Metallurgical briquette: Basic information

Authors:

1. “EcoMashGeo” Ltd.

Koteniov Vasilyi Iliich

Kitaev Alexander Andreevich

Barsukova Elena Yurievna

2. Moscow State Institute of Steel and Alloys (The Technological University)

Kurunov Ivan Philipovich

3. “Tulachermet” Plc.

Vlassov Vladimir Ivanovich

Murat Sergei Gavrilovich

4. Republican Unitary Plant “Byelorussian Metallurgical Plant”

Matochkin Victor Arkadievich

Anders Vladimir Vladimirovich

Steblov Anver Borisovich

5. “Hanino Ironworks” Close Corporation

Laptev Oleg Victorovich

6. Federal National Unitary Enterprise «National Scientific Centre of “Timber Industry Complex»

Saraikin Valeri Georgievich

Contents

Introduction……………………………………………………………………..4

The state policy in the sphere of environmental protection.

The situation in the sphere of waste utilization and recycling

abroad and in Russia.

The urgency of utilization and recycling of industrial waste.

The technology of metallurgical briquettes production………………..11

The method of production of iron-carbon-containing briquettes.

The comparative analysis of the charge preparation according to

the traditional method and our technology.

The technological scheme of production of metallurgical briquettes.

The metallurgical value of iron-carbon-containing briquettes……….15

The types of briquettes.

The mineral-graphic efforts of the processes within briquettes.

Charcoal in metallurgy……………….……………………………….………18

The calculation of the economic effectiveness of briquettes usage…19

The calculation of the economic effectiveness of briquettes

usage in blast-furnace production.

The calculation of the economic effectiveness of briquettes

usage in steel-making production.

The tests of introduction of briquettes into metallurgical refinings….22

The test of introduction of briquettes into blast-furnace production.

The test of introduction of briquettes into electric furnace steelmaking.

The test of introduction of briquettes into open-hearth production.

The test of introduction of briquettes into foundry.

References…….…………………………………………………………..…..36

8. The presentation of the technology of utilization and recycling

of industrial waste…………………….………………………………………….38

9. Conclusion……..……………………………………………………………….39

10. The list of the literature………………………………………………………41

Подпись: 1.1. The policy of Russia in the sphere of environmental
protection.

The current situation in Russia in the sphere of formation, storage, usage (recycling) and utilization

of industrial waste leads to dangerous pollution of the environment, unpractical usage of natural

resources and consequently to considerable economic damage.

Around 80 billion tons of hard waste of metallurgical, machine building, mineral resource and chemical industries and of fuel and energy complexes have been accumulated in the dumps and deposits of our country. Every year around 7 million tons of such waste are formed in Russia. Those are in fact handmade man-caused deposits, material resources that had been removed from the economic circulation. Many types of these mineral resources do not exist nowadays.

By volume, content and composition of useful components being in industrial waste, the stocks of man-caused deposits are comparable to the natural deposits in use.

There is also a reasonable suspicion that the real reserves of the man-caused deposits are much higher than it is officially stated.

For example, the geologists of the USSR used to be paid award for a discovered deposit, whose amount depended on its volume; that is why there was a stimulus to raise the volume too high (for example, Urengoi, where the original valuation of oil and gas reserves turned out to have been raised too high (almost two times more) in comparison to the reality).

The representatives of metallurgy, chemical, machine-building and other industries understate the volume of emission in order to decrease the ecological payment that a plant pays for every ton of waste. So, one can only guess the amount of reserves of industrial waste on the territory of the countries of the Commonwealth of Independent States and in Russia in general.

The waste that contains toxic as well as carcinogenic substances causes alarm as the total amount of it has reached 1,6 billion tons.

For example, for today in Tula region more than 17 million tons of waste of metallurgical and chemical plants that contain compounds of various metals (iron in the first place) have been accumulated.

Such vast deposits occupy huge areas close to men’s habitation. Around 10 000 hectares of off-the-shelf land are being used for grounds and dumps of solid industrial waste annually in Russia. One can only guess the areas that are occupied by unsanctioned dumps. The existing situation is a real threat to the health of the current and future generations of the country.

Today “EcoMashGeo” Ltd. has a unique technology of identification of the verges and volumes of man-caused waste deposits of different regions, located at a depth of up to 150 meters with the resolving ability up to 0.2 meters. This technology differs from the traditional geo-radar technologies as it has a better self-descriptiveness, resolving ability and depth of exploration.

The exhaustion of natural resources and the global character of pollution of the environment have aggravated the necessity of rational combination of flexibility of the market economy capable of a quick material reorientation and a far-sighted national policy of nature management stimulating waste usage and reducing the negative impact on the environment.

“The Ecological Doctrine of the Russian Federation” (confirmed by the decree of the Government of the Russian Federation on 31^st of August, 2002, №1225-p) defines the tendency of the development of systems of recycled resources usage including waste recycling as well as introduction of resource-saving and wasteless technologies in all spheres of economical activity as a priority tendency of the national policy in the ecology sphere.

One of the ways of succeeding the strategic aim of the national policy in the ecology sphere is maximal profound usage of the extracted minerals and mined biological resources as well as minimization of waste and damage to natural environment. The working out of the effective national policy in the sphere of waste management hasn’t been finished yet.

The formation of modern norm and technological data for generation and realization of the effective public policy in the sphere of waste recycling requires the solution of this problem at the federal level, as this problem is significant for the functioning of the economy on the whole, of its single branches and regions, for the social development and living conditions of the population.

A close analysis of the situation on the one hand and scientific and technical reserves on the other hand show that against a background of steady reduction of natural resources reserves, their net cost advance, a constant advance of energy supply and rail transport rates, the necessity of competent raw material reorientation of metallurgical, machine building, mineral resource and chemical industries and fuel and energy complexes has arisen.

The location of waste near to the plants does not require huge expenditures on exploring and opening up, routine and patented practice ensure its usage as relatively cheap raw material for different plants, that noticeably (30-50%) lowers net cost of finished products. Recycling of waste will help to solve the ecological problem of purification of industrial regions.

Подпись: 1.2. The situation in the sphere of waste utilization and recycling
abroad and in Russia.

The complex management of utilization and recycling of industrial waste is a world recognized principle of natural resources management today. Several countries, mainly in Western Europe and Northern America, began to use this principle of industrial waste utilization and recycling in the mid seventies.

After the USSR decay, Russia is still one of the biggest suppliers of raw materials, i.e. of industrial waste.

The current situation in the Russian Federation in the sphere of formation, storage, usage (recycling) and utilization of industrial waste leads to dangerous pollution of the environment, and to noticeable economic damage.

Most of waste, generated both in industrial and communal cities, is literally a resource. That is why it is necessary to switch to a new paradigm regarding hard industrial waste: it is possible not to annihilate this waste and store it in “mortuaries”, but to economically use it. In Russia, unlike in the Occident where active national policy in the sphere of secondary usage of industrial waste is being pursued, the part of secondary resources in the raw material balance is insignificant.

Difference between the level of industrial waste usage can be traced by the example of the usage of ashes of thermal power stations.

Ash-and-slag waste of ashes of thermal power stations in Germany are used by 80%, in France by 65%, in the UK by 53%, in Moscow area (the most advanced innovative technologies) only by 1,03%. So, ash and slag are not being used in fact near Moscow, i.e. they are not applied and their piling in the region is more than 20 million tons.

The situation is the same in the sphere of fine-fractional fine iron-containing waste recycling.

In 1998 in Russia the act “About waste of industries and consumption”, aimed at prevention of detrimental effect of industrial waste on population health and environment, reducing the population catastrophe in the regions and reducing waste production and involving them in economic circulation as raw material was promulgated. The federal program “Waste” was created with the purpose of gaining the annual recycling and usage of 55 billion tons of waste and of saving 20-25% of material and technical resources and of reduction of areas for waste with the perspective of creation of capacious market of resource saving, ecologically free and low-waste technologies, as well as waste recycling technologies. The perspectives of program realization are obscure owing to liquidation of program customer, the State Ecology Committee of Russia in 2000 and owing to a standard Russian problem of underfinancing.

A close analysis of “The Ecological Doctrine of the Russian Federation” (confirmed by the decree of the Government of the Russian Federation on 31^st of August, 2002, №1225-p) shows that this document does not ensure a complex approach to the questions of environmental protection and management of waste recycling. Based on this document norm and legal data is rather complex and ineffective, deserves no credit. All that leads to difficulties in its application.

The lack of mechanisms of development and management policy of waste utilization and recycling processes in regions and federal regions gave cause to the development of the offered technology.

“EcoMashGeo” Ltd. sees the solving of the existing problems in the model of industrial waste recycling management as a whole environmental ecological system. The main ecological problem of Russia is the lack of definite and distinct organizational model of management, that would reflect regional approach, consider administrative division of Russia, the possibility to use man-caused waste of near by regions, and that would open possibilities for effective interaction of different management levels in the subjects of Russia.

