Abstract:
The instant invention relates to a metallurgical furnace, comprising at least one upper stack ( 1 ), at least one lower stack ( 2 ), at least one fuel feeder positioned substantially between at least one upper stack ( 1 ) and the at least one lower stack ( 2 ), at least one row of tuyères ( 3, 4 ) positioned in at least one of the at least one upper stack ( 1 ) and at least one lower stack ( 2 ), the at least one row of tuyères ( 3, 4 ) providing a fluid communication between the inside of the furnace and the external environment, positioned in at least one of at least one upper stack ( 1 ) and at least one lower stack ( 2 ), and further comprising at least one permeabilizing fuel column fed through at least one hood ( 6 ), placed in the upper stack ( 1 ), which extends longitudinally through the furnace.

Description:
TECHNICAL FIELD 
       [0001]    The instant disclosure relates to metallurgical processes and apparatuses. More particularly, the instant disclosure is related to metallurgical processes and apparatuses for producing metallic alloys. 
       DESCRIPTION OF THE STATE OF THE ART 
       [0002]    Classic processes to produce pig iron are already known, which can be carried out, for example, in blast furnaces and electrical reduction furnaces. Other processes for producing alloys from iron oxide or iron ore after granulometric conditioning, classic pellets or other traditional agglomerates are also known, obtaining by traditional operations in these furnaces liquid or solid iron of a certain composition. 
         [0003]    In blast furnaces, the filler which may be composed of sorted ore, pellets, sinter or other classical agglomerates, coke and limestone are charged sequentially through the top of the furnace, forming a continuous column. At the bottom of the blast furnace is introduced atmospheric air, preheated in regenerative heaters or not, at an approximate temperature of 300 to 1200° C., through a row of tuyères in the upper part of a crucible. At this site, a zone with reducing atmosphere is formed due to the presence of carbon monoxide, formed by the reaction of the CO 2  with the carbon of the coke. This CO combines with oxygen from iron oxide, reducing it to metallic iron and producing pig iron. 
         [0004]    Impurities, that is, ore gangue and coke ashes form with the limestone a liquid, less dense, slag that floats on the surface of the cast pig iron. 
         [0005]    The gases formed in countercurrent with the filler preheat it and exit from the top. This gas consists mainly of CO, CO 2 , H 2  and N 2  and is conducted to the regenerative pre-heaters of the combustion air entering the furnace and other heating devices. 
         [0006]    It is also known that, in the filler consisting of classified ore, pellets, sinter or other classic agglomerates reduction is performed by the reduction of the oxidized filler by the CO generated from the partial combustion of the coke. CO diffuses inside the agglomerate or the ore particles, and the reduction according to the reaction MeO+CO→Me+CO 2  occurs. CO 2  generated in this reaction spreads in the opposite direction to CO and is incorporated into the gas stream that exits the furnace from the top. This reaction demands a certain time for the complete diffusion of CO inside the filler, thus requiring furnaces with high residence times of filler inside, as are typically the blast furnaces. 
         [0007]    The self-reducing agglomerates, on the other hand, present conditions much more favorable to the reduction. The closest contact between the ore or oxide and the carbonaceous material, which are finely divided, provides a shorter reaction time in that there is no need for the diffusion stage of CO into the self-reducing agglomerate, pre-built inside the agglomerates for this purpose: 
         [0000]      2MeO+C→2Me+CO 2  
 
