Specification
Claims:We Claim
1. A system for zinc removal from steel plant process waste and upgradation of its Fe values comprising:
classification unit generating underflow (U/F) and overflow (O/F) product ultra-fine contain major zinc containing compound along with carbon containing material which are rejected;
classification cum concentrator unit for feeding in the said underflow(U/F) of said classification unit to further generate underflow (U/F) and overflow (O/F), said over flow (O/F) being recirculated to said classification unit;
concentrator unit wherein the underflow (U/F) from said classification cum concentrator unit is fed in to thereby generate separated output magnetic product with upgraded iron oxide or Fe values for desired recycling in iron making while the non-magnetic product are rejected as tailings.
2. A system as claimed in claim 1 comprising of :
slurry preparation unit ;
said classification unit comprising hydrocyclone ;
said concentrator and classification unit comprising stub-cyclone ;
said concentrator unit comprising of a first stage magnetic separation unit and a second stage magnetic separation unit ; and
cooperative concentrate thickener and a tailing thickener.
3. A system as claimed in anyone of claims 1 or 2 wherein said steel plant process waste is fed through different lines comprising a dust feed through line , sludge feed through line and a water source line for maintaining pulp density in the range of 1.1 to 1.5 gm./cc or solid content ranging of 6 to 25% solid in a slurry preparation tank ahead of said classification unit preferably said hydrocyclone, each said flow lines provided with respective pressure and flow rate transmitters.
4. A system as claimed in anyone of claims 1 to 3 wherein said hydrocyclone maintained at flow rate and pressure in range of 8 to 20 m3/hr and 1.1 to 2.5 bar respectively with the overflow product from said hydrocyclone pumped to a tailing thickener and comprises ultra-fine particle with respect to the said material feed and predominantly zinc containing compounds;
said underflow product further processes through stub-cyclone maintained at the flow rate of slurry 6 to 20 m3/hr and pressure in the range of 1.1 to 3 bar wherefrom the overflow product is recirculated to a slurry preparation tank while the underflow product is fed to first stage high gradient magnetic separator to generate separately a non magnetic product and a magnetic product with said non mag product being pumped to tailing thickener and the mag product of said first stage of magnetic separator being fed to the second stage high gradient magnetic separator wherefrom the mag product is fed to the concentrate thickener ,said discharge of concentrated thickener having desired upgradation of its Fe values suitable for reuse in the form of pellet, sinter or briquette.
5. A method for for zinc removal from steel plant process waste and upgradation of its Fe values involving the system as claimed in anyone of claims 1 to 4 comprising :
Involving blast furnace sludge and dust comprising total Fe percentage ranging from 30% to 45% with accomplished gangue load varies from 8 to 15% and carbon contains material 9 to 25%, with unfavourable zinc containing material varying from 0.2 to 2% by weight which is processed for reduction in zinc containing compound (less than 0.15% Zn ) and enriched the iron oxide (Fe-value) more than 60% of total Fe content.
6. A method as claimed in claim 5 wherein said zinc containing material zinc oxide (ZnO), include zinc carbonate [Zn(CO3)2], zinc ferrite (ZnFe2O4), zinc silicate (Zn2SiO4 ) which are associated with the said blast furnace sludge and dust material and this association is distributed in finer particle size fraction majorly in .. to ..preferably about 20 micron passing size distribution with iron oxide containing material particle are associated in respective coarser fraction in the range of . to ..preferably about .. micron.
7. A method as claimed in anyone of claims 5 or 6 wherein size separation of the near gravity material zinc containing compound and iron oxide of said blast furnace sludge and dust are, there is provided desirable pressure drop inside the cyclone in the range of 50 KPa to 85 KPa.
8. A method as claimed in anyone of claims 5 to 7 wherein the hydrocyclone diameter used is in the range of 2 inch to 6 inch, vortex finder diameter 25mm to 45mm, spigot diameter 12mm to 25mm with vortex/spigot diameter ratio ranging from 1.2 to 2.2 and the operating inlet pressure varying from 1.1 bar to 2.5 bar, slurry (pulp) density should maintained 1.1 g/cc to 1.5 g/cc with solid content in slurry 6 to 25%.
9. A method as claimed in anyone of claims 5 to 8 wherein said hydrocyclone unit is operated to treat the said blast furnace sludge and dust such that the overflow product comprises high zinc containing compound with weighted fraction 20-40% of total feed material, whereas the underflow product comprises least zinc containing compound with weight fraction 60 to 80%, whereby almost 50 to 60% Zn is reduced in the underflow product in respect of said blast furnace dust and sludge.
10. A method as claimed in anyone of claims 5 to 9 wherein said underflow product is subjected to stub-cyclone process for further classification as well as concentrator maintaining selectively stub-cyclone diameter in the range of 2 inch to 6 inch, vortex finder diameter 20 to 60 mm, spigot diameter 10 to 40 mm with vortex/spigot diameter ratio ranging from 1.2 to 2.2. the operating inlet pressure varying from 1.1 bar to 3 bar, slurry (pulp) density maintained 1.1 g/cc to 1.5 g/cc with solid content in slurry 10 to 30%, said operating parameter enhancing the iron oxide level in underflow product and reducing the minor quantity of zinc containing compound with 10 to 30% extent such that the iron value is enriched in this process by extent of 30 to 50% in respect of underflow product of hydrocyclone.
