This application claims priority to and the benefit of Korean Patent
Application No. 10-2013-0164461 filed in the Korean Intellectual Property Office
on December 26, 2013, the entire contents of which are incorporated herein by
reference.
10 BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a method for manufacturing a binder for
a coal briquette and a method for manufacturing the coal briquette including the
same. More particularly, the present invention relates a binder for a coal
15 briquette, that is, condensed molasses solubles (CMS), and a method for
manufacturing the coal briquette including the same.
(b) Description of the Related Art
A melting reduction iron-manufacturing process uses a reducing furnace
for reducing iron ore and a melting gas furnace for melting reduced iron ore.
20 When iron ore is melted in a melting gas furnace, coal briquettes as a heat
source for melting iron ore are charged into the melting gas furnace. At this
time, the reduced iron is melted in the melting gas furnace, converted into a
molten iron and slag, and then discharged to the outside. The coal briquettes
charged into the melting gas furnace form a coal-filled bed. Oxygen is fed
25
3
through a tuyere installed in the melting gas furnace, and then the coalfilled
bed is combusted to produce combustion gas. While the combustion gas
moves up through the coal-filled bed, the combustion gas is converted into hightemperature
reducing gas. The high-temperature reducing gas is discharged
to the outside of the melting gas furnace, and then, as a reducing gas, i5 s
supplied to the reducing furnace.
Generally, a coal briquette is prepared by mixing coal and a binder. In
this case, molasses is used as a binder. The ingredients for the molasses vary
depending on where it comes from, and it is difficult to consistently control the
10 ingredients according to a sugar manufacturing process. Therefore, in the
case where a coal briquette is prepared by using molasses as a binder, it is
difficult to control the quality of the coal briquette. Particularly, in the case of
using high moisture molasses, there are problems in that the quality of the coal
briquette is reduced, and the price of molasses is continuously increased all
15 over the world.
The above information disclosed in this Background section is only for
enhancement of understanding of the background of the invention and therefore
it may contain information that does not form the prior art that is already known
in this country to a person of ordinary skill in the art.
20 SUMMARY OF THE INVENTION
The present invention has been made in an effort to provide a method
for manufacturing a low-priced coal briquette binder for manufacturing molten
iron, which is condensed molasses solubles. The present invention has also
been made in an effort to provide a method for manufacturing a coal briquette
25
4
including the above-described binder.
A method for manufacturing a binder according to an exemplary
embodiment of the present invention is used for a coal briquette for
manufacturing molten iron. A method for manufacturing a coal briquette binder
for manufacturing molten iron includes i) preparing a mixture by mixin5 g
molasses and water, ii) adding an acid to the mixture to which the acid was
added, iii) adding cultured bacterial to the mixture to which the acid was added
for fermentation, and iv) distilling the fermented mixture to remove alcohol.
In the step of preparing the mixture, the concentration of the molasses
10 may be 10 wt% to 15 wt%. A method for manufacturing a binder according to
an exemplary embodiment of the present invention may further include i)
concentrating a mixture, ii) dehydrating the concentrated mixture, and iii)
decanting the dehydrated mixture.
The step for the fermentation of the mixture may include i) a first
15 fermentation step of the mixture for 30 hours to 70 hours, and ii) a second
fermentation step of the mixture. The fermenting temperature of the second
step may be not less than the fermenting temperature of the first step. The
mixture may be fermented at 20 °C to 30 °C in the first step, and then the
mixture may be fermented at 30 °C to 40 °C in the second step. In the step of
20 removing alcohol, the solid content in the mixture after distilling the mixture may
be 95 % or more.
In a method for manufacturing a coal briquette according to an
exemplary embodiment of the present invention, reduced iron is charged into a
dome part of a melting gas furnace and then rapidly heated, in a molten iron-
25
5
manufacturing apparatus including i) the melting gas furnace charged
with the reduced iron and ii) a reducing furnace that is connected with the
melting gas furnace and that supplies the reduced iron. The method for
manufacturing a coal briquette according to an exemplary embodiment of the
present invention includes i) providing condenssed molasses solubles (CMS), ii5 )
preparing another mixture by mixing the binder, pulverized coal, and a hardener,
and iii) molding the mixture to provide the coal briquette. In the step of
providing a binder, the binder includes a protein polymer and ammonia.
In the step of preparing another mixture, the hardener may be one or
10 more of compounds selected from the group consisting of CaO, Ca(OH)2, and
CaCO3. In the step of preparing another mixture, one or more of other binders
selected from the group consisting of molasses, starch, bitumen, PVA, PE, a
silane compound, a thermoplastic resin, arabic acid, glactan, and arabane may
be further added thereto. A step of mixing pulverized coal and a hardener is
15 further included, and the other binder is mixed with the binder and then applied
to the pulverized coal with the added hardener.
In the case where the molasses is further added to the other mixture,
the ratio of the weight of the molasses and the weight of the binder may be 20:1
to 1:20. More preferably, the ratio of the weight of the molasses and the
20 weight of the binder 7:3 to 3:7. A method for manufacturing a coal briquette
according to an exemplary embodiment of the present invention may further
include heating a coal briquette. The step of heating a coal briquette may
include i) a first step of heating a coal briquette at 80 °C to 200 °C, and ii) a
second step of heating a coal briquette at 80 °C to 100 °C. A reducing furnace
25
6
may be a filled bed reduction furnace or a fluidized bed reduction
furnace.
