Patent Application
20220372591
The present invention relates to a method for removing phosphorus from a phosphorus-containing substance, in which at least a part of phosphorus and oxide in a solid oxide (phosphorus-containing substance) that is used as a main raw material or an auxiliary raw material for metal smelting or metal refining is decreased at an early stage of the smelting or refining, a method for manufacturing a raw material for metal smelting or refining, and a method for manufacturing metal. The invention particularly proposes such methods effective in improving the quality of metal products.
As described herein, alphabetical symbols such as “P” and “P2O5” denote substances expressed respectively by such chemical formulae, and the term “phosphorus” refers to phosphorus in any form contained in those substances.
As described herein, the volume of gas, when expressed in “titers,” refers to a volume value in terms of a standard state defined by a temperature of 273 K and an atmospheric pressure of 1 atm. Further, as for the pressure unit of atm, one atm equals 1.01325×105 Pa. Furthermore, the content of P in a substance, when expressed in mass %, refers to a content percentage of phosphorus in any form contained in the substance.
Phosphorus (P) is inevitably contained in molten pig iron manufactured in a blast furnace due to an ironmaking raw material component such as iron ore. Since phosphorus is a harmful component to a steel material, it is common to perform a dephosphorization treatment generally at a steelmaking stage so as to improve material properties of iron and steel products. The dephosphorization treatment is a method for removing phosphorus in molten pig iron or molten steel by oxidizing the phosphorus by use of an oxygen source such as an oxygen gas or iron oxide to form P2O5 and then transferring P2O5 into slag whose main component is CaO, While phosphorus in molten pig iron or molten steel is oxidized using a gas such as oxygen and removed into the slag, iron is also oxidized at this time, and thus even in a case of not using iron oxide as the oxygen source, the iron in the form of iron oxide is also contained in the slag.
In recent years, from the viewpoint of environmental measures and resource saving, an attempt including recycling of steelmaking slag has been made to decrease a generation amount of steelmaking slag. For example, slag (converter slag) generated during decarburization refining of molten pig iron that has been subjected to a preliminary dephosphorization treatment (a treatment of preliminarily removing phosphorus in molten pig iron before being subjected to decarburization refining in a converter) is recycled, as a CaO source for a slag forming agent or an iron source, to a blast furnace via a sintering process of iron ore or recycled as a CaO source in a molten pig iron preliminary treatment process.
When performing decarburization relining of molten pig iron to which a preliminary dephosphorization treatment has been performed (hereinafter, referred to “dephosphorized molten pig iron”), especially dephosphorized molten pig iron to which a preliminary dephosphorization treatment has been performed to a level of the phosphorus concentration of a steel product in a converter, the molten pig iron generates a converter slag barely containing phosphorus. Accordingly, for example, even when such a converter slag is used for recycling in a blast furnace, there is no need to be concerned about an increase in a phosphorus concentration (pickup) in the molten pig iron. However, a slag generated in a preliminary dephosphorization treatment or a converter slag (slag having a high phosphorus content) generated when decarburization refining is performed in a converter to a molten pig iron in which a preliminary dephosphorization treatment has not been performed (hereinafter, sometimes abbreviated as “normal molten pig iron”) or to a dephosphorized molten pig iron in which a preliminary dephosphorization treatment has been performed but the phosphorus concentration after the dephosphorization treatment is not decreased to a level of the phosphorus concentration of a steel product is used for recycling in the form of oxide in a blast furnace, phosphorus in a converter slag is reduced and manufactured in a blast furnace. Therefore, there arises a problem that a phosphorus content in a molten pig iron is increased and thus a load of molten pig iron dephosphorization treatment is rather increased.