For today local authorities do not take part in the process of making decisions in the questions of industrial waste utilization and recycling management at the level of municipal units and the subjects of Russia.

The principle “who pollutes more, pays more” does not work: the existing payments for pollution of the environment are sources of enriching budgets of different levels and only partially used to finance actions on industrial waste utilization and recycling and environmental protection.

On the basis of the said above it is possible to draw a conclusion: today there is not a single body at the federal level, in the subjects of Russia or municipal units, that would be responsible for utilization and recycling of industrial waste and men waste.

That can become a serious obstacle for effective and complex solving of the problems posed in the Ecological Doctrine of the Russian Federation.

The traditional solution of ecological problems is unprofitable, and does not make a profit for a plant. The technology of industrial waste utilization and recycling that we offer ensures not only the solution of the existing ecological problems, but is high-performance and profitable.

Подпись: 1.3. The urgency of utilization and recycling of industrial waste

The urgency of the given theme arose at the turn of two contradictions originated in metallurgy industry. They are introduced on scheme № 1:

On the one hand:

the reserves of coking coal are being steadily reduced, its price grows permanently;

the mining of natural iron-ore raw material is diminishing;

new deposits are not opened up in fact;

a constant growth of the rates on energy supply and rail transportation.

On the other hand:

the accumulated over the decades waste of metallurgical, machine-building, mining and chemical manufactures, fuel and energy complexes continues to grow;

the location of waste near to metallurgical works;

huge expenditures on their opening up are not required.

The analysis of the mentioned contradictions has allowed us to formulate a scientific problem with the solution in two directions:

On the one hand:

- waste processing and utilizing and using it as a relatively cheap raw material for metallurgical manufacture noticeably lowers expenditures on mix material and improves the quality and competitive strength, and above all lowers the net cost of the finished product.

On the other hand:

- the solution of the ecological problem of purification of whole regions where many man-caused waste deposits have been accumulated, and also reclaiming of current storage of waste of the mentioned above manufactures.

The existing technologies of secondary usage of waste of different industries (above all of metallurgical industry) are imperfect. For example, the usage of agglo-blast-furnace sludge by production of agglomerates has the technological refining of not more than 250 kg/ton of agglomerate.

The dust of dry coke-quenching installations – the most valuable fuel with a high content of carbon – is only used as a material for steel scoria frothing in electric arc ovens or is added to mix material for coking.

The experts of “EcoMashGeo” Ltd. who have been working on the development since 1997, have accumulated a major technological potential at the turn of metallurgy and building technologies and developed an essentially new method of preparation of mix material for metallurgical refining.

As a result of a long-term work the metallurgical briquette with the usage of a non-traditional binder and a carbonic filler for all types of metallurgical refining has been generated, i.e. an essentially new composite mix material, whose application in metallurgy can return industrial waste to metallurgical refining as iron-carbon-containing briquettes with a high profitability.

The manufacture of such briquettes will allow to essentially improve performance characteristics of the refining at your plants and thus improve the ecological situation.

The complex scheme of the waste utilization is shown on scheme № 2, from which we see, that to the machine industry waste that can be returned as raw material with a maximum productivity it is possible to refer:

roll scale and forge cinder;

iron and steel cuttings;

- metal sifting;

- aspiration settings dust.

To the metallurgy industry waste it is possible to refer:

- blast-furnace dust;

- aspiration settings dust;

- scorias and slurries;

- roll scale;

- coke breeze and dust.

To the coal mining industry waste can be referred:

- coal fines and dust;

- slurry;

- mill tailings.

To the by-product-coking industry waste it is possible to refer:

- coke breeze and dust;

- resin.

To the fuel and energy complex waste it is possible to refer:

- ashes;

- coal dust.

To the wood industry waste it is possible to refer:

- charcoal fine;

- lignosulphonates;

- wood waste;

- etc.

All these can be utilized by the method of cold sintering.

Подпись: 2. The technology of metallurgical briquettes production.

Подпись: 2.1. The method of production of iron-carbon-containing briquettes.

Sintering is one of the actual problems in preparation of iron-containing materials for metallurgical refining.

For today there are three known methods of sintering of small-sized ores, concentrates and waste. They are agglomeration, granulation (pelletizing) and briquetting.

Agglomeration is a process of generation of pieces (agglomerates) by the method of sintering of small-sized ores and a concentrate with the fuel material at a high combustion temperature.

Pelletizing is a process of generation of pellets, based on the character of the humidified atomized ore particles or a concentrate to organize a pellet of a greater or smaller size and durability, that is put into the necessary size and shape by rolling in special devices, the following sintering gives extra durability.

Briquetting is a process of generation of pieces (briquettes) with adding and without adding binder materials with the following pressing the mixture into briquettes of the necessary size and shape.

The return of the mentioned above waste to the economy of the country is possible in the form of raw material almost without overhead expenses by the ecologically free method of cold sintering.

In Russia at present about 52 million tons of agglomerate and 30 million tons of pellets are fabricated. At the same time only in April 2003 the production of briquettes in industrial volumes was begun for the first time in Russia at “Tulachermet” Plc.

Though briquetting in ferrous metallurgy is one of the earliest methods of sintering, which was widely used for this purpose in the second half of the 19^th century, at the beginning of the 20^th century briquetting was ousted by agglomeration. There were several reasons for that, the main of them was the diseconomy as the low-power presses had a low productivity, while in agglomeration the machines with the productivity of more than 2000 tons of agglomerate per day were generated.

For today the technological progress has reached such a level, when it is possible to briquette more than 5000 tons of raw material per day at an automatic line and this method is pollution-free and wasteless.

Unfortunately, there is not a single Russian producer of automatic lines with high productivity. Generally, all the lines for the building industry (production of blocks, curbs, paving slabs and so on) are imported. According to the data, given by the Customs Committee of the Russian Federation during two last years 960 lines of such kind with componentry and spares at the cost of 2,5 billion US dollars have been imported (only for building purposes, not registering the needs of metallurgists). The urgency of organization of production of high capacity vibrocompression equipment for industrial waste utilization and recycling is obvious.

To the doubtless advantages of briquette as compared to agglomerate and pellet it is possible to refer the following ones:

briquettes are regularly shaped and have identical weight, contain more metal in the given volume, have a higher durability and a better transportability;

have a higher relative density;

the ecological safety of briquettes (wastelessness, absence of high temperature during the production process);

the possibility of using (in any ratio) in briquette some carbonic filler for activation of the processes in the metallurgical oven (carbonizer, regenerator, energy carrier);

the possibility of using all types of fine iron-flux-alloy-carbon-containing waste of metallurgical refining.

The ultimate strength, density and porosity of briquette are taken as the parameters. They are reached in the prescribed limits by influencing on mix material by unit pressure 0,025-0,09 МPa, vibration with frequency of 35-65 Hz and vibrational amplitude 0,25-0,55 mm up to a condition, that ensures reaching the required setting values of these parameters, thus the humidification is done before obtaining the water-binding ratio, fixed for the given mix.

During the development of the briquette production technology we had the following priority objectives:

to obtain the briquette with the specified characteristics on demand of a definite customer (this technology gives the opportunity to obtain the briquette with the specified geometrical proportions and physical properties)

the composition of the briquette which defines its metallurgical value is developed by the specialists – the metallurgists of the plant – briquette consumers.

the effectiveness of briquette production and usage, that is reached by locating of the briquette plant near to the waste deposits and melting units, that are usually situated next to each other.

high productivity, low net cost of the vibropress equipment, minimal operating staff (the vibropress “Rukis” with the productivity up to 5000 tons of briquette a month is served by 5 persons per shift).

One more direction of the research is the analysis of the influence of the shape and geometrics of briquette on the metallurgical properties of the mix material.

Подпись: 2.2. The comparative analysis of the charge preparation according to the traditional method and our technology.

Let us see the traditional scheme of preparation of the mix material for steel melting and according to our technology, which are shown on scheme №3.

We do not consider the processes of mix material production for steel refining, that are connected with the direct reduction of iron and melts in the fluid pot, such as Midrex, Korex, Hill, Finmet, Rawmelt, Hissmelt, etc, though for these processes it is possible to use briquetted mix material.

The traditional method of transportation of iron and fuel to the filling and rolling stations is rather long, energy intensive and costs much. This method consists of the following stages:

geological exploration and opening up of the deposits;

mining and enrichment of the iron-ore raw material and coal;

production of iron-ore pellets, agglomerate and coal coke;

blast-furnace refining with its product – hot metal and pig-iron as well as “Synthicom”;

steel production by the known processes (open-hearth, converter, electric furnace).

At every stage waste is generated. Its metallurgical value is very high and it has not been completely realized. Among it: roll and forge scale, aspiration setting dust, ashes, blast-furnace dust, sludge, pig-iron and steel cuttings, coke breeze and others. The offered by us technology gives you the opportunity to avoid three capacious and expensive technological processes (see scheme №3).

