Reduction of iron-containing materials by carbon-hydrogen mixture in a liquid-phase reactor

   This paper presents the results of the calculation of a liquid-phase reduction reactor with a capacity of 10 tons of reconstituted iron per hour. According to the equilibrium calculation of the compositions of a multicomponent heterogeneous thermodynamic system carried out using the proven IVTANTERMO software package, the degree of metallization of the product leaving the reactor is 99 %. The necessary costs have been established to ensure this degree of metallization of various iron-containing materials. The composition and volume of gases formed after reduction were determined.

1. Crippa M. et al. CO₂ emissions of all world countries // JRC Science for Policy Report, European Commission, EUR. 2022. Vol. 31182.

2. Fedyukhin A. V. et al. Hydrogen application in the fuel cycle of compressed air energy storage // International Journal of Hydrogen Energy. – 2024. – Vol. 51. – P. 107-118.

3. Ledari M. B. et al. Greening steel industry by hydrogen: Lessons learned for the developing world //International Journal of Hydrogen Energy. – 2023.

4. Liu, W., Zuo, H., Wang, J., Xue, Q., Ren, B., & Yang, F. (2021). The production and application of hydrogen in steel industry. International Journal of Hydrogen Energy, 46(17), 10548-10569.

5. Wang, C., Walsh, S. D., Weng, Z., Haynes, M. W., Summerfield, D., & Feitz, A. (2023). Green steel: Synergies between the Australian iron ore industry and the production of green hydrogen. International Journal of Hydrogen Energy, 48(83), 32277-32293.

6. Thermostating cover as improving energy efficiency and technological steel mills / K. V. Strogonov, S. V. Tolkanov, K. A. Korkots // E3S Web of Conferens International Science Conference SPbWOSCE-2018 «Business Technologies for Sustainable Urban Development». 2019. – № 110. 01003

7. Voinov O. Yu., Lisienko V. G., Chesnokov Yu. N., Lapteva A. V. Comparison of energy consumption in modern steel production technologies // Energy and resource saving. Energy supply. Non-traditional and renewable energy sources. – Ekaterinburg, 2017. – 2017. – P. 127-131.

8. Gordon Y. et al. Comparative evaluation of energy efficiency and GHG emissions for alternate iron- and steelmaking process technologies // Creative heritage of VE Grum-Grzhimailo: history, current state, future. Part 1. – Ekaterinburg, 2014. Ural Federal University, 2014.

9. Kartavtsev S.V. Intensive energy saving and technical progress of ferrous metallurgy : Monograph. – Magnitogorsk: State Educational Institution of Higher Professional Education “MSTU”, 2008. – 311 p.

10. Tang, J., Chu, M. S., Li, F., Feng, C., Liu, Z. G., & Zhou, Y. S. (2020). Development and progress on hydrogen metallurgy. International Journal of Minerals, Metallurgy and Materials, 27, 713-723.

11. MIDREX [Electronic resource] // World direction statistics, 2020. URL: https://www.midrex.com/wp-content/uploads/Midrex-STATSbookprint-2020.Final_.pdf (access date: 01/18/2023).

12. COREX. Efficient and environmentally friendly smelting reduction, 2020. Available at: https://www.primetals.com/fileadmin/user_upload/content/01_portfolio/1_ironmaking/corex/COREX.pdf (accessed: 18 January 2023).

13. The FINEX process economical and environmentally safe ironmaking, 2020. Available at: https://www.primetals.com/fileadmin/user_upload/content/01_portfolio/1_ironmaking/finex/THE_FINEX_R__PROCESS.pdf (accessed: 18 January 2023).

14. Joulazadeh, M. H., & Etemad, A. (2022). Evaluation of the production of DRI in the world and Iran in 2021. International Journal of Iron & Steel Society of Iran, 19(1), 55-66.

15. Vokhmyakov, I. S., Bersenev, I. S., Borodin, A. V., Stepanova, A. A., Zagainov, S. A., & Gileva, L. Y. (2022). Mechanism of oxidation for hot briquetting iron (HBI). Steel in Translation, 52(3), 331-336.

16. Nanda, P. K., Sahai, A. K., & Das, S. K. (2022). Understanding the co-relationships of variables and improving product quality and productivity of DRI in rotary kiln. Materials Today: Proceedings, 56, 1538-1541.

17. Goodman, N. (2022, December). Pathways to Sustainable Steelmaking Using the HIsmelt Ironmaking Technology. In 2022-Sustainable Industrial Processing Summit (Vol. 11, pp. 231-240). Flogen Star Outreach.

18. Plaul, F. J., Böhm, C., & Schenk, J. L. (2009). Fluidized-bed technology for the production of iron products for steelmaking. Journal of the Southern African Institute of Mining and Metallurgy, 109(2), 121-128.

19. Gojic, M., & Kozuh, S. (2006). Development of direct reduction processes and smelting reduction processes for the steel production. Kem. Ind, 55(1), 1-10.

20. Floyd, J. M., & Fogarty, J. G. (1999). High quality pig iron from AusIron processing.

21. Borlee, J., Steyls, D., Colin, R., Munnix, R., & Economopoulos, M. (1999). COMET: a coal-based process for the production of high quality DRI from iron ore fines. Revue de Metallurgie, 96(3), 331-340.

22. Tsutsumi, H., Yoshida, S., & Tetsumoto, M. (2010). Features of FASTMET process. Kobelco technology review, 12, 85-92.

