Low temperature production of steel/carbon product
AssigneeForest Vue Research, LLC
InventorMichael P. Barkdoll
Life of this patent
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Abstract
In view of the foregoing embodiments of the disclosure provide a high value steel/carbon product from a low value iron-containing waste material and process for producing the steel/carbon product. The high value steel/carbon product is derived from a mixture of metallurgical coal and an oxidized iron waste material under a reducing atmosphere. The steel/carbon product has a porosity of greater than about 60% and a density of greater than about 900 kg/m3 and the steel component of the steel/carbon product has a percent of metalization of greater than about 85 wt. %.
Claims16
A steel/carbon product made by mixing metallurgical coal with an oxidized iron waste material to provide a mixture of coal and waste material;
- size reducing the mixture of coal and waste material to provide a mixture wherein 80 to 95 wt. % is less than about 5 millimeters;
- and heating the mixture of coal and waste material to a temperature less than about 1250° C. under a reducing atmosphere for a period of time sufficient to provide the steel/carbon product, wherein the steel/carbon product consists essentially of steel substantially encapsulated in metallurgical coke and has a porosity of greater than about 60% and a density of greater than about 900 kg/m3 and the steel component of the steel/carbon product has a percent of metalization of greater than about 85 wt. %.
A steel/carbon product derived from a mixture of metallurgical coal and an oxidized iron waste material under a reducing atmosphere, wherein the steel/carbon product is substantially encapsulated by coke and has a porosity of greater than about 60% and a density of greater than about 900 kg/m3 and the steel component of the steel/carbon product has a percent of metalization of greater than about 85 wt. %.
A process for the production of a steel/carbon product, comprising:
- mixing metallurgical coal with an oxidized iron waste material in a weight ratio of from greater than 1:1 to about 5:1 to provide a coal/oxidized iron mixture;
- reducing the size of the coal/oxidized iron mixture so that from about 80 to about 95 wt. % is less than about 5 millimeters;
- feeding the reduced size mixture to a coke oven;
- heating the mixture in the coke oven to a temperature of less than about 1250° C. for a period of time sufficient to convert the coal to coke and to reduce iron oxides in the oxidized iron waste material to iron, whereby the coke and iron form a steel/carbon product consisting essentially of steel substantially encapsulated in metallurgical coke;
- and
- quenching the steel/carbon product.
Dependencies are inferred from the claim text.