US 5,060,913 A · Integrated metallurgical reactor

Abstract

A smelting reduction process is carried out in a smelting reactor which includes a central internal carburization/combustion plenum or chamber in which hot metal is carburized by the injection of coal fines and heated by post combustion of the coal gases. The chamber has outlets to the first zone of an outer coaxial annular channel where the coal slag is separated off and a carburized hot metal passes into a second zone or smelting channel-chamber that permits introduction of feed material into a molten metal. A majority of the material that passes through the smelting channel-chamber is recycled to the internal carburization/combustion chamber for further processing. The internal carburization/combustion chamber and the smelting channel are completely separate so that the slag and the off gases from the two processes can be kept separate as well. The channel is positioned around the circumference of the internal carburization/combustion chamber where active heating occurs to form a compact reactor.

Claims25

Dependent claims

A totally integrated metallurgical reactor for manufacturing metal from raw materials comprising an enclosed structure having a central chamber for containing a first molten product, said chamber having an exterior periphery, said chamber being enclosed and having a heating zone;

a channel having walls defining a flow path positioned around at least portions of the exterior periphery of said central chamber and comprising a plurality of interconnected segments, each forming a processing zone;
means for introducing raw materials to the central chamber to permit establishing a first molten product;
means forming a flow opening between the central chamber and the channel for permitting a first molten product to flow into the channel;
means positioned along the channel at desired locations for removing undesirable products;
means for adding raw feed material in at least one zone of the channel to first molten product therein, the channel having sufficient length for providing at least two zones for treatment for first molten product;
passageway means connecting the flow path defined by the channel with the central chamber and opening to the chamber below a lower level of the flow opening in the central chamber for permitting recycling of a substantial portion of a first molten product in said flow path to said central chamber;
and
means for removing a finished product from the flow path.

5 more elements

An integrated metallurgical reactor for manufacturing metal comprising an enclosed reactor housing having an internal chamber having an outer periphery, said internal chamber being made for containing a molten product up to a desired level;

and being enclosed to form a plenum above the desired level, comprising:
walls defining a molten product flow path channel from an inlet to an outlet adjacent the internal chamber and extending along the outer periphery including a molten product flow portion and a plenum portion;
a first zone defined in the channel including means for receiving a molten product from the internal chamber above the desired level;
first slag removal weir means establishing a second level in the first zone;
a second zone in the channel separated from the first zone with a flow path opening between the first and second zones for permitting flows into the second zone at a third level below the second level established by the first weir means;
means in at least one of the zones for adding feed materials into the channel;
at least one second slag weir means in the channel establishing a third level in the flow path subsequent to the means for adding feed materials;
and
passageway means adjacent the outlet of the channel and extending between the channel and a lower portion of the interior chamber, the passageway means opening below the third level for recycling a substantial portion of any molten product from said channel flow path to said interior chamber.

6 more elements

An integrated reactor for containing molten product, slag and gases comprising a housing;

a combustion chamber defined in the center portions of said housing, said combustion chamber being an enclosed chamber except for desired inlets and outlets and having an exterior periphery;
a channel formed on said housing along the exterior periphery of said combustion chamber, and comprising a hot molten product flow channel;
said combustion chamber comprising a reaction chamber for holding molten product and having means for introducing feed materials and gases for combustion of off gas and carburizing of a molten product;
an orifice defined through a combustion chamber wall leading from the combustion chamber to said channel below a first level;
said channel having a first slag removal zone;
a first weir at the first zone of the channel establishing a second level for removing slag;
said channel having a second zone connected through a second orifice to the first zone, the second orifice being below the reference level;
said second zone including second feed means for introducing feed material into the channel;
first and second overflow weir walls in said second zone of the channel spaced along the exterior periphery of said combustion chamber and establishing separate levels to regulate volumes in the channel, into which feed material may be introduced;
an outflow weir formed on said channel to establish a third level for removal of slag in said second zone;
a third orifice established below the third level of said outflow weir, said third orifice connecting to a passageway to the interior of said combustion chamber adjacent a bottom portion of said combustion chamber.

8 more elements

Dependencies are inferred from the claim text.

Integrated metallurgical reactor

Life of this patent

Integrated metallurgical reactor

Life of this patent

Abstract

Claims25