces
of the furnace.
Inventors: |
MEISSNER, DAVID C.;
(CHARLOTTE, NC) ; HOFFMAN, GLENN E.; (LANCASTER,
SC) ; SHOOP, KYLE J.; (CHARLOTTE, NC) ;
NEGAMI, TAKUYA; (TOKYO, JP) ; URAGAMI, AKIRA;
(HYOGO, JP) ; TANIGAKI, YASHUHIRO; (KANAGAWA,
JP) ; ITO, SHUZO; (HYOGO, JP) ; KOBAYASHI,
ISAO; (HYOGO, JP) ; TSUGE, OSAMU; (HYOGO,
JP) ; TOKUDA, KOJI; (HYOGO, JP) ; KIKUCHI,
SHOICHI; (HYOGO, JP) |
Correspondence
Address: |
DOUGHERTY & CLEMENTS
TWO FAIRVIEW CENTER
6230 FAIRVIEW ROAD, SUITE 400
CHARLOTTE
NC
28210
US
|
Family ID: |
26805466 |
Appl. No.: |
09/266989 |
Filed: |
March 12, 1999 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60108045 |
Nov 12, 1998 |
|
|
|
Current U.S.
Class: |
75/484 ; 266/177;
266/190; 75/500 |
Current CPC
Class: |
C21B 13/105 20130101;
Y02P 10/134 20151101; C21B 13/10 20130101 |
Class at
Publication: |
75/484 ; 75/500;
266/177; 266/190 |
International
Class: |
C21B 007/18; C22B
001/00; C21B 011/00 |
Claims
What is claimed is:
1. A method for producing solid iron and carbon product from iron
oxide material containing carbon compounds, comprising the steps
of: (a) providing a rotary hearth furnace, having a hearth layer
surface; (b) feeding iron oxide and carbon materials onto said
hearth layer surface; (c) heating said iron oxide and carbon
materials; (d) reducing said iron oxide and carbon materials; (e)
forming liquid iron and carbon globules and slag particulates on
said hearth layer surface, said globules separating from said slag
particulates; (f) cooling said liquid iron and carbon globules with
a cooling surface, creating solid iron and carbon buttons; (g)
discharging solid iron and carbon buttons from said furnace; and
(h) removing slag particulates from said furnace.
2. The method of claim 1, wherein said step of providing a rotary
hearth furnace further comprises applying iron oxide, carbon, and
silica compounds to said hearth layer surface, forming a vitreous
layer on said hearth layer surface.
3. The method of claim 1, wherein said step of providing a rotary
hearth furnace further comprises introducing coating materials on
said hearth layer surface, said coating materials selected from the
group consisting essentially of magnesium oxide compounds, silicon
oxide compounds, aluminum oxide compounds, iron oxide compounds,
and carbon compounds.
4. The method of claim 1 wherein said heating step further comprise
heating said iron oxide and carbon materials with a plurality of
radiant heat sources at temperatures of at least 1450.degree. C. to
about 1600.degree. C. inside said furnace.
5. The method of claim 1 wherein said reducing step further
comprises reducing said iron oxide and carbon materials with a
plurality of radiant heat sources at temperatures of at least
1450.degree. C. to about 1540.degree. C. inside said furnace.
6. The method of claim 1 wherein said reducing step further
comprises heating said materials with a plurality of radiant heat
sources at temperatures of at least 1400.degree. C. to about
1500.degree. C. at said hearth layer surface.
7. The method of claim 1 wherein said reducing step further
comprises heating said iron oxide and carbon materials with a
plurality of radiant heat sources at temperatures of at least
1410.degree. C. to about 1480.degree. C. at said hearth layer
surface.
8. The method of claim 2 wherein said feeding step further
comprises introducing said iron oxide and carbon materials onto
said vitreous layer having iron oxide, carbon, and silica
compounds.
9. The method of claim 1 wherein said cooling step further
comprises providing a cooling surface near said hearth layer
surface, said surface cooling said liquid iron and carbon globules,
creating a solid button of iron and carbon on said hearth surface
before said discharging step.
