Claims:1. A method for production of pig iron, the method comprising:
tapping a low grade pig iron, wherein the low grade pig iron comprises a first pre-determined amount of manganese and a first pre-determined amount of titanium, wherein the first pre-determined amount of manganese is greater than 0.40 percent and wherein the first pre-determined amount of titanium is greater than 0.40 percent;
refining the low grade pig iron, wherein the refining is performed by:
selectively adding a pre-determined amount of at least one oxidizing agent in the low grade pig iron, wherein the pre-determined amount of at least one oxidizing agent is added to initialize formation of manganese dioxide and titanium dioxide, wherein the pre-determined amount of at least one oxidizing agent added is in a range of 3 percent to 30 percent; and
removing the manganese dioxide and the titanium dioxide, wherein the manganese dioxide and the titanium dioxide is present along with the high grade pig iron;
collecting a high grade pig iron comprising a second pre-determined amount of manganese and a second pre-determined amount of titanium and wherein the second pre-determined amount of manganese is less than 0.040 percent and the second pre-defined amount of the titanium is less than 0.040 percent.
2. The method as recited in claim 1, wherein the pre-determined amount of at least one oxidizing agent is added to initialize the formation of a layer of the manganese dioxide and a layer of the titanium dioxide.
3. The method as recited in claim 1, wherein the manganese dioxide and the titanium dioxide is formed by initializing an oxidation reaction of the first pre-determined amount of manganese and the first pre-determined amount of titanium present in the low grade pig iron with oxygen, wherein the oxidation reaction is initialized by utilizing latent heat of the low grade pig iron. 4. The method as recited in claim 1, wherein the tapping of the low grade pig iron comprises
collecting the low grade pig iron in each of one or more ladles; and
transferring each of the one or more ladles comprising the low grade pig iron for the refining. 5. The method as recited in claim 1, wherein the collecting of the high grade pig iron comprises:
tilting each of one or more ladles; and
pouring the high grade pig iron after tilting each of one or more ladles. 6. The method as recited in claim 1, wherein the pre-determined amount of at least one oxidizing agent added is iron (II) oxide. 7. The method as recited in claim 1, wherein the pre-determined amount of at least one oxidizing agent added is iron (III) oxide. 8. The method as recited in claim 1, wherein the pre-determined amount of at least one oxidizing agent added is iron (II, III) oxide. 9. The method as recited in claim 1, further comprising:
collecting iron ore, coke and a flux in a blast furnace;
smelting the iron ore, the coke and the flux for obtaining the low grade pig iron along with a furnace slag in the blast furnace; and
removing the furnace slag generated by the smelting of the iron ore from the blast furnace. 10. The method as recited in claim 1, wherein the low grade pig iron is tapped from a blast furnace. , Description:METHOD AND SYSTEM FOR PRODUCTION OF HIGH GRADE PIG IRON
TECHNICAL FIELD
?????? The present invention relates to the field of metallurgy of iron, and in particular relates to production of high grade pig iron.
BACKGROUND
?????? In the recent years, the iron producing industries and foundries have witnessed an exponential growth. The majority of this growth is due to a rising demand of high grade steel and alloys. The main ingredient for the production of steel and such alloys is iron. Iron generally occurs naturally in iron ores, manganiferous ores and ilmenite ores, which is an ore of titanium rich with iron. Furthermore, the iron in the iron ores, manganiferous ores or ilmenite is not a free iron metal. Moreover, the iron in these ores occurs in the form of oxides of iron.
?????? Traditionally, the iron producing industries produce iron by heating the iron ores, steel scraps and iron scraps in a blast furnace followed by refining of the hot molten iron. Further, the hot molten iron produced is a low grade pig iron with higher amount of manganese, phosphorus, silicon and titanium. Moreover, the low grade pig iron is a poor source of iron which is used for production of steel and alloys used in aircrafts, turbines and rockets. Further, the obtained steel is of poor quality. The low grade pig iron is not suitable for direct forging or steel making. There is a consistent need for producing a high grade pig iron for production of high grade steel.
