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US 2002/0162418 A1Published application
Production and shaping of steel and steel alloys
OwnerGhulam Nabiinventor
Life of this patent
Estimating the term…
Abstract
Using diversified raw materials as mixed oxide ore, steel scrap, iron sulfide ores steel and steel alloys are produced. Elements not required in steel composition are separated and recovered as individual elements. Liquid steel is cooled by performing endothermic gaseous reaction in direct contact with steel and cast in required forms. Continuously cast products go directly to rolling process with appropriate finishing treatments. CO2, N2, H2S and SO2 produced in the mill are gainfully utilized. Direct water is not used in steel making process. All by-products are gainfully utilized and pollution problems are solved. Energy recovery form hot out-put products and exit gases greatly reduces the net energy consumption of the integrated process
Claims13
A process for the treatment of a charge of steel scrap and coal for the separation of metals and non metals not required in steels and steel alloys compositions;
- comprises the steps of:
- introducing the charge into an inlet end of a primary reactor of a reactors system having an inlet end and an outlet end while injecting oxygen into said primary reactor near said inlet end and passing the charge through said primary reactor to said outlet end thereof:
- discharging said charge through a sealed connection into an inlet end of a next reactor for increasing the temperature and changing the chemical potential of said next reactor having an inlet and out let end and passing said charge through said next reactor.
- elements are separated in a unit process as melted groups and volatile groups and hereafter taken out of the reactor and separated into individual elements by fractional condensation of volatile and phase separation for liquids.
- unit processes are separated from each other and have independent means of input and outputs, control of chemical potentials and temperatures, have means to transfer gases and material from one unit -process to the next, volatile exiting from each unit process are made free of condensable materials and there after sent to particles recovery and removal of chemical impurities from gases. Several gaseous streams exiting from different unit processes are combined before going to particles and impurities removal. recovered blown out charge particles are recycled to the above said primary reactor. and recovered clean gases are recycled for various uses.
- discharging the said charge purified from impurity ingredients from an ending reactor of the above said reactors system having out let connected with a steel making reactor through above said sealed connection.
3 more elements
A process for obtaining iron oxides and alloying element oxides from mixed refractory oxides and iron aluminum silicate ores comprising the steps of:
- introducing a mix of refractory metal oxides, iron aluminum silicate ore and coal in an inlet near the upper ending of a rotary reactor, this reactor has a lower outlet for heated charge and outlet for product gases near the reactor's upper ending. Heated solid charge therefrom is introduced to an ending reactor having means of receiving heated charge, means for inlet of clean gases and oxidizing gases, means for slag discharge and means for out let of high density products. It has means for the introduction of sodium carbonate near it upper ending.
- sodium salts formation is carried out in an oxidizing atmosphere in a temperature range of 1000-1300° C., low density liquid slag material is allowed to flow out as upper layer and heavy density solid material is withdrawn from the bottom of the reactor, from high density material FeO- Fe3 O4 is separated by magnetic means.
- top gases from the system are freed of blown out charge and then freed of chemical impurities. CO2 and clean gases CO,H2 obtained are reused within the system.
- sodium salts are changed to Na2 CO3 by blowing CO2. Sodium Carbonate is recovered and recycled. Iron oxides so obtained is mixed with other alloy forming oxides recovered within the system and further processed for production of alloy steels.
1 more element
A process for the manufacturing of steel and steel-alloys comprising the steps of:
- introducing a charge material of iron and alloys making ingredients and coal in a steel making reactor having charge inlet means;
- processing the charge within this reactor and discharging the products through steel output means, slag discharge means, heavy metal discharge means and product gases output means.
- oxidizing and reducing gases and their combinations are introduced above and below above said slag layer. Meanwhile causing in put gases to flow co-current to the introduced charge, wherein the temperature inside the reactor is made higher than the decomposition temperature of iron oxides. Whereby non required ingredients in the charge are changed to volatile. Exit gases from steel making reactor are lowered in temperature by introduction of endothermic gases in the gaseous stream, steel-making reactors have refractory cooling arrangements by endothermic means.
- wherein excess carbon is introduced to solubilise the alloying elements in iron, thereafter excess carbon is removed in the same vessel, as a result of this some carbon may remain in the liquid steel or the liquid is having excess oxygen. Processing is facilitated by sampling of product streams and by making gaseous input under the slag layer.
- there after liquid steels go to composition adjustment process. Slag are discharge to a heat recovery process, product gases are sent to energy and particles recovery processes and removal from chemical impurities. A part of the clean gases is introduced in the steel making reactor. Recovered charge particles are introduced into the said charge introduction means of this reactor.
2 more elements
A process for the shaping of steels comprises the steps of:
- recovering heat from liquid steels by performing endothermic reaction in direct contact with the liquid material, where in to create an intimate contact between liquid and gases, the liquid is given the shape of small droplets or thin liquid film.
- exit gases after performing endothermic reactions are led to combustion process for steam generation. Endothermic reaction is performed in a refractory lined steel chamber;
- with controlled entry and exit of reactant and product gases, and with control entry of liquid steel. In which during cooling process the solidifying steel is given an appropriate form;
- flat, shape or near net shape while castings in a mold of appropriate dimensions. The mold is a steel shell internally lined with porous refractory;
- which is endothermically cooled.
- steel is taken up by withdrawing rolls as it exits from the mold, and it is rolled in a tunnel having protective atmosphere of gases.
- during solidification and rolling processes the surface and interior temperature is kept same and entrapped gases continue to diffuse out as the temperature of the material is lowered, during solidification and rolling, material is compressed by internally cooled chromium steel lined rolls, additional heat balancing arrangements are provided for controlled cooling of solidifying steel strand.
4 more elements
An air fractionation process for the manufacturing low temperature O2 and N2 where oxygen is used in production processes.
- cold values from O2 and N2 are recovered by producing cold gases, after giving up its cold value nitrogen is used as fertilizer in the surrounding area;
- and along with N2 lines there are CO2, and SO2 lines carrying these gases to fields.
- nitrogen is used as fertilizer as a replacement of ammonia, in fields nitrogen pipeline is buried a short distance below the plowing level and soil over the buried nitrogen pipes is mixed with bacterial clay consisting of animal and human excretion and decomposed vegetation growth. Mixture of CO2 and N2 is used as substitute of urea.
Dependencies are inferred from the claim text.