10. An apparatus for direct reduction of iron oxide material to a
solid iron and carbon product, comprising: (a) a furnace, said
furnace having an interior hearth layer of refractory material; (b)
means for introducing a mixture of coating materials onto said
hearth layer; (c) means for placing iron oxide and carbon materials
onto said hearth layer or said refractory layer; (d) means for
heating said hearth layer, said coating materials, and said iron
oxide and carbon materials; (e) means for reducing said iron oxide
and carbon materials with the formation of liquid iron and carbon
globules and slag particulates, said globules separate from said
slag particulates; (f) means for cooling said liquid iron and
carbon globules on said hearth layer with the formation of a solid
iron and carbon button; (g) means for removing said solid iron and
carbon button from said furnace; and (h) means for removing said
slag particulates from said furnace.
11. The apparatus of claim 10 wherein the furnace is a rotary
hearth furnace having a rotatable hearth surface.
12. The apparatus of claim 11, wherein said hearth layer of
refractory material further comprising a vitreous layer of iron
oxide and silica compounds, said vitreous layer is placed on said
layer of refractory material before said introducing means
introduces said coating materials onto said hearth layer.
13. The apparatus of claim 10 wherein said means for introducing
said mixture of coating material comprises a particle movement
conveyor, said conveyor having the capability to introduce said
coating material onto said hearth layer.
14. The apparatus of claim 10 wherein said mixture of coating
materials comprises a material selected from the group consisting
essentially of iron oxide compounds, silicate compounds, magnesium
oxide compounds, silicon oxide compounds, aluminum oxide compounds,
and carbon compounds.
15. The apparatus of claim 13, wherein said mixture of coating
materials further comprises another layer of carbonaceous material,
said carbonaceous material and said mixture of coating material
introduced by said introducing means into said hearth layer.
16. The apparatus of claim 13, wherein said mixture of coating
material further comprises a carbonaceous material, said
carbonaceous material introduced by said introducing means onto
said hearth layer before said iron oxide and carbon materials are
placed onto said hearth layer.
17. The apparatus of claim 10, wherein said means for placing said
iron oxide and carbon materials comprises a conveyor, said iron
oxide and carbon materials are positionable by said conveyor onto
said hearth layer.
18. The apparatus of claim 10, wherein said means for heating
comprises a plurality of radiant heat sources providing heat at a
temperature range of at least 1450.degree. C. to about 1600.degree.
C., said radiant heat sources maintaining said hearth layer within
said temperature range.
19. The apparatus of claim 10, wherein said means for heating
further comprises a plurality of radiant heat sources providing
heat at a temperature range of at least 1400.degree. C. to about
1600.degree. C. at said hearth layer inside said furnace.
20. The apparatus of claim 10, wherein said means for heating
further comprises a plurality of radiant heat sources at
temperatures of at least 1450.degree. C. to about 1530.degree. C.
at said hearth layer inside said furnace.
21. The apparatus of claim 10, wherein said means for cooling said
liquid iron and carbon globules on said hearth layer further
comprises a cooling surface in close proximity to said hearth layer
surface, said cooling surface including a cooling plate extended
over said hearth layer.
22. The apparatus of claim 10, wherein said means for removing
solid iron and carbon buttons comprises a discharge mechanism, said
discharge mechanism including a conveyor to accept said solid iron
and carbon buttons from said furnace.
23. A method for producing solid iron and carbon product from iron
oxide material containing carbon compounds, comprising the steps
of: (a) providing a furnace, said furnace providing a sub-hearth
layer surface; (b) introducing conditioning materials including
iron oxide compounds, carbon compounds, and silica compounds onto
said sub-hearth layer surface; (c) heating said conditioning
materials, forming a vitreous layer including at least iron oxide
and silica compounds; (d) placing iron oxide and carbon materials
on said vitreous layer; (e) reducing said iron oxide and carbon
materials by heating; (f) forming liquid iron and carbon globules
and slag particulates on said vitreous layer, with separating of
said slag particulates on said vitreous layer; (g) cooling said
liquid iron and carbon globules, forming solid iron and carbon
buttons on said vitreous layer; (h) discharging said solid iron and
carbon buttons from said furnace; and (i) removing said slag
particulates from said furnace.
24. The method of claim 23, wherein said providing step further
comprises providing a rotary hearth furnace having a rotatable
hearth surface.
25. The method of claim 23, wherein said step of introducing
conditioning materials further comprises providing additional
conditioning materials selected from the group consisting
essentially of magnesium oxide compounds, silicon oxide compounds,
aluminum oxide compounds, iron oxide compounds, and carbonaceous
compounds.
26. The method of claim 23, wherein said heating step further
comprises heating said coating materials with a plurality of
radiant heat sources providing heat at a temperature range of at
least 1450.degree. C. to about 1600.degree. C.