11. A method as claimed in anyone of claims 5 to 10 carried out selectively maintaining
the magnetic field intensity of magnetic separator in range of 0.6 Tesla to 1.4 Tesla at pulp density 1.15 g/cc to 1.4 gm./cc and solid content 10% to 30%, matrix diameter of magnetic coil maintained constant preferably at 1.5 mm with 3 minute of pulsation time; the pulsation rate varies from 200 rpm to 250 rpm (revolution per minute) to thereby produce a product with enhanced iron oxide, the grade of iron oxide (Fe value) upgraded by 30% to 50% and reduced the gangue content by 40 to 60% along with carbon material; and
said second stage magnetic separation carried out maintaining the magnetic field intensity of magnetic separator in range of 0.2 Tesla to 0.6 Tesla at pulp density 1.15 g/cc to 1.4 g/cc and solid content 10% to 30%, with the matrix diameter of magnetic coil kept constant preferably at 1.5 mm with 3 minute of pulsation time; the pulsation rate varying from 180 rpm to 250 rpm (revolution per minute) such as to produce product with enhanced iron oxide, the grade of iron oxide (Fe value) upgraded to more than 60% of total Fe content and 0.09% of Zn content, thereby meeting the specification of downstream process.
12. A method as claimed in anyone of claims 5 to 11 wherein the overflow product of stub cyclone process is recirculated to the hydrocyclone process along with non-magnetic portion of second stage magnetic separator ; and
the overflow product of hydrocyclone is dumped along with the non-magnetic content of first stage magnetic separator.
Dated this the 12th day of October, 2018
Anjan Sen
Of Anjan Sen & Associates
(Applicant’s Agent)
IN/PA-199
, Description:FIELD OF THE INVENTION
The present invention refers to a process developed for the removal of zinc form the process wastes (dust and sludge) and upgradation of iron bearing minerals for their recycling in ironmaking.The blast furnace sludge is a mixture of oxides expelled from the top of the blast furnace after wet scrubbing; whose majorcomponents are iron oxides and coke fines. It also contains silicon, calcium, magnesiumand other minor elemental oxides in lesser amounts. The direct recycling of flue dust isnot usually possible since it contains some undesirable elements (like zinc, lead and alkalimetals) that can cause operational difficulties in the blast furnace. Zn especially forms a problem: during the metallurgical process it evaporates because of the very high temperatures in the furnace and subsequently condenses on the walls of the furnace at lower temperature. Part of the evaporated Zn leaves the blast furnace through exhaust gas and condenses on the dust particles, the concentration of Zn being maximumon the finer dust particles.Classification unit (hydrocyclone)helps in separating out the fine material and coarse material, subsequently the said unit of process also helps in reduction of coke fines because of less terminal velocity of coke fines with respect to iron fines. Further processinginvolved in treatment of hydrocyclone underflow units are stub-cyclone and high gradient magnetic separation units. The unit operation of this process primarily remove the fine material which are enriched with zinc containing compound, and then the material treated further to upgrade the iron bearing material content for further utilization through agglomeration techniques.
BACKGROUND OF THE INVENTION
During the processing of iron ore beneficiation,agglomeration and ironmaking(blast furnace) operation, around 8 to 40kg/thm of dust is generated and blown out along with blast furnace dust. In the purification of blast furnace gases, dust is separated as flue dust with dry method and some part of flue dust stream through wet method which generates blast furnace sludge. In the case of processing of iron ore, the zinc-containing compound majorly (ZnO and ZnS) is reduced in a blast furnace to a vaporous stateZn(g) at 890 to 9500C, which majorly adhere with solid dust at low temperature zone in blast furnace and removed from the furnace working space along with said dust. When the zinc content in the blast furnace feedstock above 0.10 -0.40% zinc oxide isolation occurs at the top of the blast furnace and gas ducts, which results in increased coke consumption, fracture lining flues reduction section and, ultimately, to breakdown blast furnace operation. Furthermore, increased zinc content in blast furnace dust and especially in the blast furnace sludge does not allow these products to reusein the main iron production cycle due to zinc accumulation, hence this leads to restrict the use of valuable iron oxide present in said dust and sludge due to Zinc. To ensure proper working of the furnace, the input Zn concentration should not exceed 150 g/thm. Basically, the blast furnace sludge consist of 30-42% Fe, 7-25% C, 0.50 – 5% CaO and 0.20 - 2% Zn.
US Patent 4940487 datedJuly 10, 1990 discloses the patent which describe a process for utilising zinc-containing metallurgical dusts and sludge as agglomerate, briquetted in a cold manner or pelletized and are added to the charge into a melting furnace along with metallic scrap or pig iron. For this purpose, these agglomerates or pellets should have degree of metallizationat least 30% by weight, preferably 40% by weight.