The specialists will ask about the excessive content of the detrimental impurities in the used waste (sulphur, phosphorus, alkali, non-ferrous metals and others). I would like to say that when smelting pure special steel it is possible to use high-purity materials:

highly enriched iron concentrates;

charcoal;

pyrolytic carbon, graphite;

etc.

Surely, briquette can be one of the components of the mix material, that will supplement the traditional steel waste, hot metal or pig-iron. Though during the smetlings at the “Tiazhpromarmatura” Plc. (Aleksin, Tula Region) pig-iron was completely replaced by iron-carbon briquette.

The usage of briquette gives steelmakers (arc furnaces) the opportunity to use two components of the mix material: steel waste and iron-carbon briquette.

The actual objective of the steelmakers is the problem of carbon: there is too much of it (converter), or too little (open-hearth and electric furnace ovens). In briquette it is possible to have 50% of carbon by mass. In the same way the briquette (БЖУ-ДП, БЖУ-ДГ) is fabricated, whose basic part consists of FeO.

Подпись: 2.3. The technological scheme of production of metallurgical briquettes.

So, how could we provide the unique characteristics of briquette?

As it has already been said, this problem was solved at the turn of two technologies: metallurgy and production of building materials.

The specialists of “Ecomashgeo” Ltd have developed the ways of updating the typical vibropression equipment with the aim of its adjustment to the metallurgical briquette production.

The technological scheme of metallurgical briquette production is shown on scheme № 4, where we can see the basic technological blocks:

intake and storing of loose materials;

feeding of the mix material;

preparation of the mix material in the blending machine;

molding;

transportation to the station of the strength development;

packaging (as needed) and transportation of briquettes to the metallurgical manufacture.

The plans of the technological lines of metallurgical briquette production with different productivity is shown on scheme № 5.

The area of application of briquettes is shown on scheme № 2:

blast-furnace production;

steelmaking industry, which is divided into converter industry, open-hearth industry, and electric furnace steelmaking;

ferroalloy industry;

foundry manufacture, which is divided into cupola-furnace and electric arc oven.

The offered technology allows to avoid three most capacious and expensive processes in metallurgy and to ensure purification of regions. The most important principle of our technology is that all this raw material is located next to metallurgical plants and is not called for (if we compare the distance between a plant and weakly rich deposits of natural resources, the conclusion is obvious). For example, “MECHEL” Plc. uses concentrates of the ore mining and processing enterprise in Korshunovo with the content of iron not less than 40 %, in the presence of reserves of its own sludge with the content of iron 50 %.

Подпись: 3. The metallurgical value of iron-carbon-containing briquettes

With the metallurgists of some plants from Russia and abroad, we have defined the area of briquette application and developed its composition.

In 2001 a lot of technical specifications, such as ТУ- 0320-002-55978394-2001, ТУ- 0780-001-55978394-2001 were published.

The types of briquette and their metallurgical value are shown on scheme № 6.

Blast-furnace production:

БЖУ-Д - briquette, as a substitute of iron-containing raw material (agglomerate, pellets, metal admixture), blast-furnace coke and flux;

БЖУ-ДП - briquette for washing of the well of blast furnaces (FеО 40-60 %);

БЖУ-ДС - briquette with manganese and silicium for smelting of special iron grades;

БЖУ-ДГ - briquette for growing of the wall accretion of the well of blast furnaces.

Steelmaking manufacture:

БЖУ-C – briquette as a substitute of iron, carbonic scrap, carbonic additives and flux;

БЖУ-СЛ - briquette with deoxidizing alloy additions (Mn, Si, Аl etc.);

БЖУ-СК - briquette for scorification and temperature control in the steel furnace;

БЖУ-СД – a composite briquette with alloy additions and wood charcoal as a regenerator.

Ferroalloy manufacture:

БЖУ-Ф – a composite briquette for production of ferroalloys (with FеSi, FеСг, FеS, Сг, SiМn, FеМn, S, Аl and carbon in the form of coke breeze and dag, powdered wood charcoal).

Foundry manufacture at the machine works:

БЖУ-ЛС – a special briquette with alloy additions and deoxidizing additives;

БЖУ-ЛЧ – a composite iron-containing briquette as a substitute of pig iron and waste iron when obtaining hot metal for casts;

БЖУ-ЛД – a composite briquette with wood charcoal as a regenerator.

Thereby Tula has confirmed once again that it is called the native land of the Russian iron and steel industry.

In 2003 the first blast-furnace plant, which was constructed on the river Tuliza by Vinius and Makena, will celebrate the 370^th anniversary.

The research of the metallurgical characteristics of briquette was done in laboratories on the samples that had been smelted in the resistance furnace.

Подпись: 3.2. The mineral-graphic efforts of the processes within briquettes.

The conducted mineral-graphic efforts are shown on scheme № 7, where you can see the reductive processes in the iron-carbon briquette in the oven in the nitrogen current. The results are obtained at the sections with the help of the optical microscope.

Picture №1. The initial composition of briquette

68 % - oxide scale;

20 % - coking dust;

12 % - the binder;

Fе (total) - 48 %, C - 16 %

compression strength -130 kg / см³; t – 20 ºC

accessible porosity - 16 %;

density - 2,1 kg / см³

The light fission-fragment flakes of oxide scale with dark round slices of coke breeze and grey straps and impregnations of the binder (cement stone) between them.

Picture №2. The shear of the briquette that was heated up to t – 850…900°C is shown (the beginning of the softening).

The formation of metal iron in the form of impregnations of a light colour in wustite grains inside the bits of the oxide scale, the shape of the bits of the oxide scale is saved.

Picture №3. The shear of the briquette that was heated up to t - 900…1100°С is shown.

The junction of the impregnations of metal iron into a porous jaw of a light grey colour.

Picture № 4. The shear of the briquette that was heated up to t - 1100…1200°С is shown.

The integration of the segments of the reduced iron and its saturation with carbon in the form of the hypereutectoid steel with a light cement net at the edges of grains.

Picture №5. The shear of the briquette that was heated up to t - 1400°C is shown (the end of the softening).

The carbonization of the metal bits up to a condition of pig-iron.

Picture №6. The final composition of the briquette is shown:

the microsection from fractionally disrupted cake of a light brown colour with shiny formations of different shapes of the recovered metal iron.

Firing temperature – 1400 °С;

the degree of metallization - 95 %;

Fе (total) - 61 %, Fе (met) - 58 %, СаО/Si2 = 1,7.

From the above-stated we have come to the following conclusions:

1. The carbon of the carbon-containing component of the briquette completely reduces the oxides of iron up to metal iron with its consequent carbonization.

2. The finished product of the sintering of the iron-carbon briquette at the temperature of the end of the softening is pig-iron.

3. The accessible porosity, density and compression strength of the carbonic briquette are the regulators of mix design for the metallurgical refining.

In the same way we have proven that every iron-carbon briquette when the heat energy is placed form outside can be called a mini blast-furnace.

We have developed and counted economically sound prices of metallurgical briquettes; though for each manufacture depending on the production conditions, outputs and volumes of usage in the refining these prices will vary.

For example, for the blast furnace with the volume from 1000 m³ up to 2000 m³ the calculations have been made according to the traditional method (Table 5.1.1.) and with the usage of iron-carbon briquettes for the manufacture of foundry pig-iron and without them (Table 5.1.2.).

Подпись: 4. Charcoal in metallurgy

The best carbon-containing material for metallurgical refining is coke breeze. But it is a well-known fact that the reserves of coking coal are reducing, expenditures on production are growing, and coke breeze will be as scarce as coke.

It is specialists’ of “EcoMashGeo” Ltd. opinion that coke breeze in metallurgical briquette can be replaced by charcoal. Of course, we do not call to come back to the times of Demidov when burning of charcoal was done primitively what greatly damaged the environment. We only offer the technology of charcoal production similar to the technology that was created by “Mannesmann” for Brazil. This technology presupposes growing of high growth species of eucalyptuses during six years with the purpose of getting charcoal and resin.

This technology has one weakness: the necessity to get charcoal with high mechanical strength and of a large size.

The technology of charcoal production of “EcoMashGeo” Ltd. and Federal National Unitary Enterprise «National Scientific Centre of “Timber Industry Complex» ensures the usage of all parts of trees of different species (including low-grade trees – poplar, alder).

Of course, Russia is not Brazil, but it is possible to grow trees within 15 years for coal burning. Besides, for the last decades because of lack of sanitary felling the woods of the central region of Russia have abundant number of stale wood. That leads to negative oxygen balance due to abundant isolation of СО2 by rotting trees. This problem is urgent for the Moscow region.

This resource can be used for production of charcoal.

In such countries as Vietnam, Indonesia, Malaysia, etc. (with humid tropical and subtropical climate) where it is possible to place planting of high-growth trees, there are reserves of iron ore. Metallurgical plants can be interested in this technology.

Climate conditions of the mentioned above regions ensure reduction of production costs on heat treatment of briquettes (solar technology).