27. The method of claim 23, wherein said reducing step further
comprises exposing said iron oxide and carbon materials to a
plurality of radiant heat source providing heat at a temperature
range of at least 1410.degree. C. to about 1480.degree. C. inside
said furnace.
28. The method of claim 23, wherein said cooling step of said
liquid iron and carbon globules further comprises providing a
cooling surface near said vitreous layer, said cooling step cooling
said liquid iron and carbon globules, creating iron and carbon
solid buttons on said vitreous layer.
29. A method for producing iron product from iron oxide material
containing carbon compounds, comprising the steps of: (a) providing
a furnace, said furnace providing a sub-hearth layer surface; (b)
introducing iron oxide compounds, carbon compounds, and silica
compounds onto said sub-hearth layer surface; (c) heating said
compounds, forming a vitreous hearth layer including at least iron
oxide and silica compounds; (d) placing coating materials on said
vitreous hearth layer, forming a coated vitreous hearth layer; (e)
placing said iron oxide and carbon materials on said coated
vitreous hearth layer; (f) reducing said iron oxide and carbon
materials on said coated vitreous hearth layer; (g) forming liquid
iron and carbon globules, and slag particles on said coated
vitreous hearth layer; (h) cooling said liquid iron and carbon
globules, forming solid iron and carbon buttons on said coated
vitreous hearth layer separate from said slag particles; (i)
discharging said solid iron and carbon buttons from said furnace;
and (j) removing said slag particles from said furnace.
30. The method of claim 29, wherein said providing step further
comprises providing a rotary hearth furnace having a rotatable
hearth surface.
31. The method of claim 29, wherein said step of placing coating
materials further comprises selecting said coating materials from
the group consisting essentially of magnesium oxide compounds,
silicon oxide compounds, aluminum oxide compounds, carbonaceous
compounds, and iron oxide compounds.
32. The method of claim 29, wherein said heating step further
comprises heating said compounds with a plurality of radiant heat
sources providing heat at a temperature range of at least
1450.degree. C. to about 1600.degree. C.
33. The method of claim 29, wherein said reducing step further
comprises exposing said iron oxide and carbon material to a
plurality of radiant heat source providing heat at a temperature
range of at least 1410.degree. C. to about 1480.degree. C. inside
said furnace.
34. The method of claim 29, wherein said cooling step of said
liquid iron and carbon globules further comprises providing a
surface near said vitreous hearth surface, said surface cooling
said liquid iron and carbon globules, creating solid iron and
carbon buttons on said coated vitreous hearth layer before said
discharging step.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/108,045, filed on Nov. 12, 1998.
FIELD OF INVENTION
[0002] This invention relates to an apparatus and method for
operation of an ore processing furnace for improved processing of
iron oxide reduction. More particularly, this invention relates to
the method of operation of a furnace for production of high purity
iron and an improved furnace apparatus for iron reduction.
BACKGROUND OF THE INVENTION
[0003] In 1987, Midrex received U.S. Pat. No. 4,701,214, that
taught reduction in a rotary hearth furnace and a method of
operation which required less energy and a smaller smelting furnace
by introducing reductant gases and fuel into the rotary hearth
furnace.
[0004] All major steelmaking processes require the input of iron
bearing materials as process feedstocks. For a steelmaking method
utilizing a basic oxygen furnace, the iron bearing materials are
usually blast furnace hot metal and steel scrap. A broadly used
iron source is a product known as Direct Reduced Iron ("DRI") which
is produced by the solid state reduction of iron ore without the
formation of liquid iron. DRI and/or steal scrap are also used for
steelmaking utilizing the electric arc furnace.
[0005] Improvements are sought within the industry for furnace
modifications and improved methods of operation that provide for
efficient production of high purity iron with low carbon (<5%)
material in which iron oxides are efficiently reduced into purified
iron on a hearth surface while slag components are separated from
purified iron at increased temperatures.
[0006] In 1998, Midrex International received U.S. Pat. No.
5,730,775, that teaches an improved method known by the trade name
or trademark of FASTMET.TM., and apparatus for producing direct
reduced iron from dry iron oxide and carbon compacts that are
layered no more than two layers deep onto a rotary hearth, and are
metallized by heating the compacts to temperatures of approximately
1316.degree. to 1427.degree. C., for a short time period. For a
general understanding of the recent art, U.S. Pat. No. 5,730,775 is
herein incorporated by reference.