Furthermore, manganese (Mn) is conventionally added so as to improve the strength of iron and steel products. For example, in manufacturing manganese-containing steel, as a manganese source to be added to increase an Mn concentration in molten steel, there is used, in addition to manganese ore, ferromanganese having a carbon content of 1.0 to 7.5 mass %, silicon manganese having a carbon content of not more than 2.0 mass %, metallic manganese having a carbon content of not more than 0.01 mass %, or the like. It is known, however, that a raw material price of the manganese source except for manganese ore increases with decreasing carbon content. Thus, for the purpose of decreasing a manufacturing cost, manganese ore, which is inexpensive as the manganese source, is used to produce manganese-containing steel. However, a problem is that, a particularly inexpensive type of manganese ore contains a large amount of phosphorus, so that using such a manganese as the manganese source causes an increase in phosphorus concentration in a steel material, resulting in deterioration in quality. For this reason, the use of manganese ore is in fact limited.
As described above, a large amount of phosphorus is usually contained in a main raw material or an auxiliary raw material that is used in an ironmaking process, and thus a phosphorus content in final iron and steel products is increased depending on a concentration and a use amount of phosphorus contained in such a phosphorus-containing substance. The phosphorus content affects the quality of iron and steel products. In order, therefore, to suppress a phosphorus content in iron and steel products, it is required to use a phosphorus-containing substance such as a main or auxiliary raw material having a low phosphorus content. This, however, leads to a cost increase. Thus, there have conventionally been proposed some methods for preliminarily removing phosphorus from a phosphorus-containing substance that is a main or auxiliary raw material for ironmaking.
For example, Patent Literature 1 proposes a method for removing phosphorus by bringing iron ore, titanium-containing iron ore, nickel-containing ore, chromium-containing ore or a mixture containing these types of ore as a main component having a CaO content of not more than 25 mass % and a CaO/(SiO2+Al2O3) ratio of not more than 5, into contact with one selected from a group of Ar, He, N2, CO, H2, and hydrocarbon or a mixture gas thereof at a temperature of not lower than 1600° C.
Patent Literature 2 proposes the following method. That is, phosphate is separated and dissolved by: crushing iron ore having a high phosphorus content to a size of not more than 0.5 mm; adding water to the resultant to have a pulp concentration of about 35 mass %; and adding H2SO4 or HCl to the solution and reacting therewith at pH: not more than 2.0. Then, non-magnetic SiO2, Al2O3 and so on are precipitated and separated as slime by gathering a magnetically attracted substance such as magnetite and so on by means of a magnetic separation, while P dissolved into the solution is neutralized in a range of pH: 5.0 to 10.0 by adding slaked lime or quicklime so as to separate and collect as calcium phosphate.
Patent Literature 3 proposes a method for performing dephosphorization of iron ore by use of Microbial Aspergillus SP KSC-1004 strain or Microbial Fusarium SP KSC-1005 strain.
Non-Patent Literature 1 reports a study on reduction of high-phosphorus iron ore by use of a hydrogen-vapor mixture gas in which a water vapor pressure is controlled, thus proposing a method for performing dephosphorization directly from iron ore.
The above-described conventional techniques, however, have the following problems to be solved. That is, the method disclosed in Patent Literature 1 presents a problem of a treatment temperature of as high as not lower than 1600° C., resulting in the need for a large amount of energy. Moreover, since ore is treated in a molten state, there are also problems of wear of a vessel and handling difficulty of a high-temperature melt.
The method disclosed in Patent Literature 2 is a wet treatment using acid, presenting a problem of time-consuming and costly drying of a magnetically attractable substance recovered so that the substance can be used as a main raw material. Another problem is that preliminarily pulverizing iron ore to a size of not more than 0.5 mm is time-consuming and costly.
The method of Patent Literature 3 is also a wet treatment, presenting a problem of time-consuming and costly drying of ore after removal of phosphorus therefrom so that the ore can be used as a main raw material.
Non-Patent Literature 1 presents a problem of a removal ratio of phosphorus in ore of as low as 13% at the maximum. Another problem is that, while hydrogen is used as a reaction gas, no consideration has been made on equipment and so on for safely treating the hydrogen on an industrial scale.