When manufacturing a coal briquette, a coal briquette-manufacturing
cost can be reduced by using condensed molasses solubles as a binder.
Particularly, it is possible to manufacture a coal briquette having the sam5 e
characteristics as the coal briquette manufactured by using a molasses binder,
or excellent characteristics, so that the amount of the molasses binder used can
be reduced. In addition, by using the condensed molasses solubles prepared
through the process of removing an alkali material at the time of preparing a
10 binder, it is possible to prevent the nozzles of the fluidized bed reduction
furnace from clogging.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flowchart illustrating a method for manufacturing a
binder for preparing a coal briquette according to an exemplary embodiment of
15 the present invention.
FIG. 2 is a schematic flowchart illustrating a method for manufacturing a
coal briquette according to an exemplary embodiment of the present invention.
FIG. 3 is a schematic drawing illustrating a molten iron-manufacturing
apparatus using the coal briquette manufactured in FIG. 2.
20 FIG. 4 is a schematic drawing illustrating another molten ironmanufacturing
apparatus using the coal briquette manufactured in FIG. 2.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The terms, such as first, second and third are used for explaining
various parts, components, areas, layers, and/or sections, but the present
25 invention is not limited thereto. These terms are used only for distinguishing
7
any part, component, area, layer, or section from other parts, components,
areas, layers, or sections. Therefore, a first part, component, area, layer, or
section to be described below may be referred to as second part, component,
area, layer, or section within the range of the present invention.
The technical terms used in the present invention are only for describin5 g
a special exemplary embodiment, but it is considered that the present invention
is not limited thereto. The singular forms used in the present invention include
plural forms as long as the phrases do not clearly have a contrary sense. The
meaning of “including” used in the specification specifies a specific
10 characteristic, area, integer, step, action, element, and/or component, but it is
not considered to eliminate the existence or addition of other characteristics,
areas, integers, steps, actions, elements, and/or components.
Unless otherwise defined, all the terms including technical terms and
scientific terms have the same meanings as those generally understood by a
15 person skilled in the art of the present invention. The terms that are defined in
a dictionary and are generally used are not to be interpreted with idealized
meanings or overly formal meanings unless the terms are further interpreted
and defined to have the meanings corresponding to the related technique
documents and the content disclosed now.
20 The present invention will be described more fully hereinafter with
reference to the accompanying drawings, in which exemplary embodiments of
the invention are shown. As those skilled in the art would realize, the
described embodiments may be modified in various different ways, all without
departing from the spirit or scope of the present invention.
25 FIG. 1 is a schematic flowchart illustrating a method for manufacturing a
8
binder for preparing a coal briquette according to an exemplary embodiment of
the present invention. The flowchart of the method for manufacturing a binder
in FIG. 1 is only for illustrating the present invention, and the present invention
is not limited thereto. Therefore, the method for manufacturing a binder can be
diversely modified5 .
Condensed molasses solubles are a by-product of a fermentation
process using molasses and yeast, and conventionally, the by-product is
discharged into a river or the sea, thereby polluting the environment. In
addition, the condensed molasses solubles include a high concentration of K or
10 Mg, so that in the case of using the condensed molasses solubles as a feed, it
can cause digestive problems of domestic animals and the amount thereof is
too large to be used as a fertilizer ingredient. According to an exemplary
embodiment of the present invention, by using such condensed molasses
solubles as a binder, environmental pollution can be prevented.
15 Examples of the condensed molasses solubles may include protein
condensed molasses solubles generated during the process of preparing lysine
and protein, condensed molasses solubles (Vinasses) left at the time of
producing alcohol using beet molasses, and condensed molasses solubles left
at the time of producing alcohol using sugar cane. Such by-products
20 according to a manufacturing process have protein components and ammonia
components, and particularly, such components exist in the protein condensed
molasses solubles. The condensed molasses solubles left at the time of
producing alcohol are subjected to a process of adding ammonia, and thus
ammonia gas is generated by reacting with basic components due to existing
25 ammonia salt. Then, when the salt is removed, an amine derivative remains,
9
thereby generating a bad smell and damaging workers’ health. Cold strength
and hot strength of a coal briquette are maintained by a binder manufactured
through a process in which ammonia is not added at the time of producing
condensed molasses solubles, a minimum amount of protein is used, and it
cannot lead to problems of workers’ health. Therefore, in order to satisfy suc5 h
conditions, a coal briquette binder for manufacturing molten iron is prepared
through the following processes.
As illustrated in FIG. 1, a method for manufacturing a coal briquette
binder for manufacturing molten iron includes i) preparing a mixture by mixing
10 molasses and water S10, ii) adding an acid to the mixture S20, iii) adding
cultured bacterial to the mixture for fermentation S30, iv) distilling the mixture to
remove alcohol S40, v) concentrating the mixture S50, vi) dehydrating the
mixture S60, and vii) decanting the mixture S70. The method for
manufacturing a coal briquette may further include other steps. In addition, the
15 above-described steps S50 to S70 may be omitted according to circumstances.
First, in step S10, molasses and water are mixed to prepare a mixture.