Подпись: 5. The calculation of the economic effectiveness of briquettes usage

Подпись: 5.1. The calculation of the economic effectiveness of briquettes
usage in blast-furnace production.

Table 5.1.1.

Net cost of briquette

Briquette composition	Contents, %	Price per ton, rubles	Cost, rubles
Roll scale	30	300	90,0
Sludge of sintering plants	15	25	3,7
Fine metal additive	25	915	228,7
Coke dust	20	800	160,0
Binder	10	900	90,0
Total	100		572,4
Refining costs, (pilot factory), rubles			300,0
Net cost of briquette			872,4

The chemical composition of the briquette:

Fetotal =52,14%; С=19,37%; СаО=8,17%; SiO2 =12,56%; MgO=0,38%.

The predicted and expected effect from the usage of the iron-carbon briquette:

- cost reduction of pig-iron on 92,2 rubles/t;

lowering of the coke rate on 58 kg /t;

increase of productivity at 4,6 %;

owing to:

the substitution of a part of metallurgical coke by coke breeze of the iron-carbon containing briquette;

implication of agglomerate finely cut cheap iron-containing materials into the blast furnace mix material and returning pig-iron swaftagglomerated.

a quick pay-back of the vibropress equipment: from 2 up to 8 months.

Table 5.1.2

The comparative calculation of the net price of foundry pig-iron with the traditional mix material (basic) and with the usage of briquettes БЖУ – Д 52/19.

	Index name	Basic, kg/t	Cost, rubles	With briquettes, ru/t	Cost, rubles	Price, rubles/t
1.	Coke	630	945	572	858	1500,00
2.	Agglomerate	700	339,5	785	380,7	485,00
3.	Blast furnace pellets	585	288,5	580	253,6	488,98
4.	Fine metal additive	271	247,9	--	--	914,89
5.	Iron-carbon briquette	--	--	271	236,4	872,40
6.	Blast furnace ore	72	11,5	72	11,5	159,86
7.	Manganese ore	23	76,4	23	76,4	3322,00
	Net cost of iron, rubles		1908,8		1816,6	- 92,2
The specified parameters in the calculation
	Si,%	2,0		2,0
	CaO/SiO2	0,99		0,99
	RO/ SiO2	1,12		1,12
	Fluid-dissolved iron, kg (without metal additives)	1380		1460
	Femet, calculated %	54,87		55,03

Today we have the opportunity to bring to the notice of ecologists our development. We hope that in the result of cooperation this technology will occupy a worthy place in the Russian science and economy.

Подпись: 5.2. The calculation of the economic effectiveness of briquettes
usage in steel-making production

The calculation of the economic effectiveness of production of briquettes БЖУ–С 45/19 in steel-making production is shown in Table 5.2.1.

From this table we can see that the actual cost of the briquette is much lower than its metallurgical value (2945 rubles – 1534 rubles = 1411 rubles) and the effectiveness of its usage in recalculation for a ton of iron is 1411 rubles.

The cost efficiency of the briquette usage in the blast-furnace and steel-making production will be much higher than mentioned here, as we had to buy industrial waste and transport it to the place of briquetting. At any plant (or near) there are accumulated over the decades reserves of raw material at a minimal cost.

Table 5.2.1 The calculation of the briquette production effectiveness

(БЖУ - С 45/19)

Pig iron	Briquette БЖУ - С 45/19
1. The content of the components (% by mass):
Fe - 95,0	Fe – 45,0 C – 19,0
С - 4,5	CaO – 9,2 MgO – 0,7
Mn, Si, S, P and others - 0,5	SiO2, P2O5, S and others – 26,1
2. The market value for a ton of the material, rubles:
3100-00	Scale – 300-00 (247-50)*
	Coke breeze – 800-00 (220-00)*
	Binder – 600-00 (66-00)*
	Costs for a ton of briquette refining - 200
	Total: 727-50
	( )*- the cost of the material in briquette
3. The calculation of the one ton cost by iron, rubles:
2945-00	1534-00
4. Efficiency factor by carbon, standard unit:
1,0	1,0…1,5

When using pig-iron for steel smelting in the arc electric furnace 50 kg of iron is turned into liquid melt (without the waste).

When using БЖУ-С 45/19 the most part of carbon will be needed for reduction of ferric oxides. The residual content of carbon, turning into melt, will be 1,5…2,5% (according to the results of the meltings in the laboratory oven). The actual residual content of carbon in the melt is much higher than the results of the experimental-industrial melts in the open-hearth ovens at “Taganrog Metallurgical Plant” Plc. and “Viksa Metallurgical Plant” Plc.

We should note that we did not consider the detrimental effect of the additives of briquette, silicon dioxide, sulphur dioxide and phosphor dioxide, presence of which is determined by the chemical composition of briquette components.

Nevertheless, from Table 5.2.3. we can see that the economical practicability of the briquette production and usage is obvious and can reach 100%.

In this calculation the market value of pig iron and briquette components is meant.

Every plant has the opportunity to evaluate its own effectiveness based on the traditionally existing price level and level of costs.

Подпись: 6. The tests of introduction of briquettes into metallurgical refinings.

Experimental-industrial fusions of products of industrial waste utilization with a partial substitution of metallurgical charge by iron-carbon-containing briquettes, produced according to the technology of “EcoMashGeo” Ltd. with the usage as the main component of iron and carbonic waste were carried out in open-hearth furnaces of “Liepajas Metalurgs” Stock Corporation (Latvia), “Taganrog Metallurgical Plant” Plc. (Taganrog), “Viksa Metallurgical Plant” Plc. (Viksa), in electric furnaces of “Byelorussian Metallurgical Plant” Republican Unitary Plant (Byelorussia), “Moscow Metallurgical Plant “Serp i Molot” Plc. (Moscow), “Tiazhpromarmatura” Plc. (Aleksin), in shaft furnaces of “Hanino Ironworks” Close Corporation (Suvorov).

The usage of briquettes in blast furnaces as one of the charge components is actual for metallurgical plants that do not have their own agglomerates or that do not have sufficient production of agglomerates.

In this case the usage of briquettes ensures partial or total refusal from introduction of raw flux due to optimal basicity of briquettes. Of course, presence of carbon on briquettes helps to reduce the consumption of the most expensive component of blast furnace charge, i.e. coke.

That is why one of the first plants that used metallurgical briquettes in blast furnace melting was “Lipetsk Metallurgical Plant “Svobodni Sokol”” Plc., whose blast furnaces are run on the charge that consists of blast furnace pellets and raw fluxes.

In May, 2002 at “LMP “Svobodni Sokol”” Plc. a series of balance meltings with briquettes was carried out. From the meltings results the metallurgical characteristics and possibilities of smelting of iron-coke briquettes in blast furnace were analyzed. Briquettes consisted of metal shiftings of ferrovanadium production and coke breeze. The peculiarity of these briquettes is that coke breeze isn’t meant for reduction of ferric oxides within briquettes. Coke breeze is a lump filler, thus the problem of utilization is solved. In blast furnace fusion carbon of coke breeze takes part in the process of reduction of ferric oxides from intermediate slag.

Metallurgical characteristics of iron-coke briquettes that were produced according to the technology of “EcoMahGeo” Ltd. at “Tulit” Plc. from three types of man-caused raw material: metal shiftings of ferrovanadium production (B 1), swarf (B 2) and roll scale (B З) were analyzed. Component composition of the charge for production of these briquettes was the same: iron-containing component - 59%, coke breeze - 26%, portland cement - 15%. Chemical composition of briquettes calculated on the basis of their elemental composition that was defined in test- analytical center Giredmeta is shown in Table 6.1.1.

Table 6.1.1.

Chemical composition of iron-coke briquettes.

Briquette type	Fe met	FeO	Fe2O3	C	MnO	SiO2	Al2O3	CaO	MgO	SO3	P2O5	TiO2	V2O5	H2O hydrated
Б 1	47,92	1,26	1,18	18,65	0,68	4,93	1,53	8,75	0,46	0,13	0,03	0,31	0,49	13,04
Б 2	48,68	-	1,18	20,67	0,31	4,35	1,53	8,66	0,46	0,13	0,03	0.03	-	13,04
Б 3	0,47	32,8	18,63	18,67	0,54	4,35	1,64	8,66	0,46	0,15	0,06	0,04	-	13,04

To define reducibility of briquettes in accordance with GOST 21707-76, the change of mass of the sample in the process of reduction by hydrogen at the temperature 800 ºС and consumption of reduction gas 1,5 l/min was constantly under control. It was established that small amount of ferric oxides in briquettes B1 and B2 are reduced in the first minutes of fusion, briquettes B3 are completely reduced within 40 minutes.