The present invention has been made to overcome the above-described problems with the conventional techniques. An object of the present invention is to propose a method for removing phosphorus from a phosphorus-containing substance, which is applicable on an industrial scale, so as to effectively decrease phosphorus contained in a phosphorus-containing substance, which is a solid oxide that is used as a main raw material or an auxiliary raw material for metal smelting or metal refining, a method for manufacturing a raw material for metal smelting or refining, and a method for manufacturing metal.
While examining the above-described problems with the conventional techniques, the inventors found out that phosphorus can be efficiently removed by heating a phosphorus-containing substance at a low temperature and bringing it into contact with a nitrogen-containing gas, which has led to the development of the present invention.
The present invention is developed based on this finding, and firstly provides a method for removing phosphorus from a phosphorus-containing substance in which the phosphorus-containing substance that is used as a raw material for metal smelting or metal refining is reacted with a nitrogen-containing gas so that phosphorus in the phosphorus-containing substance is removed through nitriding. In the method, prior to a nitriding removal treatment of phosphorus from the phosphorus-containing substance, a reduction treatment is performed in which the phosphorus-containing substance is heated to an unmolten state temperature range so as to react with a reducing agent, thereby reducing at least a part of metal oxide in the phosphorus-containing substance.
The method for removing phosphorus from a phosphorus-containing substance according to the first method of the present invention, which is configured as described above, is also conceived to be a more preferred embodiment when configured as follows:
a. The reducing agent has an equilibrium oxygen partial pressure of not more than 10−1 atm determined by the reducing agent and a product resulting from complete combustion of the reducing agent at a treatment temperature of the reduction treatment.
b. A treatment temperature Tr (° C.) of the reduction treatment satisfies a condition of Expression (1) below (in Expression (1), Tm denotes a melting point (° C.) of the phosphorus-containing substance).
300≤Tr≤0.95=Tm (1)
c. A reduction ratio of iron oxide and manganese oxide in the phosphorus-containing substance at the end of the reduction treatment is set to not less than 11% and less than 33%,
where the iron oxide represents any of or a mixture of FeO, Fe3O4, and Fe2O3,
the manganese oxide represents any of or a mixture of MnO, Mn3O4, Mn2O3, and MnO2 and
the reduction ratio refers to a ratio of an amount of oxygen removed by reduction to total oxygen in the iron oxide and the manganese oxide.
d. The reducing agent is a reducing gas or a solid reducing agent.
e. The reduction treatment using the reducing gas is performed in a range of Expression (2) below (in Expression (2), x denotes twice (−) a volume ratio of an oxygen gas in a standard state required for complete combustion of a unit volume of the reducing gas in the standard state, and Q denotes an amount of the reducing gas (Nm3/kg) used for the reduction treatment with respect to a total amount of the iron oxide and the manganese oxide in the phosphorus-containing substance).
1.5≤x×Q≤6.0 (2)
f. The reduction treatment using the solid reducing agent satisfies a condition of Expression (3) below (in Expression (3), MM denotes a molar mass (kg/mol) of a solid reducing agent M, MFe2O3 denotes a molar mass (kg/mol) of Fe2O3, MMn2O3 denotes a molar mass (kg/mol) of M, Mn2O3, WM denotes a mass (kg) of the solid reducing agent M, WFe2O3 denotes a mass (kg) of Fe2O3 in the phosphorus-containing substance, WMn2O3 denotes a mass (kg) of Mn2O3 in the phosphorus-containing substance, and y denotes an amount of substance (mol) of an oxygen atom that reacts with 1 mol of the solid reducing agent M).
g. The nitriding removal from the phosphorus-containing substance is a treatment in which the phosphorus-containing substance is heated to an unmolten state temperature so as to react with a nitrogen-containing gas having a nitrogen partial pressure of more than 0.15 atm and less than 0.95 atm, thereby removing at least a part of phosphorus in the phosphorus-containing substance therefrom into a gas phase.
h. The nitriding removal from the phosphorus-containing substance is a treatment in which the phosphorus-containing substance is heated to the unmolten state temperature so as to react with a nitrogen-containing gas having a nitrogen partial pressure of more than 0.15 atm and less than 0.95 atm, thereby removing at least a part of phosphorus in the phosphorus-containing substance therefrom as a PN gas.