SUMMARY OF INVENTION
[0007] In the direct reduction of iron oxide in furnaces, this
invention improves the utilization of a rotary hearth furnace using
a method for producing high purity iron product from iron oxide
feed material containing carbon compounds, including the steps of
providing a rotary hearth furnace having a hearth layer which
consists of a refractory layer or a vitreous hearth layer formed by
placing iron oxide, carbon, and silica compounds on the sub-hearth
layer; heating the iron oxide, carbon, and silica compounds forming
a vitreous hearth layer; placing coating materials on the hearth
surface to form a coated hearth layer; feeding iron oxide material
into the furnace and onto the coated hearth layer; heating the iron
oxide material on the coated hearth layer; reducing the iron oxide
materials on the coated hearth layer; forming liquid iron and
carbon globules on the coated hearth layer, with separated slag
materials; cooling the iron and carbon globules with a cooling
surface, creating a solid button of iron and carbon product; and
discharging iron and carbon product and slag material from the
furnace. An improved apparatus includes a rotary hearth furnace
having a cooling plate that is placed in close proximity with the
hearth layer or refractory surface, the cooling plate cools the
iron globules to form solid high purity iron and low carbon buttons
that are removed from the vitreous hearth layer. The improvements
due to the present apparatus and method of operation are providing
high purity iron and low carbon buttons which are separated from
the slag particulates, discharging the buttons from the furnace
without significant loss of high purity iron in the hearth furnace,
and generating iron buttons with iron content of approximately 95%
or greater, and carbon content of approximately 5% or less in the
discharged buttons of iron material.
OBJECTS OF THE INVENTION
[0008] The principal object of the present invention is to provide
a method of achieving efficient production of high purity iron
having concentrations of carbon of 1% to 5% therein at elevated
temperatures in a rotary hearth furnace with separation of slag
components from the purified iron on the hearth surface at high
temperatures.
[0009] Another object of the invention is to provide a method of
achieving efficient reduction of iron oxide at elevated
temperatures in a processing and reducing furnace.
[0010] An additional object of the invention is to provide an
improved furnace apparatus for providing high purity iron and
cooling the high purity iron on the hearth layer surface to
facilitate separation of slag components within the furnace.
[0011] The objects of the invention are met by a method for
producing direct reduced purified iron at elevated temperatures
within a furnace, including the step of providing a rotary hearth
furnace having a sub-hearth layer, and introducing conditioning
materials of iron oxide, carbon, and silica compounds with heating
of conditioning materials to form a vitreous layer onto which
agglomerates of iron oxide containing carbon are placed. The step
of heating the conditioning materials proceeds the step of reducing
by heating the agglomerated iron oxide and carbon, at a specified
temperature, and reducing the iron oxide. The molten globules of
purified iron are separated from slag components on the hearth
layer surface within the furnace. A cooling step follows the
separating step, where globules of purified iron are cooled within
the furnace by placing a cooling apparatus in close proximity to
the hearth layer, with the resulting step of solidification of
purified iron within the furnace, and the remaining step of
discharging the purified iron from the furnace free of solidified
slag, which may be discharged separately from the furnace.
[0012] The objects of the invention are also met by an apparatus
for producing direct reduced iron at elevated temperatures within a
rotary hearth furnace having a non-reactive hearth surface made by
the placement of coating materials and agglomerates of iron oxide
and carbon onto the surface of the hearth layer. The hearth layer
may include a vitreous layer of iron oxide and silica compounds
formed before the agglomerates of iron oxide and carbon are placed
onto the vitreous or the refractory layer. The coating materials
and agglomerates of iron oxide and carbon are heated to a specified
temperature. The iron oxide is reduced followed by separation into
globules of purified iron from the slag components and coating
materials on the hearth layer. The purified iron is solidified by
passage of the liquid iron globules in close proximity to a means
for cooling above the hearth layer consisting of exposure to cooled
apparatus placed close to the hearth layer or refractory surface.