Heat stability of briquettes was defined on the installation of Moscow State Institute of Steel and Alloys of the change of layer height (60 mm) of the material with fineness 5-8 mm at heating in the reducing atmosphere at the speed of 14 °С/min during the first 45 min, and then at the speed of 5-6 °С/min. By heating the sample up to 900 °С the consumption of reduction gas Н2 и N3 was 0,3 and 1,1 l/min, at the temperature more than 900 °С - 1,1 и 0,3 l/min correspondingly. Pressure is being raised from О to 65 kilo-Pascal. It was established that by heating in the range from 900 to 1300 °С iron-coke briquettes practically do not grow soft. At the same time, briquettes B3 grow soft to a greater extend than briquettes B2, but to a lesser extend than traditional iron-ore raw material. The cause is the structure of briquettes that is created at heating in deoxidizing atmosphere: iron matrix form caked particles of iron (initial and reduced) that includes pieces of coke within casing from refractory calcium-aluminosilicates.

Heating in the reducing atmosphere at the speed of 500 °С/h to 1000 °С and at the speed of 50 °С/h to 1150 °С with the following cooling in inert atmosphere to 40-50 °С did not influence the shape and dimensions of iron-coke briquettes from metal shifting. Small cracks (10-15 mm) appeared on the surface.

So the results of the tests show that iron-coke briquettes are suitable for fusion in blast furnace, where they preserve their shape and dimensions at the temperature 1250-1300 °С.

Pilot meltings with the usage of iron-coke briquettes in the charge were carried out in blast furnace № 1 at “LMP “Svobodni Sokol”” Plc. (payload volume 700 m³, 12 jets, feeding of charge to skip by scale car). Furnace operates on imported coke and smelts foundry iron and pig iron from Lebedian pellets with the usage of limestone and dolomite as fluxes. By smelting pig iron for a partial substitution of coke schungite up to 100kg/t was used. A small amount of metal additions and manganese ore was also used (Table 6.1.2).

Pilot meltings with the usage of iron-coke briquettes in the charge were carried out at the beginning of the work for open-hearth pig iron. In two days it was switched to smelting of foundry iron. The loading of briquettes was stopped and renewed only in three days. 500 tons of briquettes were partially melted for smelting of open-hearth pig iron and partially for smelting for foundry iron. It did not negatively influenced on the work of the furnace. It is a well known fact that the averaging of information on the work of the furnace during the period less than 5-7 days always distorts the figures of discharge intensity of raw materials and fuel because of the reasons not connected with the melting technology.

Table 6.1.2. Chemical composition of charge materials used at smelting pig iron and foundry iron in blast furnace, %

Materials	Fе	SiO2	А120з	СаО	МgО	Мп	Р	W, %
Pellets Lebedian	65,73	5,96	0,45	0,3	0,5	0,053	0,020	2,6
Ore Michailovsk	37,51	47,81	0,74	0,84	0,51	0,03	0,061	1,15
manganese ore	5,77	14,27	2,92	3,52	1,13	38,07	0,151	11,4
Limestone	0,50	1,02	0,90	52,91	0,79	-	-	1,40
Dolomite	1,38	1,6	0,84	31,36	19,30	-	-	2,10

Taking this into consideration, for evaluation of impact of the usage of briquettes in the charge on technical and economic indices of furnace functioning and for reduction of distortion of information about furnace functioning, average weighted by iron mass basic and trial periods were formed. Basic period covered 3 days of furnace functioning on pig iron before the usage of briquettes and 3 days on foundry iron after the end of usage of briquettes, trial period covered 2 days of furnace functioning on pig iron and 5 days on foundry iron with the usage of iron coke briquettes (Table 6.1.3). It was stated that the usage of iron coke briquettes in the charge in quantity of 51,83 kg/t had lead to capacity increase of the furnace by 91,71 t/day and to reduction of coke consumption by 6,14 kg/t.

Evaluation of the impact of iron coke briquettes B1 on technical and economic indices of furnace functioning was done by computer simulation blast furnace fusion for the conditions of basic and trial periods with the usage of B1 in quantity of 69,5 and iron 260 kg/t. For adaptation of the mathematical model to the functioning conditions of blast furnace № 1 at “LMP “Svobodni Sokol”” Plc. average rates of the basic period to which the results of simulation were compared, were used. (Table 6.1.4.).

Table 6.1.3.

Basic indexes of functioning of blast furnace at

“LMP “Svobodni Sokol”” Plc. with the usage of iron coke briquettes by smelting pig and foundry iron in basic and trial periods.

Index	periods		Change of index	∆ coke, kg/t	∆ capacity, t/day
Index	basic	trial	Change of index	∆ coke, kg/t	∆ capacity, t/day
Capacity, t/day	1009,97	966,65	-43,32	--	--
Shutdown, %	0,09	0,56	+0,47	-1,24	+7,12
Slow speed, %	0,897	1,97	+1,073	-2,84	16,3
discharge intensity of dry skip coke, kg/t	529,64	558,99	+29,34	--	--
Iron in iron-ore part of the charge, %	65,94	65,3	-0,64	-3,39	+12,3
Material consumption, kg/t:
pellets, Lebedian ore mining and processing enterprise	1307,2	1481,9	+174,7	--	--
iron ore	--	8,344	+8,344	--	--
metallurgical briquettes	--	51,83	+51,83	--	--
plant scrap	185,04	8,977	-176,1	-16,8	+53,3
manganese ore	7,51	11,99	+4,48	--	--
schungite	12,74	37,07	-24,37	+19,5	--
limestone	108,76	121,72	+12,96	-3,43	+6,5
dolomite	67,07	91,7	+24,63	-5,21	+9,9
Blast temperature, °С	1029,18	993	-36,18	-7,68	+14,64
Natural gas consumption, m³/t	64,21	54,81	-9,4	-7,52	--
Top smoke pressure, atmosphere	0,71	0,742	+0,032	+0,33	-0,3
Content in iron,%:
Si	1,671	2,049	+0,378	-4,45	+8,48
Mn	0,247	0,405	+0,158	-1,673	+0,319
S	0,022	0,022	--	--	--
Basicity of slag (CaO/SiO₂)	1,02	1,031	+0,011	--	--
Slag volume, kg/t	243,92	249,64	+5,72	-1,059	+3,43
Given coke consumption, kg/t	529,64	523,5	--	-35,5	--
Reduced capacity, t/day	1009,97	1101,68	--	--	+135,00

Notes:

1. The factor of substitution of coke by schungite is 0,8 kg/kg according to the content of Si in trial period.

∆ coke and и ∆ capacity are the changes of coke consumption and blast furnace capacity by the usage of iron coke briquettes.

The results have proven the high effectiveness of the usage of iron coke briquettes: reduction of coke consumption and increase of furnace capacity at reduction of pellets consumption per iron smelting. For briquettes B1 the factor of substitution of coke by briquettes is 0,40-0,41 kg/kg. Reduction of coke consumption is achieved due to the following factors:

- direct substitution of coke carbon by carbon in briquettes and carbon that takes part in the reaction of gasification and in direct reduction of carbon from ferrous initial and intermediate slag;

- owing to partial withdrawal of limestone from the charge due to high basicity of iron coke briquettes;

- absence of heat consumption for direct reduction of carbon in briquettes, that goes into the furnace as reduced iron.

Increase of capacity of the furnace and the usage of iron coke briquettes are not so essential and caused mainly by reduction of coke consumption, i.e. increase of ore load. Caloricity of top smoke increased by 0,2 mega-joule/m³) by using iron coke briquettes in the quantity of 260 kg/t.

On the basis of the above-stated we can come to the following conclusions:

iron coke briquettes on cement binder produced from fine-dyspersated metal siftings of ferrovanadium production or from metal swarf have high heat resistance, do not fall apart at high heating speed in reducing atmosphere under the loads characteristic of blast furnace conditions and are high quality complex raw material for blast furnace, that contains metallic carbon, reducing agent and fluxing components.

iron coke briquettes production on cement binder helps to solve the problem of recycling of coke breeze and fine-dyspersated metallic waste of the plants that do not have an agglofactory.

the usage of briquettes can be effective in furnaces that work on nonfluxed iron-ore raw material with the usage of limestone and dolomite. Moreover, iron-coke briquettes reduce the content of oxygen in the charge and increase CO in top smoke and its caloricity that can be used in special technological regimes of blast-furnace fusion with the purpose of obtaining top smoke of necessary composition in blast furnace.

Table 6.1.4

The results of computer simulation of blast furnace fusion with the usage of iron coke briquettes.

Index	Periods
Index	basic	trial 1	trial 2
Material consumption, kg/t:
Pellelts (Lebedian)	1241,7	1192,6	1043,9
metal additive	175,8	173,1	174
limestone	103,3	80,7	46,0
dolomite	63,7	56,6	54,5
schungite	12,2	-	-
manganese ore	7,2	7,1	7,1
briquettes B1	-	69,5	262
coke	529,3	500,6	432,3
Natural gas consumption,m³/t	65,8	65,8	65,8
Blasting:
consumption, m³/t	1595	1533	1456
temperature, °С	1029	1029	1029
humidity, gr/m³	10	10	10
Top smoke pressure, kiloPascal	170	170	170
Discharge of top smoke, m³/t	2307	2216	2101
Gas caloticity, mega-joule/m³	3,48	3,55	3,76
Slag:
discharge, kg/t	233	213	206,6
basicity (СаО/SiO2)	0,997	0,998	0,998
Contents, %:
МgО	9,26	9,28	9,30
[Si]	1,67	1,67	1,67
[S]	0,021	0,022	0,022
Capacity, t/day	1002	1042	1095

The next meltings with the usage of metallurgical briquettes were carried out at “Tulachermet” Plc., the biggest manufacturer of pig iron.