CN Patent 1286315A dated March 07, 2001 discloses the patent which describes the utilization of zinc-containing blast furnace top gas mud includes Zn electrolysis method, preparing high grade iron concentrate, preparing carbon powder and preparing admixture of concrete. Its advantages are high utilization rate up to 98% and less environmental pollution. This process consists magnetic and gravity separation of iron containing material after electrolytic separation of zinc. the zinc-containing sludge utilization of blast furnace gas processing method, using zinc blast furnace gas sludge as a raw material or an intermediate thereof, by means of a series of chemical, physical or electrical processing preparation or to electrolytic zinc, iron ore, carbon and the concrete admixture, wherein: the zinc-containing composition of the blast furnace sludge; a) 20 - 45% Fe, 15 - 35% C, 0.30 - 15% Zn, 4 - 10 SiO2, and the remaining oxide 5 – 30%, b) the particle size of the zinc in the blast furnace gas sludge 100 to 300 mesh or less; zinc BF gas-slime utilization, c) processing method, comprising processing electrolytic zinc process, iron ore processing technology, and preparation process of toner preparation process of the concrete admixture; d) the product purity electrolytic zinc: Zn-containing greater than 99.5%, blast furnace gas sludge yield 90 to 95% Zn; e) the iron concentrate product containing greater than 60% TFe, iron blast furnace gas sludge was 80 to 85%; f) points in the toner product fine carbon powder and carbon powder, the carbon powder content: C> 50%; the content of fine toner: C> 80%; highGas Mud C in a yield of 80 to 85%; g) a zinc-containing clay selected from BF gas remaining substance after grinding preparation of concrete admixture product, and h) total yield of a zinc blast furnace gas sludge reaches 95 - 98%.
The closest analogue of the invention is a method for processing of zinc-containing metallurgical wastes according to the CNPatentCN1389303Adated January 8, 2003 and granted on Aug 29, 2007CN100333836C describe to utilisation of iron concentrate from the blast furnace sludge and mud gas for recovering dust containing iron is characterized by that said method includes the following steps: firstly, making the gas mud and sludge undergo the process of weak magnetic separation treatment, then making the separated tailings undergo the process of strong magnetic separation, so that the iron concentrate magnetically-separated out twice can be recovered and reused. Said invention not only can recover iron ore material from blast furnace gas mud and sludge, raise iron grade, but also can reduce action of harmful elements of lead and zinc. After the elements of lead and zinc in the tailings are collected to a certain grade, they can be comprehensively utilized.
Another closest analogue of the invention is a method for processing of zinc-containing metallurgical wastes according to the Anton Andersson et al. (Characterization and upgrading of a low zinc-containing and fine blast furnace sludge – a multi-objective analysis 2017, No. 2 © 2017 ISIJ 262ISIJ International, Vol. 57 (2017), No. 2, pp. 262–271) describe that the BF sludge with low zinc content, generated in a BF operating an aerocyclone as the primary gas cleaning equipment, has been studied. The characterization of the sludge has been utilized as a starting point in order to design and evaluate the performance of two different zinc removal processes; namely, hydrocycloning and sulphuric acid leaching. Using a multi-objective optimization approach to evaluate the results of the different hydrocycloning setups it was found that there is no conflict between the increased recovery of iron, carbon and solids. However, as a consequence of the characteristics of the sludge, a conflict between removal of zinc and recovery of iron, carbon and solids arises when aiming at removing more than 67% of the total zinc. Depending on the requirement on the removal of zinc, it was concluded from the multi-objective optimization analysis that three different hydrocyclone set-ups are optimal to use:
a) A comparably low requirement on the zinc removal allows 55% of the zinc to be removed while recovering 78, 61 and 73% of the iron, carbon and solids, respectively.
b) A comparably medium requirement on the zinc removal allows 67% of the zinc to be removed while recovering 73, 50 and 68% of the iron, carbon and solids, respectively.
c) Maximizing the zinc removal allows 77% of the zinc to be removed while recovering 57, 32 and 51% of the iron, carbon and solids respectively.
The disadvantages of the closest analogue as mentioned in CN Patent CN1389303A are the utilisation of only magnetic separation techniques may enhance the zinc value if zinc is well adhere with iron bearing particles too. It will be suitable if zinc containing particle are adhered with non-ferrous particle. Unfavorable particle size distribution of the iron-containing blast furnace sludge may affect the efficiency of magnetic separation, thus yield may deteriorate if near particles size particle are not feed in magnetic separation.
As from Anton Andersson et al. the utilization of hydrocyclone is better option to reduce the zinc content initially. But for enhancing the iron bearing value leaching process is utilized. The leaching process of iron bearing particles may lead to loss of yielding by huge amount. The CN patent 1286315A is also a closest analogue to the present invention but using a electrochemical series is not viable, this may leads lots of energy consumption and might be provide good iron bearing material but with the adherence of some surfactant which leads to problematic for downstream process like pelletization and sintering.