23. Ren, L., Zhou, S., Peng, T., & Ou, X. (2021). A review of CO₂ emissions reduction technologies and low-carbon development in the iron and steel industry focusing on China. Renewable and Sustainable Energy Reviews, 143, 110846.

24. Ramakgala, C., & Danha, G. (2019). A review of ironmaking by direct reduction processes: quality requirements and sustainability. Procedia Manufacturing, 35, 242-245.

25. Sun, M., Pang, K., Barati, M., & Meng, X. (2024). Hydrogen-Based Reduction Technologies in Low-Carbon Sustainable Ironmaking and Steelmaking : A Review. Journal of Sustainable Metallurgy, 10(1), 10-25.

26. Liquid-phase reduction of iron with a carbon-hydrogen mixture in a continuous unit / Strogonov K.V., Petelin A.L., Terekhova A.Yu., Lvov D.D., Murashov V.A. // Collection of proceedings of the XVII International Congress of Steelmakers and Metal Producers “From ore to steel - ISCON-2013”, April 03-07, 2023, Magnitogorsk: Publishing House Alliance Metallurgy Corporation, 2023. – P. 266-271.

27. Calculation of individual elements of enclosing structures of a continuous steelmaking unit / K. V. Strogonov, A. A. Borisov, V. A. Murashov, D. D. Lvov // Paper presented at the Proceedings of the 2023 5^th International Youth Conference on Radio Electronics, Electrical and Power Engineering, REEPE 2023, doi:10.1109/REEPE57272.2023.10086855.

28. Chevrier V., Lauren L., Michishita H. MIDREX® Process: Bridge to Ultra-low CO₂ Ironmaking // Kobelco Technol. Rev. – 2021. – Vol. 39. – P. 33-40.

29. Srishilan C., Shukla A. K. Static thermochemical model of COREX melter gasifier // Metallurgical and Materials Transactions B. Springer, 2018. – Vol. 49. – P. 388-398.

30. Ahmed M. et al. Effect of HYL process parameters on the quality of iron ore reduction // Journal of Petroleum and Mining Engineering. Suez University; Faculty of Petroleum and Mining Engineering, 2016. – Vol. 18, No. 1. – P. 54-60.

31. Yi S. -H. et al. FINEX® as an environmentally sustainable ironmaking process // Ironmaking & Steelmaking. SAGE Publications Sage UK: London, England, 2019. – Vol. 46, No. 7. – P. 625-631.

32. Mohsenzadeh F. M. et al. An environmental study on Persian direct reduction (PERED®) technology: Comparing capital cost and energy saving with MIDREX® technology // Ekoloji. – 2018. – Vol. 27, No. 106. – P. 959.

33. Murashov, V. A., Strogonov, K. V., Lvov, D. D., Bastynets, A. K. Continuous Degasser for Steel Melt Treatment // 2024 6^th International Youth Conference on Radio Electronics, Electrical and Power Engineering (REEPE). – IEEE, 2024. – pp. 1-6. DOI: 10.1109/REEPE60449.2024.10479925

34. Energy saving of high-temperature processes by intensive melt degassing / K V Strogonov, A. A. Zdarov // Journal of Physics: Conference Series / The Third Conference «Problems of Thermal Physics and Power Engineering», 2020. – 1683(5). 052029.

35. Strogonov, K. V., Lvov, D. D., Murashov, Borisov A. A. Steel degassing in continuous steel melting units // Bulletin of the Tomsk Polytechnic University Geo Assets Engineering. – 2024. – Vol. 335. – No. 1. – pp. 140-147. doi: 10.18799/24131830/2024/1/4154

36. Zainullin L. A. et al. High-temperature carbon-thermal reduction of siderite ores in an electric arc // Metallurg. Limited Liability Company «Metallurgizdat», 2016. – No. 11. – P. 31-34.

37. Zainullin L. A. et al. Analysis of the economic and energy efficiency of using electric arc reduction of iron-containing materials // Metallurg. Limited Liability Company «Metallurgizdat», 2018. – No. 7. – P. 33-37.

38. Epifanov A.V., Vasilyeva E. A. The best achieved technologies and technological rationing. – 2020.

39. Sazhin A. Development of energy-saving innovative processes for the complex processing of industrial waste based on new metallurgical technologies // IV conference «TRIZ. Practice of using methodological tools». – 2012.

40. Liquid-phase reduction reactor with a carbon-hydrogen mixture / K. V. Strogonov, D. D. Lvov, V. A. Murashov, A. K. Bastynets, A. Yu. Terekhova, A. L. Petelin // Paper presented at the Proceedings of the 2024 6^th International Youth Conference on Radio Electronics, Electrical and Power Engineering, REEPE 2024, pp. 1-6 doi: 10.1109/REEPE60449.2024.10479685.

41. Garnissage as an effective fence in high-temperature reactors / K. V. Strogonov, A. K. Bastynets, A. A. Ushakova, D. D. Lvov, V. A. Murashov // Paper presented at the Proceedings of the 2024 6^th International Youth Conference on Radio Electronics, Electrical and Power Engineering ,REEPE 2024, pp. 1-5. doi: 10.1109/REEPE60449.2024.10479902.

42. Romelt Process / Ed. V. A. Romenz. – M.: “MISIS”, Publishing House “Ore and Metals”, 2005. – 400 p.