Claims
- 1. Dissolving a V metal-containing coke or hydrocarbon feed in a molten metal bath comprising molten iron to produce a molten metal bath containing dissolved carbon and dissolved vanadium metal, exothermically oxidizing at least a portion of said dissolved carbon from said bath to produce carbon oxides which are removed from said bath as a product of the process to produce a heated bath containing dissolved V metal and wherein said oxidation is controlled and limited to maintain a carbon level of at least 0.5 wt % in said bath and produce a heated, carbon and V-containing bath; dissolving additional amounts of V-containing coke or hydrocarbon feed in said heated, carbon and V-containing bath, and repeating said exothermic oxidation and dissolution of V-containing feed, while maintaining said carbon level, to produce a molten metal bath containing more wt % vanadium metal as a dissolved metal than wt % carbon.
- 2. The process of claim 1 wherein said coke or hydrocarbon feed processing continues until the bath contains at least 10 wt % V on an elemental metal basis.
- 3. The process of claim 2 wherein the bath contains at least 20 wt % V.
- 4. The process of claim 3 wherein the bath contains at least 40 wt % V.
- 5. The process of claim 1 wherein said coke or hydrocarbon feed processing is continued until a predetermined V concentration is achieved in the bath, the bath is either dumped to recover a V/Fe metal product or a portion of the bath is withdrawn and at least partially replaced with fresh iron.
- 6. The process of claim 1 wherein the bath is run at superatmospheric pressure.
- 7. The process of claim 1 wherein oxygen or other oxygen containing gas is continuously introduced into the bath to produce CO and control carbon concentration.
- 8. The process of claim 1 wherein the carbon content of the bath is in excess of 1.0 wt % carbon.
- 9. The process of claim 1 wherein the carbon content is in excess of 4 wt %.
- 10. The process of claim 1 wherein the carbon content is at least 90% of the solubility limit of carbon in a pure iron bath at the same temperature.
- 11. The process of claim 1 wherein the carbon content exceeds the solubility limit of carbon in a pure iron bath and is present at a level that is dissolvable in a V/Fe solution.
- 12. The process of claim 1 wherein sufficient carbon is dissolved in the molten metal bath to ensure strongly reducing conditions which keeps the V in the elemental metal state dissolved in the metallic phase.
- 13. The process of claim 1 wherein said coke is admixed with steam and oxygen to produce a gas/particulate mixture which is added to said bath.
- 14. The process of claim 1 wherein said coke is discharged down into said molten metal bath at a velocity sufficient to carry at least a majority of said coke beneath the surface of the bath.
- 15. The process of claim 1 wherein coke is added via a coke addition means beneath the surface of the molten metal bath.
- 16. The process of claim 1 where said molten metal bath is disposed as a multiple zone bath, with either valving to permit swing bed operation or conduits permitting circulation of molten metal between zones and wherein at least one of said zones is operated exothermically and at least one of said zones operates endothermically.
- 17. The process of claim 1 wherein steam is added at least periodically to endothermically react with the carbon dissolved in the molten iron bath to produce a hydrogen rich synthesis gas.
- 18. The process of claim 1 wherein alkaline materials are added to said molten metal bath to react with and capture sulfur in said coke as slag.
- 19. The process of claim 6 wherein the bath is run at 2-200 atm pressure absolute.
- 20. The process of claim 8 wherein the carbon content of the bath is in excess of 2 wt. %.
- 21. The process of claim 8 wherein the carbon content is in excess of 3 wt. %.
Parent Case Info
This application claims priority to provisional application No. 60/088,630 filed Jun. 9, 1998.
US Referenced Citations (17)
Non-Patent Literature Citations (1)
Entry |
Lankford et al, The Making, Shaping and Treating of Steel, 10th edition, 1985, p. 400, No month. |
Provisional Applications (1)
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Number |
Date |
Country |
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60/088630 |
Jun 1998 |
US |