?????? Conventionally, high grade pig iron is produced by smelting iron bearing resources with coke and limestone in a blast furnace. The oxides of iron present in the iron bearing resources are reduced to metallic iron along with a plurality of impurities by carbon mono-oxide produced after heating coke in presence of oxygen. The iron bearing resources are the iron ores, iron scrap, steel scrap and manganiferous iron ores. Further, the low grade pig iron
obtained from the furnace is refined though multiple long steps. The steps include demanganization, dephosphorization, desulphurization, decarburization and the like.
?????? In addition, the method for production of high grade pig iron as described in the prior art is inefficient. The method as described in the prior art takes longer time. Moreover, the process consumes more power and more fuel due to higher oxygen blowing and longer smelting period. Further, the current method does not provide a control over higher generation of slag. Accordingly, this decreases the overall yield of the high grade pig iron. Moreover, the current method fails to utilize iron bearing resources with higher amount of manganese and titanium. In addition, the higher content of manganese and titanium in the low grade pig iron does not enable production of high grade pig iron. There is a consistent need to reduce the content of manganese and titanium in the pig iron in order to produce a high grade special iron.
?????? In light of the above stated discussion, there is a need for the method and system that overcomes the above stated disadvantages.
OBJECT OF THE DISCLOSURE
?????? A primary object of the present disclosure is to produce high grade pig iron having a pre-defined amount of manganese and titanium through a ladle metallurgy process.
?????? Another object of the present disclosure is to reduce amount of slag generation in a ladle.
?????? Yet another object of the present disclosure is to reduce fuel consumption in blast furnace and the blowing of oxygen.
?????? Yet another object of the present disclosure is to enhance usage of cheap low grade iron ore with high manganese content.
?????? Yet another object of the present disclosure is to reduce blowing time period of oxygen in steel making process.
SUMMARY
?????? In an aspect of the present disclosure, the present disclosure provides a method for production of pig iron. The method includes tapping of a low grade pig iron. Further, the method includes refining the low grade pig iron. Furthermore, the method includes collecting a high grade pig iron having a second pre-determined amount of manganese and a second pre-determined amount of titanium. The refining of the low grade pig iron is performed by selectively adding a pre-determined amount of at least one oxidizing agent in the low grade pig iron. Further, the refining is performed by removing the manganese dioxide and the titanium dioxide. The pre-determined amount of at least one oxidizing agent is added to initialize formation of manganese dioxide and titanium dioxide. The pre-determined amount of at least one oxidizing agent added is in a range of 3 percent to 30 percent. In addition, the manganese dioxide and the titanium dioxide are present along with the high grade pig iron. Furthermore, the low grade pig iron includes a first pre-determined amount of manganese and a first pre-determined amount of titanium. Moreover, the first pre-determined amount of manganese is greater than 0.40 percent. In addition, the first pre-determined amount of titanium is greater than 0.40 percent. Further, the second pre-determined amount of manganese is less than 0.040 percent and the second pre-defined amount of the titanium is less than 0.040 percent.
?????? In an embodiment of the present disclosure, the pre-determined amount of at least one oxidizing agent is added to initialize the formation of a layer of the manganese dioxide and a layer of the titanium dioxide.
?????? In an embodiment of the present disclosure, the manganese dioxide and the titanium dioxide are formed by initializing an oxidation reaction. The first pre-determined amount of manganese and the first pre-determined amount of titanium present in the low grade pig iron reacts with oxygen in the oxidation reaction.
?????? In an embodiment of the present disclosure, the tapping of the low grade pig iron includes collection of the low grade pig iron in each of one or more ladles. In addition, the low grade pig iron in each of the one or more ladles for refining.
?????? In an embodiment of the present disclosure, the collection of the high grade pig iron includes tilting of each of one or more ladles. In addition, the high grade pig iron is poured after tilting each of the one or more ladles.
?????? In an embodiment of the present disclosure, the pre-determined amount of at least one oxidizing agent added is iron (II) oxide.
?????? In an embodiment of the present disclosure, the pre-determined amount of at least one oxidizing agent added is iron (III) oxide.