The prior arts in this invention provide focus on the best way to utilization of blast furnace sludge contains unrespectable amount of zinc containing material and Upgradation of iron value for reuse further. These patent applications as well as other prior art technology only solves the problem of blast furnace gas from the mud or sludge and zinc, and there is no secondary waste resources are fully utilized, wherein the active ingredient is not utilized, overall economic efficiency is poor.
OBJECTS OF THE INVENTION
The basic object of the presentinvention is directed to a process for the removal of zinc form steel plant process wastes (dust and sludge) by subjecting these materials through the process developed and upgradation of iron value for their recycling in ironmaking.
A further object of the present invention is directed to said process taking in to account the fact that the sludge generated from the blast furnace flue gas scrubbing unit are finely agglomerated whose particle size distribution of 80% passing is varies from 70 micron to 150 micron, where, the concrete admixture, wherein: the composition of the blast furnace gas sludge consist: TFe 20 to 45%, Carbon 7 to 30%, Zn 0.2 to 5%, SiO24 to 10%, the remaining oxide 2 to 20%. There is colossal difference between density of iron bearing material (true density 5.1 g/cc) and carbon content (true density 1.38 g/cc), on the other hand for removal of zinc content particle, there is again colossal difference between magnetic susceptibility of iron bearing material and zinc containing material.
A further object of the present invention is directed to said process for removal of zinc and carbon material and Upgradation of iron bearing materials from the finely distributed saidblast furnace sludge can be treated by classification unit followed by gravitational separation unit and magnetic separation unit.
A still further object of the present invention is directed to said processwherein the product of magnetic separation would fulfill the specification of pellet grade material, wherein; Fe(total)> 61% and gangue material (alumina and Silica) less than 8% with Zn content less than 0.09%.
A still further object of the present invention is directed to said processwherein the product of magnetic separation unit downstream towards the pelletization unit because the particlesare very fine and after induration it can be a feed material for any reduction shaft furnace of iron making.
Thus an object of this invention leads to reduce the deleterious material like Zn and utilization of the waste material as a suitable feed for iron making unit.
SUMMARY OF THE INVENTION
The basic aspect of the present invention is directed to a system for zinc removal from steel plant process waste and upgradation of its Fe values comprising:
classification unit generating underflow (U/F) and overflow (O/F) product ultra-fine contain major zinc containing compound along with carbon containing material which are rejected;
classification cum concentrator unit for feeding in the said underflow(U/F) of said classification unit to further generate underflow (U/F) and overflow (O/F), said over flow (O/F) being recirculated to said classification unit;
concentrator unit wherein the underflow (U/F) from said classification cum concentrator unit is fed in to thereby generate separated output magnetic product with upgraded iron oxide or Fe values for desired recycling in iron making while the non-magnetic product are rejected as tailings.
A further aspect of the present invention is directed to said system comprising of :
slurry preparation unit ;
said classification unit comprising hydrocyclone ;
said concentrator and classification unit comprising stub-cyclone ;
said concentrator unit comprising of a first stage magnetic separation unit and a second stage magnetic separation unit ; and
cooperative concentrate thickener and a tailing thickener.
A still further aspect of the present invention is directed to saidsystem wherein said steel plant process waste is fed through different lines comprising a dust feed through line , sludge feed through line and a water source line for maintaining pulp density in the range of 1.1 to 1.5 gm./cc or solid content ranging of 6 to 25% solid in a slurry preparation tank ahead of said classification unit preferably said hydrocyclone, each said flow lines provided with respective pressure and flow rate transmitters.
A still further aspect of the present invention is directed to saidsystem wherein said hydrocyclone maintained at flow rate and pressure in range of 8 to 20 m3/hr and 1.1 to 2.5 bar respectively with the overflow product from said hydrocyclone pumped to a tailing thickener and comprises ultra-fine particle with respect to the said material feed and predominantly zinc containing compounds;
said underflow product further processes through stub-cyclone maintained at the flow rate of slurry 6 to 20 m3/hr and pressure in the range of 1.1 to 3 bar wherefrom the overflow product is recirculated to a slurry preparation tank while the underflow product is fed to first stage high gradient magnetic separator to generate separately a non magnetic product and a magnetic product with said non mag product being pumped to tailing thickener and the mag product of said first stage of magnetic separator being fed to the second stage high gradient magnetic separator wherefrom the mag product is fed to the concentrate thickener,said discharge of concentrated thickener having desired upgradation of its Fe values suitable for reuse in the form of pellet, sinter or briquette.
Another aspect of the present invention is directed to amethod for zinc removal from steel plant process waste and upgradation of its Fe values involving the system as described abovecomprising :
Involving blast furnace sludge and dust comprising total Fe percentage ranging from 30% to 45% with accomplished gangue load varies from 8 to 15% and carbon contains material 9 to 25%, with unfavourable zinc containing material varying from 0.2 to 2% by weight which is processed for reduction in zinc containing compound (less than 0.15% Zn ) and enriched the iron oxide (Fe-value) more than 60% of total Fe content.