After passage past the means for cooling on the hearth layer or
refractory surface, the purified and solidified iron and low carbon
buttons are removed from the hearth layer for collection outside of
the rotary hearth furnace separate from slag particulates formed
within the furnace.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing and other objects will become more readily
apparent by referring to the following detailed description and the
appended drawings in which:
[0014] FIG. 1 is a top view of a rotary hearth furnace for the
reduction of iron oxide and production of molten iron globules that
utilizes a hearth layer surface and a means for cooling purified
iron and low carbon globules within the furnace;
[0015] FIG. 2 is a top view of the spray introduction of coating
material onto a hearth surface, forming a coated hearth layer, with
iron oxide and carbon agglomerates placed on the coated hearth
layer, specific to the present invention;
[0016] FIG. 3 is a top view of a solid placement of coating
material onto a hearth layer surface, forming a coated hearth
layer, with iron oxide and carbon agglomerates placed on the coated
hearth layer, specific to the present invention;
[0017] FIG. 4 is an isometric view of a plurality of coating
materials sprayed onto and forming a coated hearth layer surface,
onto which iron oxide and carbon agglomerates are placed and
leveled, specific to the present invention;
[0018] FIG. 5 is an isometric view of a plurality of solid coating
materials containing a plurality of layers placed onto and forming
a coated surface, onto which iron oxide and carbon agglomerates are
placed and leveled, specific to the present invention;
[0019] FIG. 6 is an isometric side view of the liquid purified iron
and low carbon globules on the hearth layer surface, separate from
slag particles, specific to the present invention;
[0020] FIG. 7 is an isometric side view of a means for cooling the
liquid purified iron and low carbon globules, with the means for
cooling placed in close proximity to the hearth layer surface,
specific to the present invention; and
[0021] FIG. 8 is an isometric view of a discharge mechanism for
removing purified iron and low carbon buttons from the hearth layer
surface, specific to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] Referring now to the drawings, and more particularly to FIG.
1, a direct reduction furnace 10 is utilized for reducing iron
oxide feed material. The furnace, such as a rotary hearth furnace
(RHF) 10 has dimensions of a typical hearth furnace utilized in the
iron production industry with an active hearth width of
approximately 1 m to approximately 7 m width, or wider. The RHF 10
has a refractory layer surface or vitreous hearth layer surface 30
that is rotatable from a feed material zone 12, through
approximately two or three burner zones 14, 16, 17, a reaction zone
17 and discharge zone 18 (see FIG. 1). The refractory layer surface
or vitreous hearth layer surface 30 is rotatable in a repetitive
manner from the discharge zone 18 to the feed material zone 12, and
through the zones 12, 14, 16, 17, 18 for continuous operation. The
burner zones 14, 16 17 are each fired by a plurality of air/fuel,
oil fired, coal fired, or oxygen enriched burners 20, 22.
[0023] The feed material zone 12 includes an opening 24 and a feed
mechanism 26 by which iron oxide and carbon agglomerates 28, also
called iron oxide "greenballs", are charged. An initial layer of
iron oxide, carbon materials, and silica (silicon oxide), may be
placed on the refractory sub-hearth to form a vitreous layer 30 on
which the iron oxide agglomerates 28 are placed. Coating materials
36 placed on the refractory layer surface or vitreous hearth layer
surface 30 may include iron oxide compounds, silica compounds, and
carbon compounds. The materials may be placed by spray injector 32,
or by solid material conveyor 34. The agglomerates 28 are leveled
to a preferred height above the refractory surface or hearth layer
surface 30 by a leveler 29 that spans the width of the surface 30.
The agglomerates 28 are continuously fed to the RHF 10 by the feed
mechanism 26, as the surface 30 is rotated around the RHF 10, by a
variable speed drive (not shown). Therefore the iron agglomerate
retention time within the RHF 10, and within each zone 14, 16, 18,
is controlled by adjusting the variable speed drive.
[0024] Located in the area of the feed material zone 12, and
upstream of the feed mechanism 26 from feed hopper 27 for
agglomerates 28, is a means for introducing 32, 34 coating
materials 36 such as coal powder, silica, iron oxide compounds,
graphite, and fines generated from raw iron oxide materials. At
least one solid material conveyor 34 (FIGS. 3) may introduce these
coating materials 36, and additional coating compounds 38 in a
separate layer onto the refractory layer surface or vitreous hearth
layer surface 30. If the materials 36, 38 are fine particulates,
materials 36, 38 may be mixed with a liquid carrier and applied by
a spray injector 32. The injector 32 may be cooled internally to
allow introduction of the coating materials as fine particulates in
a liquid spray for application on the surface 30 (FIGS. 2). If the
materials 36, 38 are placed in the RHF 10 without the liquid
carrier, the conveyor 34 places the coating materials 36, and
additional coating materials 38 as close to, and across the width
of, the refractory layer or vitreous hearth layer 30 (FIGS. 3).