?????? In an embodiment of the present disclosure, the pre-determined amount of at least one oxidizing agent added is iron (II, III) oxide.
?????? In an embodiment of the present disclosure, the method further includes receiving iron ore, coke and a flux in a blast furnace. Further, the method includes smelting the iron ore, the coke and the flux for obtaining the low grade pig iron along with a furnace slag in the blast furnace. Moreover, the method includes removing the furnace slag generated by the smelting of the iron ore from the blast furnace.
?????? In an embodiment of the present disclosure, the low grade pig iron is tapped from a blast furnace.
STATEMENT OF THE DISCLOSURE
?????? The present disclosure relates to a method for production of pig iron. The method includes tapping of a low grade pig iron. Further, the method includes refining the low grade
pig iron. Furthermore, the method includes collecting a high grade pig iron having a second pre-determined amount of manganese and a second pre-determined amount of titanium. The refining of the low grade pig iron is performed by selectively adding a pre-determined amount of at least one oxidizing agent in the low grade pig iron. Further, the refining is performed by removing the manganese dioxide and the titanium dioxide. The pre-determined amount of at least one oxidizing agent is added to initialize formation of manganese dioxide and titanium dioxide. The pre-determined amount of at least one oxidizing agent added is in a range of 3 percent to 30 percent. In addition, the manganese dioxide and the titanium dioxide are present along with the high grade pig iron. Furthermore, the low grade pig iron includes a first pre-determined amount of manganese and a first pre-determined amount of titanium. Moreover, the first pre-determined amount of manganese is greater than 0.40 percent. In addition, the first pre-determined amount of titanium is greater than 0.40 percent. Further, the second pre-determined amount of manganese is less than 0.040 percent and the second pre-defined amount of the titanium is less than 0.040 percent.
BRIEF DESCRIPTION OF THE FIGURES
?????? Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
?????? FIG. 1 illustrates a system for production of a high grade pig iron, in accordance with various embodiments of the present disclosure;
?????? FIG. 2 illustrates a block diagram for the production of the high grade pig iron by a ladle metallurgy process, in accordance with various embodiments of the present disclosure; and
?????? FIG. 3 illustrates a flowchart of the method of the production of the high grade pig iron, in accordance with various embodiments of the present disclosure.
DETAILED DESCRIPTION
?????? It should be noted that the terms "first", "second", and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Further, the terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
?????? FIG. 1 illustrates a general overview of a system 100 for production of pig iron, in accordance with various embodiments of the present disclosure. The pig iron is a high grade pig iron. The high grade pig iron has lower amount of manganese and titanium. In addition, the high grade pig iron is produced through a ladle metallurgy process.
?????? Further, the system 100 is configured to tap and refine a low grade pig iron. The low grade pig iron is produced in a smelting device through pyro-treatment of a plurality of materials. In addition, the system 100 is configured to collect high grade pig iron after the refining of the low grade pig iron. Moreover, the system 100 includes an input unit 102, a refinery unit 104 and a collection unit 106. The units mentioned above perform the ladle metallurgy process of refining of the low grade pig iron to the high grade pig iron.
?????? Furthermore, the input unit 102 performs smelting process on the plurality of materials for the production of the low grade pig iron. In addition, the plurality of materials includes one or more iron bearing resources, a reductant and a flux. Further, the one or more iron bearing resources may be obtained from a plurality of sources. The plurality of sources of iron includes iron ores, iron scraps, steel scraps and the like. Examples of the iron ores include but may not be limited to haematite, goethite, limonite, magnetite and siderite. In addition, the one of the one or more iron bearing resources may be manganiferous iron ores. Further, one of the one or more iron bearing resources may be ilmenite.
?????? Moreover, the input unit 102 is a blast furnace. The input unit 102 is configured to receive the plurality of materials from the plurality of sources and perform the smelting process for the production of the low grade pig iron. The input unit 102 receives the one or
more iron bearing resources and heats the one or more iron bearing resources to a pre-defined temperature. In addition, the pre-defined temperature is above the melting point of the iron.