From 18, November to 26, December, 2002 at blast furnace №2 489 tons of briquettes with the following component composition were smelted:

roll scale - 92%;

binder - 8%.

Technologists of “Tulachermet” Plc. offered such composition of briquettes because of the lack of flue cinder that is the most effective material for washing of blast furnace forge. Problems with blocking the forge by graphite waste at blast furnace №2 occasionally arose after a long functioning of furnace. This campaign of the usage of washing briquettes produced the following results:

the usage of briquettes from scale as washing material did not negatively influence on the course of blast-furnace process;

the positive factors are stabilization of consumption of cold blast and reduction of heat variation, more even discharge of fusion products.

We should note that “Tulachermet” Plc. was the first plant in Russia that led that work on development of different compositions of metallurgical briquettes by the method of cold briquetting and the technology of their application. Laboratory tests were begun in September, 2001 together with “EcoMashGeo” Ltd.

We came to the following conclusions according to the results of the laboratory tests:

briquettes, produced according to the technology of “EcoMashGeo” Ltd. are manufacturable, mechanically strong, heat-resistant, allows partial substitution of agglomerate and blast-furnace coke;

briquettes allow to eliminate poorly balled components (agglo-blast-furnace sludge and blast furnace dust), that will bring about improvement of agglomerate durability and increase of productivity of agglomachines.

At the beginning of 2003 the program of organization of metallurgical briquettes production was accepted and on the 25^th of April, 2003 industrial production was begun. Metallurgical briquettes consist of agglo-blast furnace sludge, blast furnace dust, coke breeze, fine-fractional product of enrichment of slag-metal waste.

Today the work on briquettes usage in blast furnace fusion at “Novolipetsk Metallurgical Plant” Plc. is carried out, where the main goal is the effective utilization of waste of all metallurgical refinings, starting with by-product-coking industry finishing with rolling industry.

At metallurgical plants where balance meltings with the usage of carbon-iron-containing briquettes were carried out the ideology of industrial waste utilization has been excepted.

Подпись: 6.2. The test of introduction of briquettes into electric furnace steelmaking.

At the end of 2000 – at the beginning of 2001 in the market of metal charge arose a situation that had caused advance of prices on ferro-scrap. This fact stimulated commercial and technical services of the plants where scrap metal was used for steel smelting to start looking for alternative material.

For such plant as “Byelorussian Metallurgical Plant” Republican Unitary Plant that is situated in the republic where there are limited resources of ferro-scrap, this problem is one of the urgent ones.

Besides that, accumulated reserves of roll scale (about 5 million tons with 30 thousand tons a year) and dust of gas purification (about 20 thousand tons a year) that are practically not realized after dissolution of the USSR, have a ecological influence on the environment.

We should notice that average iron content in the mentioned waste is less than 50%, in scale it is 72%.

Hence, the technological series of production and application of iron-fuel briquettes in the charge for electrosmelting is solely acceptable for “Byelorussian Metallurgical Plant” Republican Unitary Plant, at the same time high economic results are obtained.

On the 11^th of July, 2002 “EcoMashGeo” Ltd. received roll scale from “Byelorussian Metallurgical Plant” Republican Unitary Plant, that became the basic component for briquettes. In August five types of iron-carbon-containing briquettes (60 tons of each) according to the described technology (ТУ 0320-002-55978394-01) were produced.

Compressive resistance of the briquettes was 15,3 – 15,6 mPa, accessible porosity 15-16%.

To define mechanical strength of briquettes the following methods were used:

- in accordance with GOST 2787-75;

- in accordance with the method, adapted to the real conditions of steelmaking at “Byelorussian Metallurgical Plant” Republican Unitary Plant.

The briquettes have successfully passed the test on mechanical strength according the two methods, i.e. weight loss according to GOST 2787 was 2,7% after ten drops: 5,8% with fraction output – 5 mm, in wasted mass – 3,6%.

Table 6.2.1.

Component and chemical composition of briquettes.

Batch index

Component composition, % by mass

Chemical analysis, % by mass

Variant №1

БЖУ 50/16.19

Net weight 65 t

Car №67006225

Roll scale – 69,0

Carbonic material – 21,8

Binder – 9,2

Fe_total– 50,15

CuO – 4,90

MgO – 0,70

K₂O+Na₂O – 0,07

Al₂O₃ – 0,10

P₂O₅ – 0,01

C – 16,10

SiO₂ – 2,90

S – 0,25

MnO – 0,30

Cr₂O₃- 0,06

TiO₂ – 0,09

Variant №2

БЖУ 51/16.19

Net weight 65 t

Car №67006225

Roll scale – 69,0

Carbonic material – 21,8

Binder – 9,2

Fe_total– 50,10

CuO – 4,95

MgO – 0,68

K₂O+Na₂O – 0,07

Al₂O₃ – 1,08

P₂O₅ – 0,01

C – 16,00

SiO₂ – 2,98

S – 0,24

MnO – 0,29

Cr₂O₃- 0,06

TiO₂ – 0,09

Variant №3

БУЖ 51/15.19

Net weight 65 t

Car №64331259

Roll scale – 70,7

Carbonic material – 20,1

Binder – 9,2

Fe_total– 51,95

CuO – 4,85

MgO – 0,84

K₂O+Na₂O – 0,08

Al₂O₃ – 1,11

P₂O₅ – 0,01

C – 15,12

SiO₂ – 2,89

S – 0,21

MnO – 0,28

Cr₂O₃- 0,06

TiO₂ – 0,09

Variant №4

БЖУ 54/17.19

Net weight 65 t

Car №62740023

Roll scale – 46,0

Carbonic material – 21,8

Binder – 9,2

Metal additive– 23,0

Fe_total– 54,25

CuO – 4,89

MgO – 0,88

K₂O+Na₂O – 0,07

Al₂O₃ – 1,08

P₂O₅ – 0,02

C – 17,2

SiO₂ – 3,40

S – 0,30

MnO – 0,35

Cr₂O₃- 0,06

TiO₂ – 0,09

Variant №5

БЖУ 51/19.19

Net weight 65 t

Car №63903256

Roll scale – 69,0

Carbonic material – 28,8

Binder – 9,2

Fe_total– 51,16

CuO – 5,0

MgO – 0,85

K₂O+Na₂O – 0,07

Al₂O₃ – 0,60

P₂O₅ – 0,009

C – 19,8

SiO₂ – 2,10

S – 0,20

MnO – 0,32

Cr₂O₃- 0,06

TiO₂ – 0,09

Definition of temperature conditions of softening was done on laboratory-scale plant for the definition of temperature conditions of softening of iron-ore materials by GOST 26517-85 in nitrogen current. We have obtained the following results:

temperature of the beginning of softening - 995 ^оС;

temperature of the end of softening - 1400 ^оС;

temperature interval of softening - 405 ^оС.

(for Variants №1, 2, 3, 5)

Briquettes were loaded on “the pillow” made of light scrap weighing 5-7 tons into the basket 1 and 2. By loading, a partial collapse of corners and edges of briquettes was observed. Briquettes were settled around the periphery of the basket rather compactly, similarly to pig iron loading. Melting of metal charge was carried out in the regime of traditional technology.

Required assortment and chemical composition of the first test where the briquettes were used are shown in Table 6.2.2. For comparison in the period of test the same amount of the same steel grades with practically the same metal charge composition, but without briquettes where the contents of С, Р, S at smelting were defined.

Mass share of briquettes was counted depending on the necessary content of carbon in metal at melting. At analyzing the results of chemical analysis in trial meltings with briquettes and comparative meltings without briquettes the growth of percentage of carbon content is observed. For example, in 20 pilot meltings of steel ст3сп, the average content of carbon is 0,23 %, at the same time in 24 meltings of the same steel grade without the briquettes the content of carbon in the first test was 0,14 %.

In the same way, the growth of carbon content in the steel grades ст1сп, 25Г2С, 460В was observed. The analysis of the meltings with and without briquettes shows that the growth of carbon content at melting varies and is in the range from 0,05 % to 0,09 %. That depends on different contents of carbon in briquettes.

The process of reduction was perfectly seen when by manual loading of briquettes (5-7 pieces) in to liquid melt of tank the bulbs of gas, that instantly flared up due to afterburning of CO, escaped.

Table 6.2.2.

Characteristics of meltings with the usage of briquettes and without them.