The present invention secondly proposes a method for manufacturing a raw material for metal smelting or a raw material for metal refining including, in manufacturing the raw material for metal smelting or the raw material for metal refining, a step of decreasing a phosphorus content in a phosphorus-containing substance by use of the method for removing phosphorus from a phosphorus-containing substance, which is the above-described first method according to the present invention.
The present invention thirdly proposes a method for manufacturing metal, in which in manufacturing the metal via at least one of a smelting step or a refining step, the raw material for metal smelting obtained by the second method according to the present invention is used to perform smelting in the smelting step or the raw material for metal refining obtained by the second method according to the present invention is used to perform refining in the refining step.
As described herein, the unmolten state refers to a state at a temperature lower than the temperature (melting point) Tm at which a solid sample is transformed into a liquid, which can be easily determined by any of first to third methods described below and thus is desirable. There is, however, no limitation only to these methods.
a. The first method is that a solid sample is charged into a vessel such as crucible and then continuously observed while heated at a heating rate of 5° C./minute, preferably not more than 1° C./minute, in an electric resistant furnace or the like under an objected gas atmosphere; the temperature at which a gap between particles of the solid sample is vanished and a smooth surface is generated on a surface is determined as the melting point.
b. The second method is that a measurement is performed by heating at a heating rate of 5° C./minute preferably not more than 1° C./minute under an objected gas atmosphere by means of a differential thermal analysis; a temperature at a minimum point of the endothermic peak is determined as the melting point. Here, in the case that a plurality of endothermic peaks is generated, the method is performed by: stopping the measurement at a temperature at which respective endothermic peaks are generated; observing an appearance of the measurement sample; and determining the lowest temperature at a minimum point of the endothermic peak among temperatures at which a gap between particles of the solid sample is vanished and a smooth surface is generated on a surface, as the melting point.
c. The third method is that a liquid phase ratio is calculated by inputting a sample component and varying a temperature by means of thermodynamic calculation software of a computer; a temperature at which a liquid phase ratio exceeds 95% is determined as the melting point.
According to the present invention, firstly, a phosphorus-containing substance that is used as a main raw material or an auxiliary raw material for metal smelting or metal refining is reacted, while being heated to an unmolten state temperature, with a reducing agent so that a reduction treatment of oxide in the phosphorus-containing substance is performed. This efficiently facilitates a subsequent nitriding dephosphorization treatment of removing, by use of nitrogen, phosphorus in the phosphorus-containing substance into a gas phase. The nitriding dephosphorization treatment of removing phosphorus in the phosphorus-containing substance into a gas phase is, for example, a nitriding dephosphorization treatment in which phosphorus in the phosphorus-containing substance is removed as a mononitride gas (PN) into a gas phase. Thus, according to the present invention, it is possible to use an increased amount of an inexpensive phosphorus-containing substance (a main raw material or an auxiliary raw material for smelting or refining) and to greatly decrease a load of a dephosphorization treatment process in a metal smelting or metal refining process.
According to the present invention, since phosphorus can be efficiently removed from a by-product such as steelmaking slag, the by-product can be reused during its generation process, and thus it is possible to reduce the amount of the auxiliary raw material usage in the dephosphorization treatment process in a metal smelting or metal refining process and suppress the generation amount of the by-product.
According to the present invention, phosphorus removed through nitriding is oxidized in an exhaust gas and formed into P2O5, which leads to recovery of dust having a high phosphorus concentration, and thus there is also an effect that effective utilization leading to recycling of phosphorus is enabled.