A further aspect of the present invention is directed to saidmethod wherein said zinc containing material zinc oxide (ZnO), include zinc carbonate [Zn(CO3)2], zinc ferrite (ZnFe2O4), zinc silicate (Zn2SiO4 ) which are associated with the said blast furnace sludge and dust material and this association is distributed in finer particle size fraction majorly in 0 - 45 microns preferably about 20 micron passing size distribution with iron oxide containing material particle are associated in respective coarser fraction in the range of 45 – 250 microns preferably about 75 micron.
A still further aspect of the present invention is directed to saidmethod wherein size separation of the near gravity material zinc containing compound and iron oxide of said blast furnace sludge and dust are, there is provided desirable pressure drop inside the cyclone in the range of 50 KPa to 85 KPa.
Another aspect of the present invention is directed to saidmethod wherein the hydrocyclone diameter used is in the range of 2 inch to 6 inch, vortex finder diameter 25mm to 45mm, spigot diameter 12mm to 25mm with vortex/spigot diameter ratio ranging from 1.2 to 2.2 and the operating inlet pressure varying from 1.1 bar to 2.5 bar, slurry (pulp) density should maintained 1.1 g/cc to 1.5 g/cc with solid content in slurry 6 to 25%.
Yet another aspect of the present invention is directed to saidmethod wherein said hydrocyclone unit is operated to treat the said blast furnace sludge and dust such that the overflow product comprises high zinc containing compound with weighted fraction 20-40% of total feed material, whereas the underflow product comprises least zinc containing compound with weight fraction 60 to 80%, whereby almost 50 to 60% Zn is reduced in the underflow product in respect of said blast furnace dust and sludge.
A further aspect of the present invention is directed to saidmethod wherein said underflow product is subjected to stub-cyclone process for further classification as well as concentrator maintaining selectively stub-cyclone diameter in the range of 2 inch to 6 inch, vortex finder diameter 20 to 60 mm, spigot diameter 10 to 40 mm with vortex/spigot diameter ratio ranging from 1.2 to 2.2. the operating inlet pressure varying from 1.1 bar to 3 bar, slurry (pulp) density maintained 1.1 g/cc to 1.5 g/cc with solid content in slurry 10 to 30%, said operating parameter enhancing the iron oxide level in underflow product and reducing the minor quantity of zinc containing compound with 10 to 30% extent such that the iron value is enriched in this process by extent of 30 to 50% in respect of underflow product of hydrocyclone.
A still further aspect of the present invention is directed to said method carried out selectively maintaining
the magnetic field intensity of magnetic separator in range of 0.6 Tesla to 1.4 Tesla at pulp density 1.15 g/cc to 1.4 gm./cc and solid content 10% to 30%, matrix diameter of magnetic coil maintained constant preferably at 1.5 mm with 3 minute of pulsation time; the pulsation rate varies from 200 rpm to 250 rpm (revolution per minute) to thereby produce a product with enhanced iron oxide, the grade of iron oxide (Fe value) upgraded by 30% to 50% and reduced the gangue content by 40 to 60% along with carbon material; and
said second stage magnetic separation carried out maintaining the magnetic field intensity of magnetic separator in range of 0.2 Tesla to 0.6 Tesla at pulp density 1.15 g/cc to 1.4 g/cc and solid content 10% to 30%, with the matrix diameter of magnetic coil kept constant preferably at 1.5 mm with 3 minute of pulsation time; the pulsation rate varying from 180 rpm to 250 rpm (revolution per minute) such as to produce product with enhanced iron oxide, the grade of iron oxide (Fe value) upgraded to more than 60% of total Fe content and 0.09% of Zn content, thereby meeting the specification of downstream process.
A still further aspect of the present invention is directed to saidmethodwherein the overflow product of stub cyclone process is recirculated to the hydrocyclone process along with non-magnetic portion of second stage magnetic separator ; and
the overflow product of hydrocyclone is dumped along with the non-magnetic content of first stage magnetic separator.
The above and other objects and advantages of the present invention are described hereunder in greater details with reference to following accompanying non limiting illustrative drawings.
BRIEF DESCRIPTION OF THE ACCOMPNAYING DRAWINGS
Fig. 1 :shows graphically the Size distribution of sludge.
Fig. 2 :shows graphically Size wise Fe and Zn content in sludge.
Fig. 3: EPMA micrograph of sludge particles (less than 20 microns).
Fig. 4: EPMA micrograph of sludge particles (more than 20 microns).
Figure 5 : shows the Process flow chart for Zn removal and upgradation of iron value in process wastes.
Figure 6: shows the Process control for Zn removal and upgradation of iron value.
Figure 7(a): shows the overall process output for reduction in zinc content.
Figure 7(b): shows the upgradation of iron oxide (Fe-value).
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS
Present invention is directed to the process for reducing the zinc containing compound and up-gradation of iron oxide from the blast furnace sludge and dust. The said material contains majorly iron oxide fine and coal fine material along with gangue content like silica, alumina and lime fines with most neglected material like zinc containing compound. Most of zinc containing compound are adhered on the finest aggregate surface of said material, hence this novel process involves size classification of separating ultrafine particle from respective coarse fraction, followed by concentrator for up-gradation of iron oxide and reduction of zinc containing compound.