With the usage of briquettes						Without the usage of briquettes
Steel grade	Number of fusions, pieces.	Average number of briquettes per fusion, kg.	Average content by mass,%			Steel grade	Number of fusions, pieces.	Average content by mass, %
Steel grade	Number of fusions, pieces.	Average number of briquettes per fusion, kg.	C	P	S	Steel grade	Number of fusions, pieces.	С	Р	S
Ст3 сп	20	4800	0,23	0,007	0,047	Ст 3 сп	24	0,14	0,003	0,041
Ст1 сп	16	4700	0,17	0,006	0,048	Ст1 сп	18	0,12	0,004	0,039
25Г2С	13	5000	0,18	0,007	0,042	460В	18	0,13	0,003	0,043
SAE1008	2	4500	0,12	0,008	0,043
AT500C	4	4700	0,24	0,007	0,048
Ст 3 сп	3	4200	0,13	0,006	0,043
20Г2	1	4800	0,15	0,005	0,047
Total:	59					Total:	60

In Table 6.2.3 the average value of fusion regimes of steel of pilot and comparative meltings is shown.

The data of Table 6.2.3. show that the average specific power consumption for the fusions with the usage of briquettes is 0,63 kW/t higher than in the comparative fusion, that is 0,2 %, i.e. average specific power consumption are practically the same. Slight surplus can be explained by unstable work of furnaces 1 and 2 during the test due to the lack of metal charge. Although power consumption is forecast to be lower.

Table 6.2.3.

Average value of regimes of fusions of steel of pilot and comparative meltings.

Fusion, amount	Average measures
Fusion, amount	Specific power consumption, kW/ton of liquid	Specific power consumption, kW/ton of hot	Discharge intensity of СаО, kg/ton of hot	Discharge intensity of coke, kg/ton of hot	Discharge intensity of О₂, m³/ton of hot	Output of useful, %	Discharge intensity of metal charge, kg/тг
Pilot (59 fusions)	514,38	523,12	61,24	4,42	15,64	87,93	1142,9
Comparative (60 fusions)	509,83	522,49	51,65	5,41	12,89	88,09	1140,6

Great increase (9,59 kg/ton of hot) of discharge intensity of lime at pilot meltings can be explained by the fact that in the initial stage of liquid phase formation by smelting about 30-50 % of metal charge of basket 1 and especially by smelting basket 2 a rapid formation of foamy slag was seen. The slag flows by gravity in to slag pot that is why frequent lime additive for scorification was needed. (This problem can be solved by increasing the height of sill of inspection window). The electric furnace was working properly, without uncovering of electric arc.

Beneficial effect of the early formation of foamy slag influences the process of oxidation of solid particles of carbon within the briquettes with СО formation, what later on by using in the briquette charge will allow to get a considerable decrease of specific energy consumption and coke consumption, what was observed at several fusions where the specific power consumption was 498-506 kW/ton of finished product.

Low percent of finished product and high specific consumption of metal charge are explained by the fact that during the test in the component part of the charge of pilot and comparative fusions 20-30 % of light scrap and 5,0 of swarf were used, that considerably increases the percent of loss. Swarf should be included in the content of briquettes by production of the following batch.

So, we can come to the following conclusions:

oxide-carbonic briquette is a new charge that partially or completely replaces pig-iron or scrap metal;

briquettes froth slag and ensure earlier and more profound shielding of electric arcs;

briquettes have regular shape and weight, have good durability and transportability;

usage of oxide-iron waste for production of briquettes for steel melting is a real way of resource economy;

briquettes improve deoxidizing atmosphere in furnace.

So, doubtless manufacturability of the new type of charge, i.e. iron-carbon-containing briquettes and the possibility to perfect metallurgical characteristics with the purpose of improving performance characteristics of fusion and expansion of range of the charge for electric furnace steelmaking.

Подпись: 6.3. The test of introduction of briquettes into open-hearth production.

The lack of metallurgical scrap, high price on carbonic material, impossibility to apply fine-dyspersated and fine-fractional material – this is a concise list of the problems of metallurgists of open-hearth furnace.

Pilot fusions with the usage of metallurgical briquettes of different compositions were carried out in open-hearth furnaces of the following metallurgical plants:

- “Taganrog Metallurgical Plant” Plc. (Taganrog), Russia;

- “Liepajas Metalurgs” Stock Corporation, Latvia;

- “Viksa Metallurgical Plant” Plc. (Viksa), Russia.

As a result of meltings the following conclusions have been drawn:

briquettes can be used as a charge component of open-hearth process for furnaces that work as scrap practice;

iron from scale, being a component of briquette, is reduced and absorbed by molten metal, that is proved by high percentage of finished products, low content of iron oxides in the slag after the end of the melting period;

molten scale has higher (compared to traditional charge fusions) basicity, that indicates the possibility of reduction of lime (limestone) consumption in charging;

the results of meltings where briquettes partially replaced hard iron show that there is a possibility to substitute 1,5 tons of hard iron by 2 tons of briquettes in the charge;

wisely selected schemes of packing and loading of briquettes allow to completely mechanize loading-transporting operations and to reduce the time of furnace charging.

Подпись: 6.4. The test of introduction of briquettes into foundry.

In spite of development of the technology of hot metal for casting of products in electric furnaces (arc and induction) traditional cupolas are widely spread not only in Russia, but in other countries because of process economy.

Traditional charge for copula is pig iron, whose production is often situated far from foundries. Besides, by pig iron smelting in cupolas and by following processing of castings certain amount of iron cuttings and coke breeze is generated.

The mentioned waste is not straight claimed.

In this case production of metallurgical briquettes from foundry waste can be a cheap and technologically effective way of utilization with the purpose of substitution of a part of pig iron in the charge for cupolas.

“EcoMashGeo” Ltd. together with “Hanino Ironworks” Close Corporation have developed the composition of metallurgical briquette and the technology of application of briquettes for pig iron smelting in coke cupola.

In 2002 a series of pilot meltings was carried out in coke cupolas of the plant.

The results of the meltings help to come to the conclusion of the possible replacement (up to 50%) of pig iron and 100% replacement of raw fluxes in the traditional charge.

A separate direction of metallurgical briquettes usage is the usage of ferroalloys for smelting of pig iron of the given composition.

“Extreme” development of this direction is a new technology of utilization “ОxiCup”, offered by the concern “ThyssenKrupp” and its partners - “Mannesmann”, “Kuttner”, “B.U.S.” and “Messer Griesheim”. That is the process of industrial waste utilization in a special metallurgical set, a modernized cupola. In the process pig iron is obtained from the charge that contains of carbon-fuel briquettes by 70%.

This direction is urgent for the regions where there is a traditional lack of pig iron production and reserve capacity for obtaining hot metal in cupolas.

Подпись: 7. References

Lately pilot meltings with metallurgical briquettes of various compositions in blast furnace, open-hearth, electric furnace steelmaking, induction furnace refinings have been carried out.

For all meltings effective reduction of oxides of iron by carbonic component of briquettes, that coincides with the results of researches of metallurgists of Europe as well as high predictability of fusion process with the usage of briquettes of various compositions is noted.

For today “EcoMashGeo” Ltd. has worked out (and is carrying out) compositions from the given by plants waste and material for plants of Russia, Ukraine, Europe, South America in laboratory environment.

Table 7.1.

Introduction of metallurgical briquettes.

	plant	time	refining characteristics	tons	briquette components
1	“Taganrog Metallurgical Plant” Plc., Taganrog, Russia	09.2001	open-hearth furnace 285 t	350	roll scale, coke breeze
2	“Liepajas Metalurgs” Stock Corporation, Liepaja, Latvia	10.2001	open-hearth furnace 200 t	200	roll scale, coke breeze
3	“Liepajas Metalurgs” Stock Corporation, Liepaja, Latvia	02.2002	open-hearth furnace 200 t	40	roll scale, carbonic material, gas purifier dust
4	“Viksa Metallurgical Plant” Plc., Viksa, Russia	03.2002	open-hearth furnace 250 t	130	coke breeze, iron-containing material(Fe met -82%)
5	“Tiazhpromarmatura” Public Cooperation, Aleksin, Tula Region, Russia	08.2001	electric arc furnace 6 t with acid lining	40	roll scale, coke breeze
6	“Moscow Metallurgical Plant “Serp i Molot” Plc., Moscow, Russia	08.2002	electric arc furnace 12 t with acid lining, induction 1 t	25	roll scale, coke dust, iron-containing material (Fe met-82%)
7	“Hanino Ironworks” Close Corporation, Tula region, Russia	09.2002	3 t cupolas with fireclay lining	20	iron swarf, roll scale, coke dust, iron-containing material Fe met-82%
8	“Byelorussian Metallurgical Plant”, Republican Unitary Plant, Zhlobin, Byelorussia	12.2002-1.2003	electric arc furnace 120 t with basic lining	350	roll scale, iron and steel swarf, carbonic material
9	“Byelorussian Metallurgical Plant”, Republican Unitary Plant, Zhlobin, Byelorussia	03.2003	electric arc furnace 120 t with basic lining	570	roll scale, coke breeze
10	“Lipetsk Metallurgical Plant “Svobodni Sokol”” Plc., Lipetsk, Russia	05- 06. 2002	blast furnace with payload volume of 700 m³	300	iron-containing material Fe met-82%, carbonic material
11	“Tulachermet” Plc., Tula, Russia	01.2003	blast furnace with payload volume of 1030 m³	300	roll scale (for well washing)
12	“Novolipetsk Metallurgical Plant” Plc., Lipetsk, Russia		blast furnace with payload volume of	2000

From March, 2003 “Byelorussian Metallurgical Plant”, Republican Unitary Plant, Zhlobin, Byelorussia with “EcoMashGeo” Ltd. have been producing iron-carbon-containing briquettes that effectively replace in the traditional charge metallurgical scrap, carbonizer using roll scale with high economic effect.