The molasses is diluted at a concentration of 10 wt% to 15 wt%. When the
concentration of molasses is too high, the cost for manufacturing condensed
molasses solubles may be increased. In addition, when the concentration of
20 molasses is too low, the binding effect of the condensed molasses solubles may
be deteriorated. Therefore, the concentration of molasses is controlled in the
above-described range.
Next, in step S20, an acid is added to the mixture. The acid may be,
for example, sulfuric acid. By using an acid, various bacteria included in the
25 mixture may be eliminated, and the optimum pH for the fermentation of a
10
cultured bacteria added for the fermentation in step S30 may be controlled to be
4 to 5. When an acid is added to the mixture, and then aged for about 1 week,
sucrose is separated into glucose and fructose. In addition, by adding an acid,
CaSO4 and MgSO4 are precipitated and then removed. Such inorganic
materials disturb the fermentation, and thus it is preferable to remove th5 e
inorganic material.
In step S30, cultured bacteria are added to ferment the mixture.
Examples of the cultured bacterial may include ATCC 24860S Cerevisiae that is
a yeast for forming enzymes. The mixture may be fermented in a fermentation
10 chamber at a temperature of 20 °C to 30 °C for 30 hours to 70 hours, and then
fermented at 30 °C to 40 °C. That is, the mixture is fermented for 30 hours to
70 hours in a first step and then is fermented again in a second step. The
fermenting temperature of the second step may be not less than the fermenting
temperature of the first step. Fermentation temperature increases step by step
15 and the fermentation time and fermentation temperature may be properly
maintained, thereby producing high-quality alcohol. In the case of obtaining
alcohol through the fermentation, an acid, for example hydrochloric acid, may
be added to the alcohol. A general alcohol by-product is fermented by diluting
it with water in a weight of four times the molasses weight. As the fermentation
20 progresses, the sugar components of the molasses are converted into alcohol
and then the fermentation is completed.
In step S40, the mixture is distilled to remove the alcohol. In other
words, alcohol and products are separated by using a distillation column. An
organic acid, alcohol, and cellulose that are produced in the distillation are
25 reacted to form a thermoplastic resin, and thus the viscosity of the binder is
11
increased. In the step of removing alcohol, the solid content included in the
mixture after distilling the mixture may be 95 % or more. The solid amount is
controlled in the above-described range to enhance the binding effect of protein
components. When moisture and a volatile liquid are distilled from a protein
fermentation by-product to increase the ratio of the solid, the viscosity thereo5 f
can be maximally increased to 40,000 cp. Therefore, the cold strength and hot
strength of the coal briquette prepared in the follow-up processes can be
improved.
Next, step S50 for concentrating the mixture, step S60 for dehydrating
10 the mixture, and vii) step S70 for decanting the mixture are used for removing
alkali components from the binder. Here, step S50 to step S70 may be
continuously repeated. As a result, the alkali components can be removed
from the binder, and thus, in the case of using the coal briquette for
manufacturing molten iron, clogging of a nozzle in a fluidized bed reduction
15 furnace due to alkali materials can be prevented.
In further detail, in step S50, the mixture without alcohol and organic
acid is re-concentrated. To achieve this, before performing step S50,
ammonium sulfate may be added to the mixture. As a result, the content of the
inorganic materials in the mixture is relatively increased. The by-product left
20 when removing alcohol and organic acid is concentrated. The concentration
may be performed according to binding conditions to increase the concentration.
When the solid is concentrated to be an amount of 70 wt% to 85 wt%, the
concentration of the solid becomes the same as the concentration of molasses.
In addition, the viscosity of the concentrate is 30,000 cp to 40,000 cp that is a
25 similar viscosity to molasses. When the condensed molasses solubles used
12
as a coal briquette binder includes 10 wt% or more of the solid, it may be used
either singly or in combination with other binders.
In step S60, the mixture is dehydrated to remove the water component.
In this time, potassium sulfate, ammonium sulfate, nitrogen, and potassium that
are used as fertilizer can be isolated, and by using these wastes, condense5 d
molasses solubles can be prepared.
For by-products left after producing alcohol among condensed molasses
solubles, the components of the by-product in the case of using ammonia
components are different from the components of the by-product in the case of
10 not using ammonia components. The components of the by-products after the
alcohol fermentation without using ammonia include sugar, other organic
materials, inorganic materials, and water. Here, the sugar is included in an
amount of 1 wt% to 50 wt%, other organic materials are included in an amount
of 1 wt% to 90 wt%, inorganic materials are included in an amount of 0.5 wt% to
15 30 wt%, and the solid amount may be controlled. The liquid and volatile
materials in the alcohol by-product are removed at 10 °C to 100 °C and low
pressure of 300 mPa.
In step S70, condensed molasses solubles may be prepared through
decantation. Step S50 to step S70 are continuously repeated to remove the
20 alkali materials, particularly K.
The properties of condensed molasses solubles prepared through the
manufacturing method of FIG. 1 are listed in the following Table 1.
As listed in Table 1, the viscosity of condensed molasses solubles can
be significantly increased according to the operation conditions.
25 (Table 1)
13
Condensed molasses solubles Ratio (%)
Physical
properties
pH 3-9
Specific gravity 3.8-4.2
Viscosity (cps) 2-40,000
Brix 40-95
FIG. 2 is a schematic flowchart illustrating a method for manufacturing a
coal briquette according to an exemplary embodiment of the present invention.