[0025] The coating materials 36, may include iron oxide compounds,
silica compounds, and carbon compounds. The additional coating
compounds 38 may include any of the following compounds: iron
oxide, silica, magnesium oxide (MgO), aluminum oxide
(Al.sub.2O.sub.3) , and silicon oxide (SiO.sub.2), particulates
generated from iron oxides reduction and melting, and carbonaceous
materials. The coating materials 36, and compounds 38 may have a
variable material size of less than 10 mm, or preferably
approximately 1 mm, or less. The bulk density of coating materials
36, 38 may be approximately 0.5 g/cm.sup.3, or greater. The
thickness of the coating materials 36, 38 may be approximately 0.1
mm or greater.
[0026] The refractory layer surface or vitreous hearth layer
surface 30 of the RHF, with the coating materials 36, and compounds
38 introduced onto the surface 30, may be heat treated at
temperatures with hearth temperatures of approximately 1500.degree.
C. to approximately 1600.degree. C. The preferred hearth
temperature is approximately 1530.degree. to approximately
1550.degree. C. After rotation through the heating zones 14, 16,
the coating materials 36, 38 are cooled. The cooling device may be
a plate 48 having cooling liquid flowing internally, with the plate
48 positioned before the discharge zone 18. The plate 48 is in
close proximity and spanning the width of the surface 30, to
provide a zone of cooler temperatures near the surface 30.
[0027] The preferred combustion temperature in zone 17 (see FIG.
1), is approximately 1450.degree. C. to approximately 1600.degree.
C. The iron oxide and carbon agglomerates 28 may be maintained at a
temperature range of approximately 1400.degree. C. to approximately
1500.degree. C. The preferred temperature to maintain the iron
oxide agglomerates 28 is approximately 1410.degree. C. to
approximately 1480.degree. C.
[0028] The means for heating the surface 30, and coating materials
36, and additional compounds 38 thereon, may include either fuel
burners or other devices for heating a RHF 10, located in the
furnace enclosure of the burner zones 14, 16, or 17. The burner
fuel includes fuel mixtures commonly utilized in the iron
processing industry, such as coke oven gas, natural gas, fuel oil,
and/or pulverized coal combusted with air or oxygen enriched
air.
[0029] After the coating materials 36 and/or coating compounds 38
are introduced on surface 30, the placement of iron oxide and
carbon agglomerates 28 and carbon onto the upper layers of surface
30, 36, 38 occurs by the means for placing iron oxide and carbon
agglomerates 28 and other feed materials by feed mechanism 26, or
other standard continuous or intermittent belt, or spiral conveyor
of agglomerate sized materials (FIG. 1).
[0030] The iron oxide and carbon agglomerates 28 are heated and
moved from the first zone 14, to a second zone 16, or a third zone
if needed (not shown), on the rotatable layer 30. The reducing of
iron oxide agglomerates 28 occurs in the burner zones 14, 16, and
17, the formation of molten iron globules and solidification of the
globules occurs in a reaction zone also having a cooling device 48,
at temperatures as specified above. During the reducing phase, the
coating materials 36, 38, reduce the attack of the hearth layer 30.
The coating compounds 38 provide a barrier to the highly reactive
and purified liquid iron released by the iron oxide agglomerates
28, forcing the liquid iron to remain on the coated layer of the
hearth layer 30.
[0031] The optimal intermediate phase of molten metal that is
created in the method of operation of a RHF is the formation of
liquid globules 41 of molten metal carbon and iron having
approximately 95% iron and approximately 5% carbon in solution. The
preferred intermediate phase of molten metal carbon and iron is
approximately 95.5% to 97.5% iron and approximately 2.5% to 4.5%
carbon in liquid globules 41 on the hearth surface 30.
[0032] A specific benefit of the coating compounds 38 introduced
onto the surface 30, includes the creation of physically separated
liquid globules 41 of iron/carbon, formed as the iron oxide and
carbon agglomerates 28 reduce, melt and separate into iron/carbon
globules 41 and separate slag and gangue regimes (not shown). The
iron/carbon globules 41 form within the agglomerates 28 or outside
the agglomerates on the hearth layer surface 30, and form molten
purified iron/carbon globules 41 within burner zones 14, 16 and/or
the reaction zone 17. The molten globules 41 of iron/carbon remain
isolated from the slag and gangue regimes on the hearth layer
surface 30, and the globules 41 are not absorbed into the hearth
layer surface 30 due to prior coating of the surface 30. Therefore,
solidified buttons 42 of highly purified solid iron product
(greater than 95% iron), may be recovered from the discharge zone
18, without contamination by other gangue particulate or slag
materials on the hearth surface 30, or on other interior surfaces
of the RHF 10.