In developing the present invention, the inventors focused on inexpensive substances having a high phosphorus concentration as main raw material and auxiliary raw material for metal smelting or metal refining and pursued a study on a method for preliminarily removing phosphorus from such phosphorus-containing substances prior to the smelting or refining using the substances.
The phosphorus-containing substances that are used as raw material (main raw material and auxiliary raw material) for metal smelting or metal refining contain phosphorus mainly as an oxide such as P2O5 and usually contain, in addition thereto, metal oxides such as CaO, SiO2, MgO, Al2O3, MnO, Mn2O3, FeO, and Fe2O3. Examples of such raw material for metal smelting or metal refining, particularly raw material for ironmaking, include iron ore, manganese ore, or steelmaking slag. Table 1 shows typical compositions thereof.
As mentioned above, the main raw material and the auxiliary raw material for metal smelting and metal refining (hereinafter, an explanation will be made taking “a raw material for iron- and steel-making” as an example) comprises various metal oxides. Since phosphorus has a weak affinity with oxygen compared to calcium (Ca) and silicon (Si), it is known that P2O5 in the phosphorus-containing substance is easily reduced in a reduction of the phosphorus-containing substance by carbon, silicon, aluminum and so on. On the other hand, iron is included in various raw materials for iron- and steel-making as an oxide in the form of FeO or Fe2O3 (hereinafter, abbreviated as “FexO”). Since the affinity of these iron oxides with oxygen is comparable to that of phosphorus, FexO is reduced at the same time when the phosphorus-containing substance is reduced by carbon, silicon, aluminum and so on. In this regard, manganese is included as an oxide in the form of MnO, Mn2O3 or MnO2 (hereinafter, abbreviated as “MnxO”). Since the oxide of manganese is strong in affinity with oxygen compared to that with phosphorus but weak compared to that with carbon, silicon, aluminum and so on, MnxO is also reduced together with phosphorus when the phosphorus-containing substance is reduced by these substances.
Phosphorus, however, has a high solubility into iron or manganese, and especially, phosphorus formed by reduction is quickly dissolved into iron or manganese that are formed through reduction, thus forming a high phosphorus-containing iron or a high phosphorus-containing manganese.
Therefore; the method for removing phosphorus formed by reduction presents a problem that a phosphorus removal ratio is low because phosphorus is absorbed and dissolved into iron and manganese which are valuable components.
As a result of diligent research to solve the problem, the inventors have found out that it is possible to perform a treatment under a temperature and oxygen partial pressure at which a metal iron and a metal manganese are not formed by removing phosphorus as a gas of nitride, and whereby absorption of phosphorus into iron and manganese can be suppressed.
That is, the inventors have confirmed, by a thermodynamic consideration, that a reaction (a) represented by the following chemical equation 1 that removes phosphorus present as P2O5 in a phosphorus-containing substance is removed as a gas of nitride such as, for example, a gas of phosphorus mononitride (PN) is more stable than reactions (b) and (c) described in the following chemical equations 2 and 3, respectively, in which iron oxide or manganese oxide included in the phosphorus-containing substance are reduced to form a metal iron or a metal manganese, respectively.