The present invention is thus directed to reduction of zinc from the blast furnace sludge and upgradation of iron value to meet its specification for downstream processes such as pelletization and other agglomeration techniques of iron making. The blast furnace sludge material consists of iron bearing material, carbon, lime containing material, silica alumina along with trace of Zinc containing material. The chemical specification of blast furnace sludge consisting total Fe percentage ranging from 30% to 45% with accomplished gangue load varies from 8% to 15%, whereas the most unfavourable zinc consisting material varies from 0.2 to 2% by weight.The physical, chemical and mineralogical specification of the said iron ore fines are briefly tabulated below:
Table1: Chemical composition of blast furnace (BF) sludge, %
Fe(Total) SiO2 Al2O3 Zn CaO Carbon
30-45 4-10 3-8 0.2-2 2 -6 7-25
The size distribution of the particles is shown in Figure 1. The cut size of the blast furnace sludge (d50) is 40micron and the d80% passing is 90micron as represented in Figure 1. The slurry density of Blast furnace sludge is lying in the range of 2.5-3.2g/cc.
The size wise distribution of Zinc containing material and iron bearing material is represented in Figure 2, which illustrate that colossal population of Zinc bearing material are present in finer size fraction of blast furnace sludge material whereas the iron bearing materials observe in least amount in finer particle size distribution of 20 micron passing size.In the further aspect of invention it is necessary to analyse the mineralogical behaviour of the said sludge, which can represent the complexity of the material also towards the selection of unit operation for treatment of the said material. The Electron Probe Micro analyser (EPMA) divulges the elemental analysis present in the said material as shown in Figure 3 and Figure 4.
Table 2: Elemental analysis of blast furnace sludge in finer fraction (below 20 micron)
Site Elemental Analysis of finer fraction by EPMA in %(Fig. 3)
Point Fe O Mg Al Si Ca Zn
1 45.15 34.12 0.89 7.32 6.11 1.11 4.73
2 62.83 29.89 1.86 1.86 0.31 0.56 1.36
3 29.89 50.59 0.64 6.74 1.8 10 0.33
4 62.17 30.96 0.08 3.77 0.31 ND 0.39
5 68.66 29.03 0.31 0.48 0.63 0.49 0.6
6 68.48 29.05 0.03 0.37 ND 0.51 0.9
7 65.6 32.5 0.2 0.79 ND ND 0.68
Table 3: Elemental analysis of blast furnace sludge in coarser fraction (above 20 micron)
Site Elemental Analysis coarse fraction by EPMA in % (Fig. 4)
Point Fe Mg Al Si Ca Zn
1 59.31 2.34 2.42 ND 7.34 0.7
2 4.76 0.38 41.6 3.81 0.76 ND
3 67.83 0.01 0.05 0.45 ND 0.28
4 68.04 0.82 1.73 1.07 4.63 2.14
5 73.06 0.22 0.74 ND 0.42 0.04
6 67.23 ND 0.48 0.37 ND 0.62
7 58.84 0.31 3.49 8.82 1.45 0.06
For the aspect of present invention divulging of elemental analysissets a focal role for adopting the beneficiation route to treat the said material of blast furnace sludge, as most of the zinc containing material are finely associated with iron bearing particle in finer size fraction of 20 micron and less, where the concentration of iron bearing material are very less and the concentration of gangue mineral (silica and alumina) are high as shown in Figure 3 and Table 2. Whereas the reversal of mineralogical assemblage of different materials is seen in coarser fraction above 20 micron sample, where concentration of zinc containing material is seems to be less and mostly adhere near to the porous structure. The gangue material in said size is mostly liberated and does not reveal the complex mineralogical association as shown in Figure 4 and Table 3.
In further aspects of this invention deals with effective utilization of iron bearing materials and reduction of zinc content as well, the said blast furnace sludge are lean graded with respect to iron value. The said blast furnace sludge is subjected to hydrocyclone for removing the ultra-fine particles. Set of experiments were carried out for obtaining the cut size below 20 microns to extract the zinc containing particle from overflow and respective coarser fraction in the underflow. The level of parameters and its process variables are mentioned and tabulated below in Table 4.
Table 4: Operating parameters for Hydrocyclone
Process variables Unit Value
Cyclone Dia inch 2 to 6
Spigot Dia mm 12 to 25
Vortex Dia mm 25 to 45
Feed rate m3/hr 8 to 20
Vortex: spigot Ratio 1.2 to 2.2
Inlet Pressure Bar 1.1 to 2.5
Pressure drop KPa 50 to 85
Pulp density g/cc 1.1 to 1.5
Solid content % 6 to 25
The further aspect of invention deals with to achieve the desired pressure drop inside the hydrocyclone. Zinc containing particle has near gravitytendency with the iron bearing particles, hence, to get the pressure drop of desired value the mechanistic micro-mathematical solid-liquid hydrocyclone model has been developed which takes into account the fundamental differences between solid-liquid and liquid-liquid systems and the hydrodynamic implications of such differences to get desired output in terms of separation efficiency, cut size and pressure drop.