         [0000]      CO 2 +C→2CO
 
         [0000]      MeO+CO→Me+CO 2  
 
         [0008]    In this sense, the agglomerate itself establishes, in practice, a semi-closed system in which the atmosphere is reducing during the period of time when there is available carbon inside. Alternatively, self-reducing agglomerates, such as the designation itself, maintain within inner part a reducing atmosphere that does not depend on the characteristics of the external atmosphere, that is, the type of atmosphere inside the stack furnace provided by the ascending gases. 
         [0009]    Thus, it is possible to convert in energy for the process the CO present in the furnace atmosphere from the partial combustion of the fuel and the reduction reaction inside the self-reducing agglomerates. 
         [0010]    On the other hand, in the melting processes in stack furnaces, the presence of coke or other solid fuel, charged at the top during the operation, travels downward with the rest of the filler, reacting with the CO 2 , traveling upward, in countercurrent, according to Boudouard&#39;s reaction CO 2 +C→2CO, thus increasing the consumption of carbonaceous material, without resulting in effective use in the reduction-melting process. If it were possible to burn this CO gas in the process itself, a higher efficiency would be achieved, resulting in savings in fuel coke in cupola furnaces and the fuel and reducer in blast furnaces, as in the case of all other stack furnaces used in the reduction/melting or only melting of any other alloys. 
         [0011]    Document PI9403502-4, by the same Applicant, solves the above problem by providing a furnace comprising a fuel feed separate from the cargo inlet (raw material). In particular, the furnace described in the document PI9403502-4 shows an upper stack, which receives the filler (oxides/ores, for example) and a lower one, the fuel being inserted approximately at the junction between the two stacks. 
         [0012]    Gases from the lower zone, in countercurrent with the filler, transfer to it the thermal energy required for heating and reduction or simple melting. 
         [0013]    However, for the use of self-reducing agglomerates an adequate control of the gaseous flow is essential to allow the self reduction thereof in a homogeneous way. In spite of having numerous advantages, such as those mentioned above, the furnace described in the document PI9403502-4 does not have an adequate control of the gaseous flow in the upper stack allowing abrupt escape of gases in certain points of the furnace thus hindering the control of energy exchange between the gas and the filler in the upper stack. 
       OBJECTIVES OF THE DISCLOSURE 
       [0014]    One objective of the instant disclosure is to provide a metallurgical furnace for producing metal alloys by self-reduction of agglomerates having metal oxides, including the production of liquid iron, pig iron and cast iron, as well as metal alloys, allowing an adequate control of the gaseous flow and the energy exchange to allow the reduction of self-reducing agglomerates in a homogeneous way. 
       SUMMARY OF THE DISCLOSURE 
       [0015]    In one embodiment, in order to achieve the above-described objectives, the instant disclosure provides a metallurgical furnace, comprising (i) at least one upper stack, (ii) at least one lower stack, (iii) at least one fuel feeder positioned substantially between at least one upper stack and the at least one lower stack, (iv) at least one row of tuyères positioned in at least one of the at least one upper stack and at least one lower stack, the at least one row of tuyères providing fluid communication between the inside of the furnace and the external environment, positioned in at least one of at least one upper stack and at least one lower stack, and further comprising (v) at least one permeabilizing fuel column fed through at least one hood extending longitudinally through the furnace. 
     
    
     