[Chemical Formula 1]
2/5P2O5(I)+2/5N2(g)=4/5PN(g)+O2(g) (a)
[Chemical Formula 2]
2FeO(s)=2Fe(s)+O2(g) (b)
[Chemical Formula 3]
2 MnO(s)=2Mn(s)+O2(g) (c)
[Chemical Formula 4]
2CO(g)=2C(s)+O2(g) (d)
In
Here, in order to reduce the oxygen partial pressure, it is effective that an element such as a single element of Ca, Mg, Al, Ti, Si, C or the like, which is stable when formed into an oxide, is coexistent. The single metallic element, however, is expensive and requires an increased reaction time. Thus, in the present invention, from the viewpoint of decreasing treatment cost and treatment time, it is preferable to decrease the oxygen partial pressure by use of carbon (C). This can be understood also from the diagram of
Furthermore, in reduction reactions of Fe2O3 and Mn2O3 in the phosphorus-containing substance, a partial pressure of oxygen resulting from reactions (e) and (f) below in which these metal oxides are reduced to form Fe3O4 and Mn3O4, is higher than that in the reaction (a). That is, under a condition that Fe2O3 and Mn2O3 remain, the reaction (a) in which phosphorus is removed as phosphorus mononitride does not progress, and thus it is effective to preliminarily perform reduction treatments to reduce these oxides, whereby case the reaction (a) is expected to be further promoted. In order for reduction of Fe2O3 to progress, it is required that, by use of a reducing agent, the oxygen partial pressure in an atmosphere be made lower than an equilibrium oxygen partial pressure determined for the reaction (e) at a treatment temperature Tr. Accordingly, there is used, as the reducing agent, a gas having an equilibrium oxygen partial pressure lower than an equilibrium oxygen partial pressure determined for the reaction (e) at the treatment temperature Tr or a solid capable of reducing the equilibrium oxygen partial pressure, Here, the equilibrium oxygen partial pressure of the reducing agent is determined by the treatment temperature Tr, a partial pressure or an activity of the reducing agent and a partial pressure or an activity of a product, Here, from the viewpoint of decreasing treatment cost and treatment time, it is desirable and effective to use, as the reducing agent, a reducing gas or a solid reducing agent such as, for example, carbon monoxide (CO), hydrocarbon (CxHy), hydrogen (H2), or a carbonaceous material, though there is no limitation to these examples.
[Chemical Formula 5]
6 Fe2O3(s)=4Fe3O4(s)+O2(g) (e)
[Chemical Formula 6]
6Mn2O3(s)=4Mn3O4(s)+O2(g) (f)
[Chemical Formula 7]
2H2O(g)=2H2(g)+O2(g) (g)
Thus, based on the above-described results of examination, the inventors performed an experiment to confirm whether or not phosphorus is removed through nitriding. In this experiment, 10 g of iron ore whose particle size was adjusted to 1 to 3 mm was used as a phosphorus-containing substance, and 5 g of reagent carbon (having a particle size of under 0.25 mm) was used as solid carbon. Then, they were put on different boats made of alumina and placed stably in a compact electric resistance furnace. The furnace was heated to a predetermined temperature (600 to 1400° C.) while an Ar gas was supplied thereinto at 1 liter/min, after which the supply of the Ar gas was stopped and followed by supply of a mixture gas of carbon monoxide (CO) and nitrogen (N2), instead of the Ar gas, at 3 liter/min; and the temperature was maintained constant for 60 minutes. In this case, a ratio of the mixture gas between carbon monoxide and nitrogen was made to vary so that a nitrogen partial pressure PN2 fell within a range of 0 to 1 atm. After a lapse of a predetermined time, the supply of the mixture gas of carbon monoxide and nitrogen was stopped and followed by supply of an Ar gas instead at 1 liter/min, and after a temperature decrease to room temperature, the iron ore was collected. In this experiment, the gases were supplied from an upstream side on which the reagent carbon was placed stably so that the carbon monoxide gas reacted with the reagent carbon first.
