KR-20260062981-A - Use of basic oxygen for producing granular metal units, and related systems, devices, and methods

KR20260062981AKR 20260062981 AKR20260062981 AKR 20260062981AKR-20260062981-A

Abstract

Systems and methods for using a liquid high-temperature metal processing unit to produce granulated metal units (GMUs) are disclosed herein. In some embodiments of the present invention, a liquid high-temperature metal processing system for producing GMUs comprises a liquid high-temperature metal processing unit comprising a granulator unit. The granulator unit may include a tilter positioned to receive and tilt a ladle, a controller operably coupled to the tilter to control the tilting of the ladle, a tundish positioned to receive molten metal from the ladle, and a reactor positioned to receive molten metal from the tundish. The reactor may be configured to cool the molten metal to form granulated metal units (GMUs).

Inventors

리처드슨 존 마이클
멀라키 패트릭 제임스
슈와케 데이비드 제임스
부토 앤드류 마이클
퍼킨스 조나단 헤일
콴시 존 프랜시스
최 춘와이

Assignees

선코크 테크놀러지 앤드 디벨로프먼트 엘엘씨

Dates

Publication Date: 20260507
Application Date: 20240911
Priority Date: 20230911

Claims (20)

As a liquid high-temperature metal processing system for producing granular metal units (GMUs), the system comprises: It includes a liquid high-temperature metal processing unit, and the liquid high-temperature metal processing unit, It includes a granulator unit, and the granulator unit, A tilter positioned to receive rays, A controller operably coupled to the above tilter to control the tilt of the above ladle, A tundish positioned to receive molten metal from the above ladles, and A liquid high-temperature metal processing system comprising a reactor positioned to receive the molten metal from the tundish—the reactor being configured to cool the molten metal and form the GMU.
In paragraph 1, the liquid high-temperature metal processing unit is, Ladle configured to receive and store the molten metal; and A liquid high-temperature metal processing system comprising an overhead crane configured to transfer the above ladles to and from the above tilter.
In paragraph 1, the liquid high-temperature metal processing unit is, A basic oxygen furnace (BOF) vessel configured to receive the molten metal; and A liquid high-temperature metal processing system further comprising an oxygen lance insertable into the BOF vessel to deliver the oxygen gas to the molten metal.
A liquid high-temperature metal processing system according to claim 1, wherein the liquid high-temperature metal processing unit further comprises an oxygen lance configured to deliver oxygen gas to the molten metal, and the oxygen gas is configured to react with carbon in or on the molten metal to reduce the carbon content of the molten metal.
A liquid high-temperature metal processing system according to claim 1, wherein the liquid high-temperature metal processing unit further comprises a desulfurization unit configured to reduce the sulfur content of the molten metal, and the desulfurization unit is configured to reduce the sulfur content of the molten metal by providing at least one of calcium carbide or magnesium to the molten metal.
In claim 1, the ladles include a first ladle, the granulator unit includes a first granulator unit, and the liquid high-temperature metal processing unit further includes a second ladle and a second granulator unit located adjacent to the first granulator unit, and the second granulator unit is, A second tilter positioned to receive and tilt the second ladle; A second controller operably coupled to the second tilter to control the tilting of the second ladle; A second tundish positioned to receive the molten metals from the second ladle; and A liquid high-temperature metal processing system comprising a second reactor positioned to receive the molten metal from the second tundish, wherein the second reactor is configured to cool the molten metal to form a granulated metallic unit (GMU).
A liquid high-temperature metal processing system according to claim 1, wherein the granulator unit further comprises a stopper rod assembly coupled to the tundish, and the stopper rod assembly comprises a stopper rod and an actuator operably coupled to move the stopper rod into and out of the outlet of the tundish.
A liquid high-temperature metal processing system according to claim 1, wherein the granulator unit further comprises an ejector positioned to receive the GMUs from the reactor and a lift line downstream of the reactor, the lift line comprises a curved region, the ejector further comprises a lock box in the curved region, and the lock box is configured to receive and store a portion of the GMUs received by the ejector.
A liquid high-temperature metal processing system according to claim 1, wherein the granulator unit further comprises a dehydration assembly located downstream of the reactor, and the dehydration assembly is configured to filter GMU particles smaller than 1 millimeter in size.
A liquid high-temperature metal processing system according to claim 1, wherein the granulator unit further comprises a dehydration assembly located downstream of the reactor, and the granulator unit further comprises an imaging device located to capture images of the GMUs on the dehydration assembly, and the images captured by the imaging device are configured to be used in an optical particle size measurement feedback system to adjust the flow rate of the molten metal into the reactor.
A liquid high-temperature metal processing system according to claim 1, wherein the granulator unit further comprises a dehydration assembly located downstream of the reactor, the granulator unit further comprises a classifier assembly located downstream of the dehydration assembly, and the classifier assembly is configured to classify a filtrate received from the dehydration assembly and output GMU microparticles.
A liquid high-temperature metal processing system according to claim 1, wherein the liquid high-temperature metal processing unit further comprises a transfer vessel preparation unit configured to deslag and dekish the ladle.
In paragraph 1, A furnace configured to melt iron ore to output molten metal; and A liquid high-temperature metal processing system further comprising a torpedo car configured to transport molten metal from the above-mentioned furnace to a liquid high-temperature metal processing unit.
A method for producing a granular metal unit (GMU) in a liquid high-temperature metal processing unit, A step of transferring molten metal to ladles within the liquid high-temperature metal processing unit; A step of transporting the ladles to a granulator unit within the liquid high-temperature metal processing unit - the granulator unit includes a tilter positioned to receive and tilt the ladles -; A step of tilting the ladle through the tilter to transfer the molten metal to the tundish of the granulator unit; A step of directing the molten metal from the above tundish to the reactor of the granulator unit; and A method comprising the step of granulating the molten metal in the reactor to form a GMU.
In Paragraph 14, A step of supplying the molten metal to a basic oxygen (BOF) vessel within the liquid high-temperature metal processing unit; and The method further includes the step of delivering oxygen to the molten metal within the BOF container to form a decarbonized molten metal, A method comprising the step of transferring the above-mentioned transferring step of transferring the decarbonized molten metal from the BOF container to the ladle.
In claim 15, the step of delivering oxygen comprises the step of reducing the carbon content of the molten metal in the BOF container.
A method according to claim 14, wherein the transporting step comprises transporting the ladles to one of a plurality of granulator units within the liquid high-temperature metal processing unit.
A method according to claim 14, further comprising the step of reducing the sulfur content of the molten metal, wherein the step of reducing the sulfur content comprises the step of adding at least one of calcium carbide or magnesium to the molten metal.
A method according to claim 14, further comprising the step of moving a stopper rod to control the flow rate of the molten metal out of the outlet of the tundish.
In claim 14, the method comprises the step of operating an overhead crane in the liquid high-temperature metal processing unit to transport the ladles to the granulator unit.