?????? Further, each of the one or more iron bearing resources is composed of an oxide of iron. In addition, the reductant is fed to the input unit 102. In an embodiment of the present disclosure, the reductant is coke. In another embodiment of the present disclosure, the reductant may be any suitable material. In addition, a flux is fed through a feed path of the input unit 102. In an embodiment of the present disclosure, the flux is limestone. In another embodiment of the present disclosure, the flux is any suitable material.
?????? Furthermore, the reductant chemically reduces the one or more iron bearing residues to the low grade pig iron. Further, the refinery unit 104 is associated with one or more ladles. Each of the one or more ladles taps the pre-defined amount of the low grade pig iron. Further, the low grade pig iron includes a first pre-determined amount of manganese and a first pre-determined amount of titanium. In addition, the pre-defined amount of the low grade pig iron is based on capacity of each of the one or more ladles.
?????? Moreover, the refinery unit 104 performs the refining of the low grade pig iron through selective addition of a pre-determined amount of at least one of oxidizing agents. Further, each of the oxidizing agents initializes an oxidation reaction of with the low grade pig iron inside each of the one or more ladles. The pre-determined amount of at least one oxidizing agentreacts with the first pre-determined amount of manganese, the first pre-determined amount of titanium and silicon present in the low grade pig iron. The first pre-determined amount of manganese, the first pre-determined amount of titanium and the silicon oxidizes to form a layer of manganese dioxide, a layer of titanium dioxide and a layer of silicon dioxide. The layer of silicon dioxide, the layer of manganese dioxide and the layer of titanium dioxide are removed from the high grade pig iron present in each of the one or more ladles. In addition, each of the one or more ladles is left with the high grade pig iron after removal of the layer of manganese oxide and the layer of titanium oxide.
?????? Further, the high grade pig iron includes a second pre-determined amount of manganese and a second pre-determined amount of titanium. The first pre-determined amount of manganese is less than 0.040 percent and the second pre-defined amount of the titanium is less than 0.040 percent. In addition, the refinery unit 104 is associated with the collection unit 106. The collection unit 106 is configured to collect the high grade pig iron by tilting each of the one or more ladles. Moreover, the high grade pig iron is molten and suitable for further processing.
?????? FIG. 2 illustrates a block diagram 200 for the production of pig iron, in accordance with various embodiments of the present disclosure. The pig iron is the high grade pig iron. The ladle metallurgy process is a post iron making process. It may be noted that to explain the system elements of FIG. 2, references will be made to the system elements of FIG. 1. In addition, the high grade pig iron has the lower amount of manganese and titanium.
?????? Further, the block diagram 200 provides the method to tap and refine the low grade pig iron. The low grade pig iron includes the first pre-determined amount of manganese and the second pre-determined amount of titanium. Moreover, the first pre-determined amount of the manganese is greater than 0.040 percent and the second pre-determined amount of the titanium is greater than 0.040 percent. The low grade pig iron is produced in the smelting device through pyro-treatment of the plurality of materials. Moreover, the block diagram 200 includes a furnace unit 202, the refinery unit 104 and the collection unit 106. The units mentioned above perform the ladle metallurgy process for refining of the low grade pig iron to the high grade pig iron.
?????? Furthermore, the furnace unit 202 is produces the low grade pig iron by smelting the plurality of materials. In addition, the plurality of materials includes the one or more iron bearing resources, a reductant and a flux. Further, the one or more iron bearing resources may be obtained from a plurality of sources. The plurality of sources of iron includes iron ores, iron scraps, steel scraps and the like. Examples of the iron ores include but may not be limited to haematite, goethite, limonite, magnetite and siderite. In addition, one of the one or
more iron bearing resources may be manganiferous iron ores. Further, one of the one or more iron bearing resources may be ilmenite.
?????? Moreover, the furnace unit 202 is a blast furnace. The furnace unit 202 is configured to receive the plurality of materials from the plurality of source and perform smelting process for the production of the low grade pig iron. The furnace unit 202 is physically designed to include a feed path on top, a heating device and a hot metal collector at bottom. In addition, the furnace unit 202 is physically designed to include a slag outlet at the top of the hot metal collector and a tap at the bottom. The furnace unit 202 receives the one or more iron bearing resources from the feed path present on the top of the furnace unit 202. The heating device present at the bottom of the furnace unit 202 heats the one or more iron bearing resources to the pre-defined temperature. In addition, the pre-defined temperature is above the melting point of the iron.