Next, a small-scale experiment was performed to confirm whether or not phosphorus is removed through nitriding when the nitriding dephosphorization treatment is carried out after a reduction treatment using the reducing gas. In this experiment, 20 g or 40 g of iron ore was put on a boat made of alumina and subjected first to the reduction treatment and then to the nitriding dephosphorization treatment. In the reduction treatment, a flow rate of a carbon monoxide (CO) gas and a treatment time were adjusted so that a reducing gas unit consumption x×Q was 0.3 to 9.0 in the iron ore, and the temperature was set to 1000° C. Here, x denotes twice (−) a volume ratio of an oxygen gas in a standard state required for complete combustion of a unit volume of reducing gas in the standard state, and when CO is used as the reducing gas, since CO reacts with ½O2 to form CO2, x ½×2=1 is established. Furthermore, Q denotes an amount of the reducing gas (Nm3/kg) used for the reduction treatment with respect to a total amount of Fe2O3 and Mn2O3 in a phosphorus-containing substance. After that, the nitriding dephosphorization treatment was carried out at a temperature of 1000° C. under an atmosphere in which a ratio of a CO gas flow rate to a CO2 gas flow rate was 2 and N2=80 vol % (nitrogen partial pressure=0.8 atm).
As a result, as is clear from
Furthermore, after 40 g of iron ore was subjected to a reduction treatment at a temperature of 1000° C. for a treatment time of 30 minutes or 10 minutes, a nitriding dephosphorization treatment was performed as in the above-described case where 20 g of iron ore was subjected to the reduction treatment for a treatment time of 30 minutes or 10 minutes.
Next, to verify the method of the present invention, the reduction treatment was first carried out by holding a carbon monoxide (CO) gas whose flow rate was adjusted in iron ore at various temperatures (200 to 1400° C.) for 30 minutes so that the reducing gas unit consumption x×Q was 5, and then a treatment for nitriding dephosphorization was carried out at a temperature of 1000° C. under an atmosphere in which a ratio of the CO gas flow rate to a CO2 gas flow rate was 2 and N2 80 vol % (nitrogen partial pressure 0.8 atm).
A small-scale experiment was performed to confirm whether or not phosphorus is removed through nitriding when the nitriding dephosphorization treatment is carried out after a reduction treatment using the solid reducing agent. In this experiment, reagent carbon was also mixed into iron ore, and the iron ore mixed with the reagent carbon was subjected to a reduction treatment in which heating to a predetermined temperature (Tr=200 to 1400° C.) was performed and then to a nitriding dephosphorization treatment as in the case of using a reducing gas.
This reduction treatment was carried out in the following manner. That is, the reagent carbon was mixed into the iron ore so that a reducing agent ratio M/O on an amount-of-substance basis was 0.11 to 1.34, and the iron ore mixed with the reagent carbon was kept at Tr=1000° C. for 30 minutes. Herein, where Wm, WFe2O3, and WMn2O3 denote masses (kg) of a solid reducing agent M and Fe2O3 and Mn2O3 in a phosphorus-containing substance, respectively, and MM, MFeO3, and MMn2O3 denote molar masses (kg/mol) of the solid reducing agent M and Fe2O3 and Mn2O3 in the phosphorus-containing substance, respectively, the reducing agent ratio M/O on an amount-of-substance basis is expressed as (WM/MM)/{(WFe2O3/MFe2O3)÷(WMn2O3/MMn2O3)}. After that, the nitriding dephosphorization treatment was carried out at the treatment temperature TDP=1000° C. under an atmosphere in which a ratio of a CO gas flow rate to a CO2 gas flow rate was about 2.0 and N2=80 vol % (nitrogen partial pressure PN2 0.80 atm).
Further experiments were carried out for different particle sizes by applying the above-described nitriding dephosphorization treatment to manganese ore and steelmaking slag. It was then confirmed that a high phosphorus removal ratio can be obtained in a nitrogen partial pressure range of “more than 0.15 atm and less than 0.95 atm” and a temperature range of “not lower than 750° C. and not higher than a melting point (° C.)×0.95” under all conditions. It was confirmed that a high phosphorus removal ratio can be obtained particularly in a case where manganese ore or steelmaking slag is subjected to the reduction treatment with the reducing gas unit consumption x×Q of “1.5 to 6.0” or the reducing agent ratio M/O on an amount-of-substance basis of “0.33 to 1.0” and in a temperature range of “not lower than 300° C. and not higher than a melting point (° C.)×0.95.”