Description

Use of basic oxygen for producing granular metal units, and related systems, devices, and methods Cross-reference to related application(s) This application claims priority to U.S. Provisional Application No. 63/581,946, titled "SYSTEM AND METHOD FOR CONTINUOUS GRANULATED PIG IRON (GPI) PRODUCTION," filed September 11, 2023, the entire disclosure of which is incorporated herein by reference. This application also claims priority to the following applications: U.S. Patent Application No. [Attorney Case Management No. 084553.8072.US00], titled "RAILCARS FOR TRANSPORTING GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS," filed September 11, 2024; U.S. Patent Application No. [Attorney Case No. 084553.8073.US00] for "LOADING GRANULATED METALLIC UNITS INTO RAILCARS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" filed on September 11, 2024; U.S. Patent Application No. [Attorney Case No. 084553.8074.US00] for "LOW-SULFUR GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" filed on September 11, 2024; U.S. Patent Application No. [Attorney Case No. 084553.8075.US00] for "CONTINUOUS GRANULATED METALLIC UNITS PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" filed on September 11, 2024; U.S. Patent Application No. [Attorney Case No. 084553.8077.US00] for "LOW-CARBON GRANULATED METALLIC UNITS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS" filed on September 11, 2024; U.S. Patent Application No. [Attorney Case No. 084553.8078.US00] filed on September 11, 2024, for "TORPEDO CARS FOR USE WITH GRANULATED METALLIC UNIT PRODUCTION, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS"; U.S. Patent Application No. [Attorney Case No. 084553.8079.US00] filed on September 11, 2024, for "TREATING COOLING WATER IN IRON PRODUCTION FACILITIES, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS"; U.S. Patent Application No. [Attorney Case No. 084553.8080.US00] filed on September 11, 2024, titled "USE OF RESIDUAL IRON WITHIN GRANULATED METALLIC UNIT PRODUCTION FACILITIES, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS"; and U.S. Patent Application No. [Attorney Case No. 084553.8081.US00] filed on September 11, 2024, titled "PROCESSING GRANULATED METALLIC UNITS WITHIN ELECTRIC ARC FURNACES, AND ASSOCIATED SYSTEMS AND METHODS", titled on September 11, 2024, the disclosures thereof are incorporated herein by reference in their entirety. Technology field The present invention relates to converting a basic oxygen furnace facility to produce granular metal units in general, and to associated systems, devices, and methods. Granulated pig iron (GPI) is a form of pig iron that is granulated into small, uniform particles, making it easier to handle, transport, and use in different metallurgical processes compared to conventional pig iron. The demand for GPI is steadily increasing due to its diverse applications in various industries, including automotive, construction, and manufacturing. The growing popularity of GPI can be attributed to its high purity, consistent quality, and the efficiency it brings to the production of steel and other iron-based products. Granulated pig iron is produced by rapidly cooling molten iron with water, resulting in the formation of granules. This process, known as granulation, is typically carried out after the blast furnace. However, current production methods are often characterized by intermittent production cycles due to various operational constraints, such as the need for periodic maintenance, fluctuations in raw material supply, and energy consumption issues. These interruptions not only affect overall efficiency but also lead to increased production costs and variability in product quality. Therefore, an improved production process is required to ensure continuous and stable granulation of iron, thereby enhancing productivity and reducing operating costs. The features, embodiments, and advantages of the technology disclosed herein can be better understood in conjunction with the following drawings. FIG. 1 is a schematic block diagram of a liquid high-temperature metal processing system configured according to embodiments of the present technology. FIG. 2 is a plan view of the liquid high-temperature metal processing system of FIG. 1 configured according to embodiments of the present technology. FIG. 3 is a partial schematic side view of a container for basic oxygen constructed according to embodiments of the present technology. FIG. 4 is a schematic plan view of two granulator units of a first array configured according to embodiments of the present technology. FIG. 5 is a schematic plan view of two granulator units of a second array configured according to embodiments of the present technology. FIGS. 6a to 6c are partial schematic side views illustrating the tilting of a transfer container according to embodiments of the present technology. FIGS. 7, FIGS. 8a, and FIGS. 8b are a front perspective view, a rear perspective view, and a side cross-sectional view, respectively