?????? Further, each of the one or more iron bearing resources is composed of the oxides of iron. In addition, the reductant is fed to the furnace unit 202 through the feed path. In an embodiment of the present disclosure, the reductant is coke. In another embodiment of the present disclosure, the reductant may be any suitable material. In addition, the flux is fed through the feed path of the furnace unit 202. In an embodiment of the present disclosure, the flux is limestone. In another embodiment of the present disclosure, the flux is any suitable material.
?????? Furthermore, the reductant reduces the one or more iron bearing residues to the low grade pig iron. The low grade pig iron flows to the hot metal collector present at the bottom of the furnace unit 202. In addition, reduction of the one or more iron bearing resources in the furnace unit 202 generates slag. The slag is removed through the slag outlet present at the top of the hot metal collector. In an embodiment of the present disclosure, the low grade pig iron is a basic steel grade pig iron. In another embodiment of the present disclosure, the low grade pig iron is a haematite pig iron.
?????? Further, the furnace unit 202 is associated with the refinery unit 104. The refinery unit 104 is configured to reduce amount of the first pre-determined amount of manganese and the first pre-determined amount of titanium present in the low grade pig iron through the ladle metallurgy process. In addition, the refinery unit 104 is associated with one or more ladles 204. Furthermore, the refinery unit 104 includes a feeder unit 206. In general, each of the one or more ladles 204 is a vessel used to transport and pour out molten metals. Each of the one or more ladles 204 taps the low grade pig iron from the furnace unit 202. The low grade pig iron is tapped by collection of the low grade pig iron from the blast furnace.
?????? Furthermore, the refinery unit 104 performs the ladle metallurgy process on the tapped low grade pig iron present in each of the one or more ladles 204. The ladle metallurgy process is the refining process of the low grade pig iron. The refining of the low grade pig iron includes the selective addition of the pre-determined amount of at least one oxidizing agent in each of the one or more ladles 204. In addition, the pre-determined amount of at least one oxidizing agent selectively added is an oxide of iron. In an embodiment of the present disclosure, the pre-determined amount of at least one oxidizing agent added is iron (II) oxide. In another embodiment of the present disclosure, the pre-determined amount of at least one oxidizing agent added is iron (III) oxide. In yet another embodiment of the present disclosure, the pre-determined amount of at least one oxidizing agent added is iron (II, III) oxide.
?????? Moreover, each of the one or more ladles 204 is present in vicinity of the feeder unit 206. The feeder unit 206 is configured to store and feed the pre-determined amount of at least one oxidizing agent to each of the one or more ladles 204 present inside the refinery unit 104.
?????? Further, the pre-determined amount of at least one oxidizing agent is added to initialize the formation of the first layer of manganese dioxide and the second layer of titanium dioxide. In addition, the formation of the first layer of manganese dioxide and the second layer of titanium dioxide is performed by initializing the oxidation of the first pre-determined amount of manganese and the first pre-determined amount of titanium in the low
grade pig iron with oxygen. Moreover, the pre-determined amount of at least one oxidizing agent is added in the range of 3 percent-30 percent.
?????? Moreover, the first layer of manganese dioxide and the second layer of titanium dioxide are removed from the high grade pig iron present in each of the one or more ladles 204. In addition, the layer of silicon dioxide is separated from the high grade pig iron present in each of the one or more ladles 204. In an embodiment of the present disclosure, the first layer of manganese dioxide and the second layer of titanium dioxide are removed manually. In another embodiment of the present disclosure, the first layer of manganese dioxide and the second layer of titanium dioxide are removed automatically by a machine. In addition, the ladle metallurgy process for the production of high grade pig iron generates a reduced amount of the slag in each of the one or more ladles 204.