The flowchart of the manufacturing method of FIG. 2 is only for illustrating the
present invention, and the present invention is not limited thereto. Therefore,
the method for manufacturing a coal briquette can be variably modified5 .
As illustrated in FIG. 2, the method for manufacturing a coal briquette
includes i) providing pulverized coal S100, ii) adding a binder and hardener to
the pulverized coal to provide a mixture S200, iii) adding another binder to the
mixture S300, iv) molding the mixture to provide a coal briquette S400, and v)
10 heating the coal briquette S500. The method for manufacturing a coal
briquette may further include other steps.
First, in step S100, pulverized coal is provided. The pulverized coal is
used as a raw coal. Moisture is mixed with the pulverized coal in advance to
maintain the amount of moisture included in the pulverized coal to be 6.5 wt% to
15 9.5 wt%. In the case where the amount of moisture mixed in the pulverized
coal is controlled in the above-described range, the moisture may close the
pores in the particles of pulverized coal. As a result, a hardener and binder to
be mixed in the following processes do not penetrate into the particles of the
pulverized coal, and thus exist on the outside of the particles of the pulverized
20 coal. Therefore, the particles of pulverized coal are well bound to each other,
14
and thereby hot strength and cold strength of the coal briquette can be
efficiently improved.
Next, in step S200, a binder and hardener are added to the pulverized
coal to provide a mixture. The mixture may be mixed for 3 minutes to 10
minutes. At this time, the above-described condensed molasses solubles ma5 y
be used as a binder. The physical properties of the coal briquette prepared by
using the condensed molasses solubles as a binder are similar to the physical
properties of a coal briquette prepared by using molasses as a binder.
Therefore, by replacing a high-priced molasses binder with a condensed
10 molasses solubles binder, which is basically waste, the cost for manufacturing a
molten iron can be significantly reduced. As a hardener, CaO, Ca(OH)2, MgO,
Mg(OH)2, K2O, KOH, Na2O, NaOH, CaCO3, phosphoric acid, or sulfuric acid
may be used. More preferably, by forming a binder and a salt using CaO,
Ca(OH)2 and CaCO3, the coal briquette may be hardened by the binding of
15 calcium saccharate. The hardener may be added in an amount of 1 part by
weight to 3 parts by weight with respect to 100 parts by weight of the coal
briquette.
Meanwhile, in step S300, another binder is added to the mixture. At
this time, the other binder may be molasses, starch, bitumen, PVA, PE, a silane
20 compound, a thermoplastic resin, arabic acid, glactan, or arabane. The other
binder includes 50 wt% or less of moisture. When the moisture content in the
binder exceeds 50 wt%, it is difficult to prepare a coal briquette. Among the
above-described another binders, molasses and starch are easily fermented.
Therefore, the binder prepared from FIG. 1 is mixed with molasses or starch,
25 and then applied to the pulverized coal added with a hardener to prevent the
15
fermentation of molasses or starch. As a result, the deterioration of the
strength of the coal briquette can be prevented.
Further, the binder that is condensed molasses solubles may be used
without adding another binder to the mixture. In addition, the other binder may
be first added to the pulverized coal, and then, the binder that is condense5 d
molasses solubles may be mixed therein. In addition, polymer materials such
as siloxane, PVA (polyvinyl alcohol), or PE (polyethylene) may be used as a
waterproof agent. The polymer materials may be dispersed in water and then
used.
10 Meanwhile, in the case of adding molasses to a mixture, the ratio of the
weight of the molasses and the weight of the binder may be 20:1 to 1:20.
More preferably, the ratio of the weight of the molasses and the weight of the
binder may be 7:3 to 3:7. When the amount of the molasses is much higher
than the amount of the binder, the cost for manufacturing a coal briquette is
15 increased. In addition, if the amount of the binder is much lower than the
amount of the molasses, cold strength and hot strength of the coal briquette are
slightly deteriorated. Therefore, the amounts of the molasses and binders are
controlled in the above-described range.
In step S400, the mixture is molded to prepare a coal briquette. For
20 example, although not illustrated in FIG. 3 and FIG. 4, the mixture may be
charged between twin rolls rotating in opposite directions to prepare a coal
briquette as a pocket or strip type.
Finally, in step S500, the prepared coal briquette may be heated.
When the condensed molasses solubles in the case of preparing the protein
25 using ammonia is used as a binder, the condensed molasses solubles are
16
composed of protein components, such as a protein polymer and lysine, nonfermented
monosaccharides, ammonium sulfate, calcium sulfate, and inorganic
components. Therefore, it is necessary to heat the coal briquette in order to
express the strength of the lysine and protein polymer, such as gelatin. In this
case, heat of 80 °C to 300 °C is applied to the coal briquette to harden th5 e
protein and polymer. When the heating temperature of the coal briquette is
very low, the polymer incorporated into the binder is not well melted, and thus
the cold strength and hot strength of the coal briquette may be deteriorated. In
addition, when the heating temperature of the coal briquette is very high, the
10 binder comes loose, and thus the coal briquette may not be molded. Therefore,
the heating temperature of the coal briquette is controlled to be the abovedescribed
range to improve the cold strength and hot strength of the coal
briquette.