[0033] The coated layer of materials 36, and coating compounds 38
may be rejuvenated by the periodic or continuous introduction of
additional coating materials 36, 38 during processing cycles of the
RHF 10 when the molten iron buttons 42 are discharged, and before
the iron oxide and carbon agglomerates 28 are placed onto the
hearth layer surface 30.
[0034] Reduced and purified iron material in the form of iron
buttons 42 containing low concentrations of carbon are removed from
the discharge zone 18 by a means for removing materials from a
rotatable surface by a standard discharge mechanism, such as a
discharge conveyor 50, such as a continuous or intermittent belt,
screw, or spiral conveyor, located above the surface 30 (FIG. 8).
The purified iron metal buttons 42, after separation by cooling
from residual slag, is of a higher purity and a higher carbon
content than that produced by prior hearth furnace technologies
such as FASTMET.TM..
ALTERNATIVE EMBODIMENTS
[0035] In an alternative operation of the RHF 10, a vitreous iron
oxide and silica layer 36, and conditioning material layer 38 may
have been previously formed as hearth layer 30. The vitreous iron
oxide and silica hearth layer 30 assists with inhibiting the attack
of the iron globules 41 on the hearth layer.
[0036] In an alternative embodiment, coating materials 38 such as
iron oxide, silica, magnesium oxide (MgO), aluminum oxide
(Al.sub.2O.sub.3), and silicon oxide (SiO.sub.2), coal powder, and
carbon particulates generated from iron oxides reduction and
melting, may be added to the surface 30. After rotation through the
heating zones 14, 16, 17, the coating compounds 38 are cooled. The
cooling device may be a plate 48 having cooling liquid flowing
internally, with the plate 48 positioned before the discharge zone
18. The plate 48 is in close proximity and spanning the width of
the hearth layer surface 30, to provide a zone of cooler
temperatures near the surface of the hearth layer.
[0037] In another alternate embodiment, carbonaceous coating
material 38, may be placed on the hearth layer surface 30 to form a
separate carbon layer (not shown). The carbonaceous material 38
serves as a non-reactive sacrificial carbon layer which promotes
formation of molten iron globules 41 (see FIG. 6), and solidified
iron buttons 42 without the globules 41 or the buttons 42 attacking
into the hearth layer 30. By keeping the globules 41 or the buttons
42 separated from the slag particulates and the hearth layer 30,
high purity iron of approximately 95% content, and residual carbon
of approximately 5% may be produced.
SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION
[0038] From the foregoing, it is readily apparent that we have
invented an apparatus and method of operation for efficiently
producing increased volumes and a higher purity of solid iron and
low carbon product from rotary hearth furnaces without significant
increases in costs, processing time, or excessive furnace
temperatures. The invention achieves significantly higher quality
of purified solid iron and low carbon product by adding the
specified coating materials to form either a protective hearth
layer 30 of iron oxide, silica, aluminum, MgO or silicate
compounds, and/or carbon compounds on the hearth layer surface 30.
The layers of materials of varying compositions 36, 38 are formed
by adding the coating materials prior to adding the iron oxide and
carbon agglomerates onto the rotatable refractory hearth surface 30
(see FIG. 7).
[0039] The observed improvements due to the described invention are
due to the conditions that at normal furnace temperatures the
coating materials may form a protective layer 38 attached onto or
on a refractory or vitreous layer 30, thereby preventing the
purified solid iron and low carbon product from coating the surface
of the refractory layer or vitreous hearth layer 30. Such a coating
or bonding condition makes it difficult to remove or discharge the
purified solid iron and low carbon product from the furnace. The
present invention, as claimed below, solves this problem of loss of
purified iron and low carbon product within the RHF 10.
[0040] The invention has been described in detail, with reference
to certain preferred embodiments, in order to enable the reader to
practice the invention without undue experimentation. It is to be
understood that the foregoing description and specific embodiments
are merely illustrative of modes of the invention and the
principles thereof, and that various modifications and additions
may be made to the apparatus by those skilled in the art, without
departing from the spirit and scope of this invention.
* * * * *