The Formulation of the Governing Equations for hydrocyclone desired output:
Formulation for Velocity Profile and Force balance
On the basis of equilibrium orbit theory the concept of equilibrium radius of the particle, since the motion inside the hydrocyclone is developed by the swirling liquid flow itself. The tangential velocity and the radial fluid velocity toward the center are both assumed to vary exponentially with radius:
v_t r^n=Constt
v_r r^m=constt
Whereas to determine the particle net velocity following assumption is made: v_p=v(?&?v_t?^2+?v_r?^2 )
The equation of motion of a spherical particle in a fluid neglecting the interactions with other particles can be written as: (?x_p)/?t=v_p ;m_p (?v_p)/?t=m_p (1-?/?_p )g+F_p
Where x_p is the particle position, m_p is the mass and ?_p is the density of particle, u_p the instantaneous velocity of the particle. The term F_p represents the force caused by solid-liquid interaction. In the most general case it could constitute of the following contributors modeled using empirical formulas:
F_p=F_1+F_2+F_3+F_4+F_5+F_6
The first term F_1 represent the drag force that was derived with assumption of uniform velocity and pressure field: F_1=0.5?C_d (pd^2)/4 |u-v_p |(u-v_p )
Similarly F2, F3, F4, F5 and F6 represents mechanical force, viscous force, lift force, rotational lift force and force due to pressure gradient respectively and formulated as below: F_2=0.5(m_p ?)/?_p d(u-v_p )/dt F_3=1.5d^2 vp?µ ?_(t_0)^t¦?1/v(t-t) d(u-v_p )dt/dt? F_4=1.6d^2 vµ?? (u-v_p ) F_5=0.5?(u-v_p )^2 C_L (pd^2)/4 F_6=-v_p ?p
Put all the force value in the equation of motion of spherical particle:
m_p (?v_p)/?t=m_p (1-?/?_p )g+0.5?C_d (pd^2)/4 |u-v_p |(u-v_p )+0.5(m_p ?)/?_p d(u-v_p )/dt+1.5d^2 vp?µ ?_(t_0)^t¦?1/v(t-t) d(u-v_p )/dt?±1.6d^2 vµ?? (u-v_p )+1.6d^2 vµ?? (u-v_p )-v_p ?p …………….Eq-1
Assuming we have the following differential equation: dv_p/dt=f(v_p,t)
Let initial conditions are: v_p (t_0 )=v_0p
The computation formula of Runga-Kutta method for solving the above differential equation is following:
v_(n+1)=v_n+1/6 (k_1+?2k?_2+?2k?_3+k_4 )
k_1=hf(v_n,t_n )
k_2=hf(v_n+h/2,t_n+k_1/2)
k_3=hf(v_n+h/2,t_n+k_2/2)
k_4=hf(v_n+h,t_n+k_3 )
The balance between these forces corresponds to an equilibrium orbit position of the particle within the hydrocyclone. If Stokes’ law is assumed, the governing equation is: v_r=t (v_t^2)/r
Wheret can be obtained from:
t=?sd2/18?
The equations can be combined to give vrur = c at equilibrium
d2˜r^(1+2n-m)
Where d is a diameter of particle, and ? is the dynamic viscosity of carrier fluid.
And 1+2n-m > 0 (always) therefore larger particles will be found close to the wall and entrained to the outer vortex swirling downwards toward the underflow outlet. Smaller particles, on the other hand, will be found toward the center and entered the inner fluid core swirling upward.
Formulation for residence time
As proposed, it takes into account non-equilibrium conditions considering whether a specific size particle d, will reach the hydrocyclone wall within its residence time, T , and report to the underflow, i.e., dt/dr=2L/(v_z Dc)where v_z=f(v_r,r,t) = f(ur)
For the inlet diameter, Di, the necessary velocity, vr, is expressed as: ?_0^T¦v_r dt=0.5D_i
Based on Stokes’ analysis, the radial velocity in a centrifugal field of particles of the cut size is:? u?_r=d_50^2 (?_s-?)(v_r^2)/(18?×r)
Formulation for cut size and reduced grade recovery
On the basis of sizing or geometry of hydrocyclone the Stokes number and the Euler number, Stk50Eu, is constant for geometrically similar hydrocyclones. However, recently, Coelho and Medronho (2001) reported that the product Stk50Eu can be expected as a function of water flow ratio Rw and volumetric feed concentration f since the feed concentration reduces the terminal settling velocities of the particles. Also, it is expected to vary with Du or of an operational variable greatly affected by parameters Du, such as the water flow ratio Rw. Based on experimental works of Coelho and Medronho (2001), a semi-empirical model, based on dimensionless groups for Reitema’s optimum design given in following equation was adopted in this study for analysis and verification purposes.