In more detail, the step of heating a coal briquette includes i) a first step
15 of heating a coal briquette at 80 °C to 200 °C, and ii) a second step of heating a
coal briquette at 80 °C to 100 °C. For example, first, the coal briquette may be
heated at 80 °C to 200 °C. When the heating temperature of the coal briquette
is very low, the improvement in cold strength and hot strength of the coal
briquette is negligible. In addition, when the heating temperature of the coal
20 briquette is very high, the coal briquette may be differentiated in advance.
Therefore, the heating temperature of the coal briquette is controlled to be in the
above-described range.
FIG. 3 is a schematic drawing illustrating an apparatus for
manufacturing molten iron using the coal briquette manufactured in FIG. 2.
25 The molten iron-manufacturing apparatus 100 of FIG. 3 is only for illustrating
17
the present invention, and the present invention is not limited thereto.
Therefore, the molten iron-manufacturing apparatus 100 of FIG. 3 may be
variously modified.
As illustrated in FIG. 3, the molten iron-manufacturing apparatus 100
includes a melting gas furnace 10, a fluidized bed reduction furnace 22, 5 a
reduced iron compression device 40, and a compression reduced iron reservoir
50. The compression reduced iron reservoir 50 may not be provided.
The prepared coal briquettes are charged into the melting gas furnace
10, form a coal-filled bed inside the melting gas furnace 10. The coal
10 briquettes generate reducing gas in the melting gas furnace 10, and the
generated reducing gas is supplied to the fluidized bed reduction furnace 22.
Fine iron ore is supplied to a plurality of fluidized bed reduction furnaces 22
each having a fluidized bed, is fluidized by the reducing gas supplied into the
fluidized bed reduction furnaces 22 from the melting gas furnace, and then
15 becomes reduced iron. The reduced iron is compressed by the reducing iron
compression device 40, and then stored in the compression reduced iron
reservoir 50. The compressed reduced iron is supplied from the compression
reduced iron reservoir 50 to the melting gas furnace 10, and then melted in the
melting gas furnace 10.
20 A dome part 101 is formed at the top of the melting gas furnace 10.
That is, a wide space is formed as compared with other parts of the melting gas
furnace 10, and high-temperature reducing gas is directed to the wide space.
Therefore, the coal briquettes charged into the dome part 101 are easily
differentiated by the high-temperature reducing gas. In other words, the coal
25 briquettes are charged to the top of the melting gas furnace that is maintained
18
at 1000 °C, and thus the coal briquettes are quickly shocked by heat.
Therefore, while the coal briquettes are moved to the lower part of the melting
gas furnace, the coal briquettes may be differentiated.
However, since the coal briquettes prepared according to the method of
FIG. 1 have high hot strength, the coal briquettes are not differentiated at th5 e
dome part 101 of the melting gas furnace 10, and fallen to the lower part of the
melting gas furnace 10. The char produced by the pyrolytic reaction of the
coal briquettes is moved to the lower part of the melting gas furnace 10, and
then subjected to an exothermic reaction with oxygen supplied from a tuyere 30.
10 As a result, the coal briquettes may be used as a heat source for maintaining
the melting gas furnace 10 at a high temperature. Meanwhile, since the char
exhibits a breathable property, a large amount of gas generated at the lower
part of the melting gas furnace 10 and reduced iron supplied from the fluidized
bed reduction furnace 22 can be easily and uniformly passed through the coal15
filled bed in the melting gas furnace 10.
In addition to the above-described coal briquettes, if necessary, lump
coal ash or coke may be charged into the melting gas furnace 10. The tuyere
30 is provided on the external wall of the melting gas furnace 10 to feed oxygen.
Oxygen is fed into the coal-filled bed and forms a combustion zone. The coal
20 briquettes may be combusted in the combustion zone to generate reducing gas.
Meanwhile, unlike an exemplary embodiment of the present invention, in
the case where the coal briquettes prepared with a molasses binder are
charged into the melting gas furnace, volatile materials that are hydrocarbons in
the coal briquettes are generated due to internal heat of the melting gas furnace.
25 In this case, the alkali materials included in the molasses included in the coal
19
briquettes are volatilized. Although the alkali materials have high boiling
temperatures due to high vapor pressure, the alkali materials are changed as a
gas, and then the gaseous alkali materials are supplied to the fluidized bed
reduction furnace along with the gas generated in the melting gas furnace. A
distributing plate having a plurality of nozzles for spraying a gas in order 5 to
perform the fluidized reduction of the fine ore is provided inside the fluidized bed
reduction furnace. When the gas including alkali materials is fed into the
fluidized bed reduction furnace, the above-described nozzles are contacted
thereto. In this case, the temperature of the melting gas furnace is 1000 °C or
10 more, while the temperature of the fluidized bed reduction furnace is 800 °C or
less.
Therefore, the gaseous alkali components are easily condensed and
precipitated in the nozzles. The nozzle is mostly made of metal materials, and
thus is corroded due to alkali components and clogged by a reaction with dust
15 included in the reducing gas. When the nozzle is clogged, it is difficult to
supply gas to the fluidized bed reduction furnace through a distributing plate,
and thus it causes serious problems in the molten iron-manufacturing process.
On the contrary, according to an exemplary embodiment of the present
invention, the condensed molasses solubles without alkali components are
20 used as a binder. Therefore, as binder does not include alkali materials, the
clogging of the nozzles in the fluidized bed reduction furnace 22 can be
prevented.