?????? Furthermore, the reduction in the amount of the slag generated in each of the one or more ladles 204 is due to a reduced requirement of a refining flux. The oxides of iron added in each of the one or more ladles 204 acts as an oxidizer and iron supplement. In addition, the reduced amount of the slag is based on the selective addition the pre-determined amount of at least one oxidizing agent in each of the one or more ladles 204. In addition, the high grade pig iron is obtained in each of the one or more ladles 204. The high grade pig iron includes the first pre-defined amount of the manganese and the second pre-defined amount of the titanium. Moreover, the second pre-defined amount of the manganese is less than 0.040 percent and the second pre-defined amount of the titanium is less than 0.040 percent. For example, the high grade pig iron includes carbon in a range of 3.5 percent to 4.6 percent, less than 0.015 percent sulphur, less than 1.00 percent silicon, less than 0.040 percent manganese, less than 0.050 percent phosphorus and 0.040 percent titanium.
?????? Further, each of the one or more ladles 204 is associated with the collection unit 106. The collection unit 106 tilts each of the one or more ladles 204 to collect the high grade pig iron. In an embodiment of the present disclosure, the collection unit 106 collects the high grade pig iron in metal ingots for casting of the high grade iron. In another embodiment of the present disclosure, the collection unit 106 collects the high grade pig iron in steel
converters for steel making process. In yet another embodiment of the present disclosure, the collection unit 106 collects the high grade pig iron in vessels for alloy formations. In yet another embodiment of the present disclosure, the collection unit 106 collects the high grade pig iron in vessels for any other metal processing. In addition, the collected high grade pig iron in the collection unit 106 is a basic steel grade pig iron.
?????? Furthermore, it may be noted that in FIG. 2, the furnace unit 202 is associated with a refinery unit 104; however, those skilled in the art would appreciate that more number of furnace units are associated with the one or more refinery units. Moreover, it may be noted that in FIG. 2, the one or more ladles 204 are associated with the feeder unit 206; however those skilled in the art would appreciate that the one or more ladles 204 are associated with more number of feeder units.
?????? FIG. 3 illustrates a flowchart 300 of the method for the production of the high grade pig iron, in accordance with various embodiments of the present disclosure. It may be noted that to explain the process steps of flowchart 300, references will be made to the system elements of FIG. 1 and FIG. 2. It may also be noted that the flowchart 300 may have lesser or more number of steps which enables the production of high grade pig iron with lower amount of the manganese and the titanium.
?????? The flowchart 300 initiates at step 302. Following step 302, at step 304, the low grade pig iron is tapped into each ladle of the one or more ladles 204 present in the vicinity of the furnace unit 202. In addition, the tapped low grade pig iron is a molten pig iron. Further, at step 306, the refinery unit 104 performs the refining of the tapped low grade pig iron present in each of the one or more ladles 204. Further, the refinery unit 104 selectively adds the pre-determined amount of at least one oxidizing agent in each of the one or more ladles 204. The pre-determined amount of at least one oxidizing agent initializes the formation of the first layer of the manganese dioxide and the second layer of the titanium dioxide. In addition, the refinery unit 104 removes the first layer of the manganese dioxide and the second layer of the titanium dioxide from the high grade pig iron present in each of
the one or more ladles 204. Moreover, at step 308, the collecting unit 106 collects the high grade pig iron. In addition, the flow chart 300 terminates at step 310.
?????? Further, the method disclosed in the present disclosure has numerous advantages over prior art. The high grade pig iron facilitates a reduction in a blowing time period of oxygen in steel making process. Moreover, the reduction of the blowing time period reduces fuel consumption. In addition, the addition of the oxides of iron as the oxidizing agents promotes reduction in the amount of the slag. The reduced amount of the slag evidently increases yield of the high grade pig iron. In addition, the reduced amount of the slag is removed easily. The oxides of iron added selectively acts the supplementary iron source and facilitates reduction in flux requirement in the ladle metallurgy process. Moreover, the production of high grade pig iron is cost effective. The method facilitates use of any grade of the one or more iron bearing resources. In addition, the high grade pig iron produced can be directly utilized for steel and nodular iron production. The method reduces quantity of the oxygen blown during steel production.