REDUCCION DIRECTA DEL ACERO
El procedimiento consiste en triturar la mena de hierro y pasarla por un reactor con los agentes reductores, con lo que algunos elementos no convenientes para la fusión del hierro son eliminados.
El producto del sistema de reducción directa es el hierro esponja que consiste en unos pelets de mineral de hierro los que pueden ser utilizados directamente para la producción de acero.
La metalización que se logra es del orden del 90-95%.
Reduccion Directa con Reductor Solido
Características más importantes para la aplicabilidad
del Carbono en reducción directa:
- Fusibilidad de las cenizas
Limita la T° a alcanzarse en el proceso pues puede mantenerse esta
a unos 100°C por debajo del punto de fusión de las cenizas para
evitar los encostramientos. - Reactividad
El tamaño del horno y la economía de la planta depende de la
reactividad del carbón pues la concentración suficiente del CO que domina la
reducción esta en función de la velocidad que reacciona el C y CO2
para generar agua. C+CO2à2CO. - Contenido de Azufre
Es importante si las cenizas del Carbón son ácidas, es decir, si no puede
retenerlo como en las cenizas básicas. Es recomendable menor al 1% - Materiales volátiles
La reactividad del carbón suele ser equivalente al contenido de
material volátil sin embargo si es muy alto el contenido de estas
ultimas puede superar la cantidad utilizable dentro del horno. - Composición de cenizas
Si la composición de cenizas es tal que da lugar a la formación de
compuestos de bajo del punto de fusión se presenta una
desfavorable limitación en la T° y da lugar a la formación de
compuestos de baja composición. - Contenido de las cenizas
Una cantidad grande de las cenizas que propicia la formación de
anillos en el horno rotativo, el contenido de cenizas en el carbón debe
estar por debajo del 20%.
PROCESO FASTMET®
Proceso de reducción directa de mineral de hierro a pelets metálicos de hierro que puedan alimentar a un horno eléctrico con una cantidad equivalente de chatarra.Se ha diseñado este proceso a fin de evitar la ruta horno de coque – alto horno para producir metal caliente a partir de mineral de hierro. Además, es uno de los varios métodos que las acerias podrían utilizar para reducir su dependencia de alimentación de chatarra de alta calidad.
Se ha demostrado que el proceso FASTMET logra una alta metalización y una alta recuperación de Zinc en polvo que recicla el proceso a través del laboratorio pruebas y pruebas en KAKOGAWA, planta de FASTMET comercial.
El proceso FASTMET convierte los desechos de acero, con o sin la suma de finos férricos, en la metalización del hierro en un horno de hogar rotatorio (RHF) se usa el carbono como el reductor. El producto puede ser DRI frío, DRI caliente o HBI; dependiendo de los requisitos de uso.
La mayoría de las siderurgias están buscando maneras apropiadas de reciclar los polvos de laminación, polvos del Horno de desechos, horno básico de oxigeno, horno de arco eléctrico, sinters, balanza del molino, etc.
Hay dos aspectos en el reciclando de polvo de acero :
- Reciclar los recursos valiosos, materiales férricos para la fabricación de acero y el óxido de Zinc crudo a la recuperación de metales no férreos.
- Reducir la polución medioambiental, del punto de vista económico y medioambiental, el proceso de FASTMET es muy atractivo como una tecnología limpia.
DESCRIPCIÓN DEL PROCESO
El proceso FASTMET convierte los pelets de oxido ferrico y/o los desechos de acero de fundición, en hierro metálico, cuando el carbón pulverizado u otro material de carbón se usa como reductor.
En funcionamientos dónde el alimento primario es la mena virgen, los reductores se concentran, son peletizados y secados antes de enviarlos al horno rotatorio RHF. Aquí los materiales se llevan al horno en una sola capa.
En casos en que los desechos de la fundición de acero son los materiales del alimento primarios, los desechos pueden ser los briqueteados, que proporciona más flexibilidad al utilizarlos, reduce la necesidad de moler los materiales del alimento y elimina la necesidad de secar las bolas verdes.
Como el hogar rueda, los materiales del alimento se calientan de 1250 - 1400 °C, y el óxido férrico se reduce al hierro metálico por acción del CO.
Tiempo de la residencia en el hogar es de 6 - 12 min., dependiendo del material a procesarse, el tamaño del alimento, y otros factores. Durante este tiempo, se metaliza de 85% – 95%.
La rápida reducción lograda en el Proceso FASTMET se atribuye a la alta temperatura de la reducción, la alta Tº de transferencia, y el contacto íntimo de carbono con el óxido férrico en el alimento.
El gas que deja el horno rotatorio es totalmente el combustible y parcialmente enfriado en el acondicionador de gas, donde se usa la energía termal para precalentar el aire de la combustión para los quemadores del mismo horno. El gas se purifica en un limpiador de SO2, determinada por las regulaciones medioambientales.
La metalización del DRI puede ajustarse, el carbono en los materiales del alimento también pueden ajustarse para obtener el volumen del carbono necesario, la química del producto variará, dependiendo de la química de la mena, los reductores, y aglomerantes usados.
Reacción global de reducción en el proceso FASMET
Reduccion del gas:
CO2 + C → 2 CO
Reduccion del Fe:
Fe3O4 + 4 CO → 3 Fe + 4 CO2
Fe2O3 + 3 CO → 2 Fe + 3 CO2
BENEFICIOS FASTMET®
- Reducción total del costó de eliminación de desechos y obligación del basural.
- Las pérdidas cambiaron a una fuente de hierro de calidad (DRI). Para ser reciclado en hierro o proceso de fabricación de acero.
- El grado de Metalización:
Hierro: 85-92%
Níquel: 95-100% - La recuperación de Zinc al 95% o superior, contenido en las basuras. Para ser vendido a un productor de Zinc.
- El contenido de carbono en los polvos se usará como el reductor. El carbono suficiente en el DRI puede ajustarse según el requisito de cliente
PROBLEMAS ASOCIADOS AL PROCESO
Muchas fundiciones de acero que opera hoy se preocupan por el
manejo de basuras. Estas preocupaciones componen anualmente, y la
necesidad de la industria siderurgica es más proactivo hacia encontrar
las soluciones.
Algunos de estos problemas son:
- Eliminación de basuras
- Recuperación de valiosas unidades férricas
- Control de costos de material crudo
- Conservación de capital
- Problemas medioambientales
*Metalurgia Peru
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