As a result, according to an exemplary embodiment of the present
invention, the efficiency of the operation of the fluidized bed reduction furnace
25 22 can be improved. In addition, the cold strength of the coal briquettes can
20
be maximized by using sucrose as a binder, and the cost for manufacturing the
coal briquettes can be reduced by using raw sugar. In addition, the efficiency
of the operation of the fluidized bed reduction furnace can be maximized, and
the distribution cost for long-distance transportation of molasses can be
reduced5 .
The changes before and after using the condensed molasses solubles
as a binder are exemplarily listed in the following Table 2. When the
condensed molasses solubles are used as a binder, the amount of the
molasses may be decreased by about 682 g/t-p. Therefore, the amount of
10 high-priced molasses can be reduced, and thus the manufacturing cost can be
decreased.
(Table 2)
NO
Raw
material
name
Before using condensed
molasses solubles
After using condensed
molasses solubles
1 Ore 293.1 g/t-p 293.1 g/t-p
2
Sub-raw
material
243.0 g/t-p 243.0 g/t-p
3 Coal 604.2 g/t-p 604.2 g/t-p
4 Molasses 974.3 g/t-p 292.3 g/t-p
Total 2,114.6 g/t-p 2114.6 g/t-p
FIG. 4 is a schematic drawing illustrating another molten iron15
manufacturing apparatus using the coal briquette manufactured in FIG. 2. The
structure of the molten iron-manufacturing apparatus 200 illustrated in FIG. 4 is
21
similar to the structure of the molten iron-manufacturing apparatus 100
illustrated in FIG. 3, and thus the same parts are indicated by using the same
reference numerals and the detailed descriptions thereof are not provided.
In addition, the structure of the molten iron-manufacturing apparatus 200
illustrated in FIG. 4 is only for illustrating the present invention, and the presen5 t
invention is not limited thereto. Therefore, the molten iron-manufacturing
apparatus illustrated in FIG. 4 may be variously modified.
The molten iron-manufacturing apparatus 200 illustrated in FIG. 4
includes a melting gas furnace 10 and a filled bed reduction furnace 20. In
10 addition, the molten iron-manufacturing apparatus 200 may include other
devices if necessary. Iron ore is charged into the filled bed reduction furnace
20, and then reduced. The iron ore charged into the filled bed reduction
furnace 20 is dried in advance, and then, while being passed through the filled
bed reduction furnace 20, the iron ore becomes reduced iron. The reduced
15 gas is supplied from the melting gas furnace 10 to the filled bed reduction
furnace 20, and thus the filled bed is formed inside the filled bed reduction
furnace 20.
Hereinafter, the present invention will be described in more detail with
reference to experimental examples. These experimental examples are only
20 for illustrating the present invention, and the present invention is not limited
thereto.
Experimental Examples
Binder preparation and pulverized coal-preparing experiments
Alcohol was distilled without using ammonia. In addition, the moisture
25 in CMSa was distilled at 50 mPa to 100 mPa to prepare a binder, condensed
22
molasses solubles. The distillation time varied to prepare condensed
molasses solubles binders having solid content of 56 wt% and 72 wt%,
respectively.
The amount of pulverized coal having a particle size of 3 mm or less
was controlled to be 90 %, and the amount of moisture was controlled to be 65 .5
wt% to 9.5 wt%. 1 part by weight to 5 parts by weight of quicklime was added
with respect to 100 parts by weight of the pulverized coal, and then mixed for 3
minutes to 10 minutes to prepare a mixture.
The components of the binders applied for the experimental examples of
10 the present invention are listed in the following Table 3. It can be confirmed
that each of the binders includes components such as C, H, N, S, K, and Na,
and also inorganic components.
(Table 3)
Type
Cane
Alcohol
CMS (a)
Beet Root
Alcohol
CMS (b)
Lysine
CMS (L)
Cane
Alcohol
CMS a2
Cane
Molasses
Elementary
analysis
C 37.9 31.3 32.6 38.3 44.7
H 5.89 6.57 8.47 5.37 5.13
N 1.99 8.65 10.2 2.71 1.78
S 0.31 0.700 5.83 1.05 0.92
Alkali
(%)
K 3.4 2.4 0.12 1.5 3.19
N
a
0.27 1.44 0.96 0.96 0.03
Viscosity (cp) 280 182 346 9.9 27,345
23
Other organic
components
Arabans
10 %
Galactans
10 %,
Arabinose
5 %,
Raffinose
5 %
Pectin,
Humic
acid,
Calcium
lactate,
Arabic
acid,
Butyric
acid,
Aconic
acid,
Phenoliron
complex,
Caramel,
Melanoidi
Arabans
10 %
Galactans
10 %,
Arabinose
5 %,
Raffinose
5 %
Pectin
5 %
Humic acid,
Calcium
lactate,
Arabic acid,
Butyric acid,
Aconic acid,
Phenol-iron
complex,
Caramel,
Melanoidin,
Amino acid,
Betaine
Glycerine
Glutamic
Arabans
5 %
Galactans
5%,
Arabinose
1 %,
Raffinose
1 %
Protein
33 %
Gelatin
Vitamin
Arabans
1 %
Galactans
1 %,
Arabinose
(0.5 %),
Raffinose
(0.5%)
Pectin,
Humic acid,
Calcium
lactate,
Arabic acid,
Butyric acid,
Aconic acid,
Phenol-iron
complex,
Caramel,
Melanoidin,
Glycerine
Arabans
5 %
Galactans
5 %,
Arabinose
(2.5 %),
Raffinose
(2.5%)
Pectin,
Humic acid,
Calcium
lactate,
Arabic acid,
Butyric acid,
Aconic acid,
Phenol-iron
complex,
Caramel,
Melanoidin
Amino acid
24
n,
Glycerine
Acid
32.4 38.5 48.2 10.3 17.8
Coal and binder-mixing experiment
Molasses as a first binder was mixed with the above-described mixture.