Stk_50 Eu1=A(Dc/D_o )^0.95 (Dc/(L-l))^1.33 [ln(1/R_w ) ]^0.79 exp(12.0f)
E_u=B Dc^0.57 (Dc/D_i )^2.61 (Dc/(D_o^2+D_u^2 ))^0.42 (Dc/(L-l))^0.98 R_e^0.12 exp(-0.55f)
R_w=C?(Dc/Do )?^5.97 (Du/Dc)^3.10 ?E_u?^(-0.54)
Where according to the slurry characteristics the product Stk50Eu, the Euler number Eu, the Reynolds number Re, and the water flow ratio Rw can be found from following equation respectively.
Stk_50 Eu2=(p(?_s-?)?PDc(d_50^' )^2)/36??Q
E_u=(p^2 ?P Dc^4)/(8?Q^2 )
R_e=4?Q/p?Dc
R_w= (Q_u (1-f?))/Q(1-f)
The reduced grade efficiency curve G’ as expressed in equation below was given by a modification of the Rosin-Rammler distribution function:
G^'=1-exp[-0.693(d/(d_50^' ))^m ]
By considering the equation stk50Eu1 and Eu2, the reduced cut size as expressed in the following equation ? d?_50^'= ?D Dc?^0.64/(?D_o?^0.475 (L-l)^0.665 ) [??Q/(?_s-?)?P]^0.5 [ln(1/R_w ) ]^0.395 exp(6.0f) ………Eq-2
Formulation for Pressure drop:
The most used method for measuring a pressure drop in the process industry is to measure the static pressure at the wall in the upstream and downstream piping. For a hydrocyclone case this is complicated because there is a swirling flow pattern in the exiting liquid. The swirling flow causes the static pressure at the wall to be higher than the cross-sectional average, and we need to think of how to deal with the dynamic Pressure stored in the swirling motion. To understand the pressure drop we therefore need to have a closer look on the two pressures contributes, namely the static and the dynamic pressure.
We can recognize the static and the dynamic pressure from the well-known Bernoulli equation for a steady flow of a fluid as:
Pi+0.5?_p u_i^2=P_u+0.5?_p ?v_p?^2+(?_p-?)gsin?L+?
Hence, ?P= 0.5?_p (?v_p?^2-u_i^2 )+(?_p-?)gsin?L+?…………. Eq-3
Where ?the wall loss or loss is in the cylindrical body, can be described as follows:
?=f A_r/0.9Q (v_r v_t )^1.5 ?/2
A_r=0.25p(D_c^2-D_o^2)+pD_c L_l+pD_c S+p(D_c+D_u )/2 ?((L_l-L_c)^2+(?(D-Du)/2)?^2 )?^0.5
f=log_10??(1.6/(C-0.00059))^2.38 (1+2.25E5/(R_e^2 (C-0.00059) ))? (A_r And f is area correction factor and wall friction factor respectively)
Formulation for Separation Efficiency:
Assuming a homogeneous distribution of particles inside thehydrocyclone , the separation efficiency of a given particle diameter,, can be expressed as the ratio of the length within which the particle reaches the downward flow region and is separated, over the total trajectory length, Lc. Thus, the particle separation efficiency prediction proposed in this study is given by:
e_d=¦(0,if L_v=L_c@(L_c-L_f)/L_c ,if0
Documents
Application Documents
#
Name
Date
1
201821038857-STATEMENT OF UNDERTAKING (FORM 3) [12-10-2018(online)].pdf
2018-10-12
2
201821038857-FORM 1 [12-10-2018(online)].pdf
2018-10-12
3
201821038857-DRAWINGS [12-10-2018(online)].pdf
2018-10-12
4
201821038857-COMPLETE SPECIFICATION [12-10-2018(online)].pdf
2018-10-12
5
201821038857-Proof of Right (MANDATORY) [24-10-2018(online)].pdf
2018-10-24
6
201821038857-FORM-26 [24-10-2018(online)].pdf
2018-10-24
7
Abstract1.jpg
2018-11-26
8
201821038857- ORIGINAL UR 6(1A) FORM 1 & FORM 26-311018.pdf
2019-03-19
9
201821038857-FORM 18 [14-04-2022(online)].pdf
2022-04-14
10
201821038857-FER.pdf
2022-06-17
11
201821038857-RELEVANT DOCUMENTS [15-12-2022(online)].pdf
2022-12-15
12
201821038857-FORM 13 [15-12-2022(online)].pdf
2022-12-15
13
201821038857-OTHERS [16-12-2022(online)].pdf
2022-12-16
14
201821038857-FER_SER_REPLY [16-12-2022(online)].pdf
2022-12-16
15
201821038857-COMPLETE SPECIFICATION [16-12-2022(online)].pdf
2022-12-16
16
201821038857-CLAIMS [16-12-2022(online)].pdf
2022-12-16
17
201821038857-US(14)-HearingNotice-(HearingDate-26-02-2024).pdf
2024-02-13
18
201821038857-Correspondence to notify the Controller [23-02-2024(online)].pdf
2024-02-23
19
201821038857-Written submissions and relevant documents [11-03-2024(online)].pdf
2024-03-11
20
201821038857-PatentCertificate18-03-2024.pdf
2024-03-18
21
201821038857-IntimationOfGrant18-03-2024.pdf
2024-03-18
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201821038857ssE_17-06-2022.pdf
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