       DESCRIPTION OF THE FIGURES 
         [0016]    The detailed description shown below refers to the attached figures, wherein: 
           [0017]      FIG. 1  shows a furnace with a hood according to one embodiment of the instant disclosure; 
           [0018]      FIG. 2  shows a filler means according to one embodiment of the instant disclosure; 
           [0019]      FIGS. 3A and 3B  show the gaseous flow obtained by the instant disclosure in relation to the gas flow of the furnaces described in the prior art. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    This description starts with one embodiment of the disclosure. Nonetheless, the disclosure is not limited to this specific embodiment, as it will be evident for a person skilled in the art. Furthermore, the content of document PI9403502-4 is incorporated herein by reference. 
         [0021]    The instant disclosure provides a metallurgical furnace with innovations allowing an adequate control of the gaseous flow to enable the reduction of self-reducing agglomerates in a homogeneous way, also controlling the energy exchange between the gas and the filler, a fundamental principle of the self-reduction process. 
         [0022]    The metallurgical furnace of the instant disclosure is shown in  FIG. 1 , consisting essentially of an upper stack  1  where the filler (feedstock) is charged into the furnace. It is important to note that the stack may have a number of shapes such as, for example, a cylindrical shape having a circular cross-section, or a parallelepiped shape having a rectangular cross-section, inter alia. Hence, let us note that the instant disclosure is not limited to any specific shape of the furnace. 
         [0023]    In the upper stack  1  there is an assembly of at least one row of secondary tuyères  4 , which are preferably holes which allow blowing of hot or cold atmospheric air to burn CO and other combustible gases present in the ascending gas. The inflated air may optionally comprise O 2  enrichment. Moreover, gaseous, liquid or solid fuel can be injected into the tuyères  4  together with the blown air. 
         [0024]    The furnace of the instant disclosure further comprises a lower stack  2 , preferably of circular or rectangular cross-section, of sufficient diameter or dimensions for solid fuel feed. The diameter or width of the cross section of the stack  2  is greater than the one of the stack  1  sufficient for positioning fuel feeders. In the feeders, located around the junction of the upper stack  1  and the lower one  2 , fuel supply ducts  5  may be coupled to ensure that the fuel filler goes into the bed of the furnace, avoiding occurrences of filler drag when using thin materials. As the filler falls on the feeder, preheating, pre-drying and distillation of the volatile fractions present in solid fuels and combustible carbonaceous residues occur. 
         [0025]    The lower stack  2  has one or more rows of primary tuyères  3  which, as well as the secondary tuyères described above, serve to blow hot or cold air and can be enriched with O 2  or not. It is also possible to inject powder, liquid or gaseous solid fuels for partial combustion of the fuel, producing gas and providing the thermal energy necessary for the reduction and/or melting of the filler. 
         [0026]    If hot air is blown in the primary and/or secondary tuyères  4 , blower assemblies  7 , which can be connected with any air heating system (not shown) known from the prior art, can be used. 
         [0027]    Optionally, the lower stack  2  may have refractory lining and/or have refrigerated panels. 
         [0028]    Furthermore, the furnace according to the instant disclosure comprises at least one permeabilizer fuel column fed through at least one hood extending longitudinally through the furnace, as shown in said  FIG. 1 . This hood  6 , which can be a vertical duct positioned in the central vertical axis of the furnace, consists of an equipment that serves to channel the gas generated countercurrent with the flow of the filler, allowing a better control of the gas distribution of the entire upper stack  1 . Therefore, the instant disclosure provides an excellent control of the energy exchange between the gas and the filler, enabling the reduction of self-reducing agglomerates homogeneously and generating gains of operational stability of the process. 
         [0029]    The hood  6  is placed on top of the upper stack  1  and extends longitudinally through the furnace, preferably being limited above the secondary tuyères  4 . In one embodiment, the hood  6  preferably consists of a set of structured panels made of cast iron, steel or any other alloy, filled with refractory concrete and anchored in a sheet welded in the furnace structure. The hood  6  may also be fully or partially made of a refrigerated panel. During operation, part of the hood  6  is buried in the filler, forcing the passage of the generated gases both in the region of the primary tuyère  3  and in the region of the secondary tuyères  4 , that is, the hood acts as a gas channeling 
         [0030]    It should be noted that there is a region, called the cohesion zone  11 , where the softening and melting of the metallic filler occurs and, as a result, it is the zone of lower permeability, which considerably hinders gas passage. This difficulty in the passage of gas causes a preferential passage of the gas at specific points of the upper stack  1 , making it impossible to control the gaseous flow and causing an irregular thermal exchange between the filler and the gas. The basic operating model provides for the placing of a volume of permeabilizing fuel as a fillher in the center, which not only provides thermal input, but also has the function of ensuring the passage of the gases in the cohesion zone  11 , as shown in  FIG. 2 . When the metallic filler melts, it forms a zone of liquid and slurry material of very low permeability (cohesion zone  11 ). When a volume of the permeabilizing fuel is placed as a filler together with the metal charge in the upper part of the furnace, it allows the gases from the bottom vessel to reach the upper vessel easily. Thus, ideally the permeabilizer fuel is formed from at least one material which does not melt at internal temperatures of the metallurgical furnace, preferably the carbon base (C), such as, for example, metallurgical coke, petroleum coke, mineral coal, Charcoal, anthracite, briquette fuel, inter alia. 
         [0031]    Moreover, a filler means  8  is provided to enable charging of the permeabilizing fuel into the furnace. Such filler means  8  may be preferably a simple system, for examples, containing an enclosed silo  9  and an open silo  10 , with metering valves in the discharge of each silo; it may optionally have a pressure equalization system to enable the charging of the permeabilizer fuel from the closed silo into the furnace. The filler means  8  together with the hood  6  enables a channeling of the gas generated in the combustion of the fuel from the lower stack  2  with the air blown by the primary tuyères  3  and secondary tuyères  4 , more efficiently controlling the gas distribution in the furnace. 
         [0032]      FIGS. 3A and 3B  show the difference in the gaseous flow of the furnace  12  of the instant disclosure with respect to the gaseous flow of the furnace  13  described in the prior art document. It is noted that in the furnace of the instant disclosure there is a channeling of the gas generated due to the area of increased permeability formed by the permeabilizer fuel charge by the filler means  8 . As mentioned above, this allows a greater control of the permeability of the upper stack  1 , thus controlling the energy exchange between the gas and the filler, allowing the reduction of self-reducing agglomerates in a homogeneous way generating gains of operational stability of the process. 
         [0033]    The configuration of the hood  6  defines the filler distribution in the furnace  12 . Hence, the filler takes the dimensions imposed by it, that is, the width between the walls of the hood  6  is the width of the permeabilizing fuel column in the upper tub that will obey the dimensions and distances between the walls. During operation, part of the hood  6  is buried in the filler, forcing the passage of the generated gases both in the region of the primary tuyère  3  and in the region of the secondary tuyères  4 , as shown in  FIG. 5 . 
         [0034]    Thus, the furnace of the instant disclosure prevents the fuel from being fully charged with the filler at the top of the stack, therefore differing from the classical manufacturing processes and minimizing carbon gasification reactions (Boudouard&#39;s reactions) and increase both of the heat and fuel consumption in the furnace. 
         [0035]    Furthermore, the furnace of the instant disclosure differs from the other prior art furnaces because permeabilizing fuel is used in small quantities in the top of the stack in order to obtain only a control of the permeability of the upper stack  1 . In general, the use of this permeabilizing fuel does not affect the reduction and melting of the filler, since in this furnace self-reducing briquettes (but not just them) are used. In this case, the carbon required to reduce the filler is contained within the self-reducing briquette, thus not requiring that all the gas pass through the filler column as is the case of prior art conventional furnaces and in the classic manufacturing processes. 
         [0036]    Countless variations affecting the scope of protection of this application are allowed. Therefore, it is to be emphasized that this invention is not limited to the specific configurations/embodiments described above.