Condensed molasses solubles as a second binder were mixed for 3 minutes.
The first binder and the second binder were added part from each other on th5 e
mixture in a circle so as to not mix the first binder and the second binder, and
then they were mixed for 3 minutes. The mixture prepared by adding the first
binder to the pulverized coal was heated at 80 °C to 200 °C. In the case of
using starch as a binder, the mixture was heated at 90 °C to 200 °C by applying
10 hot water or steam. The condensed molasses solubles were heated at 100 °C
to 200 °C, heated in a state of applying water at 80 °C to 200 °C, or heated by
applying steam at 80 °C to 200 °C. When the condensed molasses solubles
were polymers, the mixture was heated at 50 °C to 200 °C, heated in a state of
applying water at 50 °C to 200 °C, or heated by applying steam at 50 °C to
15 200 °C.
The starch mixed as a second binder was heated by applying water or
steam at 90 °C to 200 °C. The mixture mixed with the first binder and the
second binder was molded to prepare the coal briquettes. The coal briquettes
were heated at 80 °C to 200 °C for 2 hours. Otherwise, the coal briquettes
20 were heated at 100 °C to 200 °C for 2 hours or heated at a heating rate of
1 °C/s to 50 °C/s for 1 hour in a range of 1 °C to 5 °C at 80 °C to 100 °C. The
coal briquettes were then heated at 100 °C to 200 °C for 1 hour.
25
Experimental Example 1
10 parts by weight of 72 % CMS was used with respect to 100 parts by
weight of the pulverized coal to prepare the coal briquettes. The remaining
experimental processes were the same as the above-described experimental
example5 .
Experimental Example 2
10 parts by weight of 56 % CMS was used with respect to 100 parts by
weight of the pulverized coal to prepare the coal briquettes. The remaining
experimental processes were the same as the above-described experimental
10 example.
Experimental Example 3
3 parts by weight of 72 % CMS and 7 parts by weight of a molasses
binder were mixed with respect to 100 parts by weight of the pulverized coal to
prepare the coal briquettes.
15 The remaining experimental processes were the same as the abovedescribed
experimental example.
Experimental Example 4
5 parts by weight of 56 % CMS and 5 parts by weight of a molasses
binder were mixed with respect to 100 parts by weight of the pulverized coal to
20 prepare the coal briquettes. The remaining experimental processes were the
same as the above-described experimental example.
Experimental Example 5
3 parts by weight of 72 % CMS and 7 parts by weight of a molasses
binder were mixed with respect to 100 parts by weight of the pulverized coal to
25 prepare the coal briquettes. The remaining experimental processes were the
26
same as the above-described experimental example.
Experimental Example 6
5 parts by weight of 72 % CMS and 5 parts by weight of a molasses
binder were mixed with respect to 100 parts by weight of the pulverized coal to
prepare the coal briquettes. The remaining experimental processes were th5 e
same as the above-described experimental example.
Experimental Example 7
7 parts by weight of 72 % CMS and 3 parts by weight of a molasses
binder were mixed with respect to 100 parts by weight of the pulverized coal to
10 prepare the coal briquettes. The remaining experimental processes were the
same as the above-described experimental example.
Comparative Example 1
10 parts by weight of the molasses binder was mixed with respect to
100 parts by weight of the pulverized coal to prepare the coal briquettes. The
15 remaining experimental processes were the same as the above-described
experimental example.
Experiment results
The results of measuring the cold strengths and compression strengths
of the coal briquettes prepared according to the above-described Experimental
20 Example 1 to Experimental Example 7, and Comparative Example 1, are listed
in the following Table 4.
In Table 4, the compression strengths and falling strengths are
measured cold strengths of the coal briquettes, and HTS 16, HTS 13, HTS 10,
and IDrum are measured hot strengths of the coal briquettes. The measuring
25 processes of the compression strengths and cold strengths of the coal
27
briquettes are known by a person skilled in the art of the present invention, and
thus the detailed descriptions about them are not provided. (Table 4)
Experim
ental
Example
1
Experime
ntal
Example
2
Experim
ental
Example
3
Experim
ental
Example
4
Experime
ntal
Example
5
Experime
ntal
Example
6
Experim
ental
Example
7
Comparative
Example
1
Mixing
ratio
Moisture 5.5-8.5 5.5-8.5 5.5-8.5 5.5-8.5
5.5-
8.5
5.5-
8.5
5.5-
8.5
5.5-8.5
CaO 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7
Molasses 0 0 7 5 7 5 3 10
CMS a
56 %
0 10 3 5 0 0 0 0
CMS b
56 %
10 0 0 0 3 5 7 0
Mixing
amount
(g)
Compres
sion
strength
47.3 43.9 46.1 46.8 45.9 46.8 47.2 45.9
Falling
strength
4 times
96.3 90.4 95.4 93.2 96.4 94.6 90.2 95.2
HTS 16 13.6 8.8 22.6 21.9 22.6 21.9 22.6 16.7
HTS 13 63.2 50.5 68.2 68.7 68.2 68.7 68.2 69.1
HTS 10 90.6 85.6 92.2 92.0 92.2 92.0 92.2 92.7
I-Drum 75.1 61.0 78.3 76.3 78.3 76.3 78.3 79.7
Binder 28.2 44.2 30.1 34.1 30.1 34.1 30.1 24.0
28
moisture
(%)
As listed in Table 4, it can be confirmed that the cold strengths and hot
strengths of the coal briquettes prepared according to Experimental Example 1
to Experimental Example 7 are slightly higher or the almost same level as
compared with the coal briquette prepared according to Comparative Example 1.