Подпись: 8. The presentation of the technology of utilization and recycling of industrial waste.

This technology of industrial waste recycling was presented and won the recognition and support at:

the 7^th International Congress of Blast-furnace Men that took place in September, 9-12, 2002 in Moscow-Cherepovez where the report “Blast furnace in every briquette” was presented;

the 7^th Congress of Steelmakers that took place in October, 14-18, 2002 in Magnitogorsk where the report on the subject “The Technology and the Economy of Briquette Production from Fine-dyspersated Waste of Metallurgical and By-product-coking Plants for Economically Sound Replacement by it Traditional Mix Material of Steel, Blast-furnace and Ferroalloy Refinings and its Production Method”;

at the meeting of mayors of the Central Federal region that was held in Tula in December, 6-8, 2002, where the report on the subject “The Initiative project of the program of industrial waste recycling in the context of ecological doctrine of the Russian Federation”;

at the business meeting of Byelorussia-Russia-Ukraine – “The perspectives and ways of economic development” in the section “High-end technologies and industrial cooperation” that was held in Tula in April, 8-11, 2003 where the report on the subject “The Initiative project of the program of industrial waste recycling for reduction of natural resources consumption in the countries of the Commonwealth of Independent States”.

The sixth chapter of the book “Engineering protection of the environment. Water purification and waste utilization” written by U.A.Birman, N.G.Vurdova (publishing house ASB, 2002) is devoted to the technology of cold sintering.

This book is oriented for engineers, technicians and scientists of the developers, operational and research organizations and is recommended as a manual for institutions of higher education.

The authors of the book think that:

“iron industry plants have all the necessary background to become the core industry of utilization of all kind of waste within the realization of the conception of the global recycling of the man-caused materials”.

It is important to underline that this technology was worked out within the priority lines of the Ecological Doctrine of the Russian Federation.

Подпись: 9. Conclusion.

As mentioned earlier, reserves of iron-carbon-containing waste of metallurgical, machine building, mineral resource and chemical industries as well as fuel and energy complex constitute about 80 billion tons. Every year about 7 billion tons of waste is generated in Russia.

Our abundant experience in using briquettes in metallurgical industry helps us to draw a conclusion about the possibility to have in briquettes 30-90% of iron-carbon-containing waste.

So,

the technology of “EcoMashGeo” Ltd. will allow not only to recycle the present waste but also to liquidate slime fields and iron-carbonic industrial waste within 8-10 years and to set free the areas of usable land.

We offer introduction of the technology of “EcoMashGeo” at industrial plants for solving the problems of utilization of generated and current waste with the purpose of:

following reduction and liquidation of pollution of environment by industrial waste;

- integration of industrial and scientific potentials for solving the problem of waste recycling;

economy of natural resources due to maximum involving of waste into economic circulation;

- creation of standard-technical data of the united national policy in the sphere of waste management at all levels of management;

creation of control system of waste recycling and utilization.

Having the abundant experience in the sphere of production organization and application of briquettes in metallurgical industry, “EcoMashGeo” Ltd. will help you:

to define verges and volumes of man-caused waste deposits of metallurgical, machine building, mineral resource and chemical industries as well as fuel and energy complex in any region of the Commonwealth of Independent States and abroad.

to define the economic and metallurgical value of briquettes for a definite metallurgical plant, taking into consideration availability of dumps with industrial waste;

to work through the technology of briquettes production for a definite plant;

to make a pilot batch of briquettes from the given man-caused waste and to do the technological accompaniment of balance meltings with the purpose of getting a maximal economic effect for a definite metallurgical plant;

to help to buy, adjust and set up vibropression equipment (foreign and native);

to guarantee service accompaniment of the processes of metallurgical briquette production;

to guarantee a further service expansion in the sphere of developing of the briquette technology in the metallurgical manufacture.

We offer cooperation!

A more detailed information on this technology of utilization (recycling) we can get on our site:

http://www.briket.ru/

and by phones:

8 +7 (0872) 458 116 Koteniov Vasiliy Iliych

8 +7 (0872) 389 933 Barsukova Elena Yurievna

8 +7 (0872) 365 631 Kitaev Alexander Alexandrovitch

our e-mail:mashgeo@tula.net

Подпись: 10. The list of the literature.

1. B.M.Ravich Briquetting in colour and iron and steel industry. М. "Metallurgy", 1975.

2. L.A.Lurie Briquetting in metallurgy. М. "Metallurgy",1963.

3. V.P.Bulgakov, G.V.Bulgakov The research of the mineralogical content of the scale-carbonic briquettes during the process of reduction. М. "Iron and steel industry", 1998, №7

4. The report by I.M.Mischenko Utilization of the agglomerate carbon-containing metallurgical dust, "Pig iron production", 1998.

5. O.V.Yuzov, V.A.Isaev The analysis of the expenditure of the base resources in iron and steel industry of Russia. "Steel" №10, 1999.

6. V.S. Lisin The tendencies of re-structuring of iron and steel industry. "Steel" №10, 1999.

7. Patent for invention № 2183679. “Briquette for metallurgy industry, briquette for furnace washing of the blast furnace and the method of briquette production”.

8. Patent for invention № 2197544. “Briquette for metallurgical production and the method of briquettes production”.

9. “Engineering protection of the environment” edited by U.A.Birman, N.G.Vurdova, publishing house ASB, 2002, 296 p. with illustrations.

Koteniov V.I., Kitaev А.А., Barsukova E.Y. Briquettes from fine-dyspersated waste of metallurgical and by-product-coking industries are economically sound substitution of traditional charge of metallurgical refining. – М. “Metallurgist”, № 10, 2002.

Koteniov V.I., Kitaev А.А., Barsukova E.Y., Republican Unitary Plant “Byelorussian Metallurgical Plant”. The test of introduction of iron-carbon-containing briquettes into electric furnace steelmaking. – М. “Metallurgist”, № 1, 2003.

Belkin A.S., Yusfin Y.S., Kurunov I.Ph. and others. The usage of iron-coke briquettes on a cement binder in blast furnace.– М. “Metallurgist”, № 4, 2003.

Operation of Charcoal Blast Furnaces in Brasil, Montairo L.C. Steel Times 2000. №5.С. 176, 180.

OxiCup Process for Recycling Steel Mill Waste Oxides Von Vambuler, C.B., Peters M., Shueller R.H., AISE Steel Technology. 2002.79. № 5. C.49-52.

Koteniov V.I., Kitaev А.А., Barsukova E.Y. Blast furnace in every briquette. Materials of the 7^th International Congress of Blast-furnace Men. Moscow, 2002.

Koteniov V.I., Kitaev А.А., Barsukova E.Y The Technology and the Economy of Briquette Production from Fine-dyspersated Waste of Metallurgical and By-product-coking Plants for Economically Sound Replacement by it Traditional Mix Material of Steel, Blast-furnace and Ferroalloy Refinings and its Production Method”. Materials of the 7^th Congress of Steelmakers. Magnitogorsk, 2002.

Koteniov V.I., Kitaev А.А., Barsukova E.Y “The Initiative project of the program of industrial waste recycling in the context of ecological doctrine of the Russian Federation. Materials of the meeting of mayors of the Central Federal region. Tula, 2002.

Koteniov V.I., Kitaev А.А., Barsukova E.Y., “The Initiative project of the program of industrial waste recycling for reduction of natural resources consumption in the countries of the Commonwealth of Independent States”. Materials of the business meeting of Byelorussia-Russia-Ukraine. Tula, 2003.

Koteniov V.I., Kitaev А.А., Barsukova E.Y., The technology of cold briquetting (agglomeration) of industrial waste with the purpose of its usage in metallurgy industry as raw material. Materials of the third international congress “Waste Tech-2003”, Moscow, 2003.

Kurunov I.Ph., Savchuk N.A. Blast furnace production on the boundary of the 21^st century. News of ferrous metallurgy abroad, 2000, supplement 5.

Kurunov I.Ph., Savchuk N.A. The state and perspectives of without-blast furnace metallurgy of iron. – М: Chermetinformation, 2002.

Kurunov I.Ph. Perspectives of the usage of non-agglomerated iron-containing materials in blast furnace. – М. “Metallurgist”, № 5, 2003.

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