Even in the case of preparing the coal briquettes only using condense5 d
molasses solubles like Experimental Example 1 and Experimental Example 2,
similar results are exhibited. Therefore, it is confirmed that the conventional
molasses binder can be replaced with a condensed molasses solubles binder.
Price comparison
10 The price comparison between the above-described condensed
molasses solubles and molasses are as listed in the following Table 5. As
listed in the following Table 5, the price of condensed molasses solubles is
about 35 % to 40 % of the molasses price. Therefore, in the case of using the
condensed molasses solubles instead of a molasses binder, the molten iron15
manufacturing cost can be significantly reduced.
(Table 5)
NO Binder Item Note
1 Molasses USD 160-180
2 Alcohol CMS
Expectation of 70,000
won
It is now waste.
3 Lysine CMS
Expectation of 70,000
won
It is now used as feed and
fertilizer.
29
While this invention has been described in connection with what is
presently considered to be practical exemplary embodiments, it is to be
understood that the invention is not limited to the disclosed embodiments, but,
on the contrary, is intended to cover various modifications and equivalent
arrangements included within the spirit and scope of the appended claims5 .

WE CLAIMS:-
1. A method for manufacturing a binder for a coal briquette for
manufacturing a molten iron, the method comprising:
preparing a mixture by mixing molasses and water5 ;
adding an acid to the mixture;
fermenting the mixture by adding cultured bacteria to the mixture to
which the acid was added; and
removing alcohol by distilling the fermented mixture.
10
2. The method of claim 1, wherein in the step of preparing the
mixture, a concentration of the molasses is 10 wt% to 15 wt%.
3. The method of claim 1, the method further comprising:
15 concentrating the mixture;
dehydrating theconcentrated mixture; and
decanting the dehydrated mixture.
4. The method of claim 1, wherein the step of fermenting the
20 mixture includes:
a first step of fermenting the mixture for 30 hours to 70 hours; and
a second step of fermenting the mixture, and
wherein the fermenting temperature of the second step is not less than
the fermenting temperature of the first step.
25
31
5. The method of claim 1, wherein the mixture is fermented at 20 °C to
30 °C in the first step, and then the mixture is fermented at 30 °C to 40 °C in the
second step.
6. The method of claim 1, wherein in the step of removing th5 e
alcohol, an amount of a solid included in the mixture after distilling the mixture is
95 % or more.
7. A method for manufacturing a coal briquette, wherein reduced
10 iron is charged into a dome part of a melting gas furnace and then quickly
heated in the melting gas furnace, in a molten iron-manufacturing apparatus
including the melting gas furnace charged with the reduced iron and including a
reducing furnace that is connected to the melting gas furnace and that supplies
the reduced iron,
15 wherein the method includes:
providing condenssed molasses solubles (CMS);
preparing another mixture by mixing the binder, pulverized coal, and a
hardener; and
molding the mixture to provide a coal briquette, and
20 wherein, in the step of providing the binder, the binder includes a protein
polymer and ammonia.
8. The method of claim 7, wherein, in the step of preparing the
32
other mixture, the hardener is at least one compound selected from the
group consisting of CaO, Ca (OH)2, and CaCO3.
9. The method of claim 7, wherein, in the step of preparing the
other mixture, at least one other binder selected from the group consisting 5 of
molasses, starch, bitumen, PVA, PE, a silane compound, a thermoplastic resin,
arabic acid, glactan, and arabane is further added thereto.
10. The method of claim 9, wherein the method further includes
10 mixing the pulverized coal and the hardener and mixing the other binder with
the binder, and then the mixture thus obtained is applied to the pulverized coal
with the added hardener.
11. The method of claim 9, wherein, in the case of further adding
15 molasses to the other mixture, a ratio of the weight of the molasses and the
weight of the binder is 20:1 to 1:20.
12. The method of claim 10, wherein the ratio of the weight of the
molasses and the weight of the binder is 7:3 to 3:7.
20
13. The method of claim 7, the method further comprising
heating the coal briquettes,
wherein the step of heating the coal briquettes includes
a first step of heating the coal briquettes at 80 °C to 200 °C, and
25
33
a second step of heating the coal briquettes at 80 °C to 100 °C.
14. The method of claim 7, wherein the reducing furnace is a filled
bed reduction furnace or a fluidized bed reduction furnace.