As described above, as a treatment of removing phosphorus in a phosphorus-containing substance through nitriding, it is required that nitrogen be suppled at a high temperature and a low oxygen partial pressure as preset conditions. As equipment used for the treatment, any type of equipment capable of heating-up and atmosphere adjustment, such as an electric furnace, a rotary hearth furnace, a kiln furnace, a fluidized bed heating furnace, and a sintering machine, can be used with no problem. Also, as a method for decreasing an oxygen partial pressure, any of the following methods may be used as long as a predetermined oxygen partial pressure can be obtained:
(a) Bringing a solid reducing agent into contact with a nitrogen gas at a high temperature,
(b) Mixing a reducing gas such as any of carbon monoxide, hydrogen, and hydrocarbon into a nitrogen gas,
(c) Introducing a nitrogen gas into a solid electrolyte to a voltage has been applied so as to remove oxygen.
In a case where a reduction treatment is performed before a nitriding dephosphorization treatment, however, it is required that the treatment be performed at a high temperature. Further, equipment used for the treatment may include any type of equipment capable of heating-up, such as a high-frequency heating furnace, an electric furnace, a rotary hearth furnace, a kiln furnace, a fluidized bed heating furnace, and a sintering machine. As a reducing gas, for example, types of gas such as carbon monoxide (CO), hydrocarbon (CmHn), and hydrogen (H2) are desirable and effective from the viewpoint of decreasing treatment cost, but any type of gas may be used. A value of x noted above varies depending on a type of the reducing gas. When CO is used as the reducing gas, x=1 as described above, and also when H2 is used as the reducing gas, the number of oxygen atoms required for H2 to form H2O is one. Furthermore, when CmHn is used as the reducing gas, x denotes the number of oxygen atoms required for a C atom to form CO2 or for an H atom to form H2O, and x=2 m+0.5 n is established. It is also effective that the reducing gas is used by being circulated during the reduction treatment so as to increase reaction efficiency. A solid reducing agent may be any substance containing an element stable as an oxide, such as a single element of Ca, Mg, Al, Ti, Si, or C. Furthermore, the solid reducing agent may be used in a granulated state of being mixed with a phosphorus-containing substance.
According to the method of the present invention, iron ore that has been subjected to a reduction treatment and then to a nitriding dephosphorization treatment can be used as powder ore to obtain a low phosphorus-containing sintered ore by use of a downward suction type Dwight-Lloyd sintering machine. By blending this sintered ore in a blast furnace, low-phosphorus molten pig iron can be manufactured. This makes it possible to reduce an amount of a refining agent used for a molten pig iron pretreatment and to achieve a reduction in treatment time to maintain a high molten pig iron temperature, thus contributing to large-volume use of a cold iron source, and is, therefore, effective in terms of energy saving and a reduction in environmental load. Furthermore, according to the method of the present invention, manganese ore that had been subjected to a reduction treatment and then to a nitriding dephosphorization treatment was charged as a manganese source during converter refining to manufacture low-phosphorus and high-manganese steel. In this method, low-phosphorus and high-manganese steel could be economically manufactured without the need to use an expensive manganese alloy or to perform a dephosphorization treatment in a subsequent treatment. Without being limited the above-described example, the method of the present invention is applicable to a preliminary dephosphorization treatment of iron and steel slag to be recycled, an auxiliary raw material to be charged in a preliminary treatment, or the like.
Into a rotary hearth furnace having a scale of 5 ton/hr, 2 t or 4 t of iron ore was charged, and a reduction treatment thereof was performed for one or two hours by adjusting respective amounts of fuel and oxygen to be supplied to a heating burner and supplying a carbon monoxide gas into the furnace. Then, a nitriding dephosphorization treatment was carried out for 30 minutes, in which the respective amounts of fuel and oxygen and an amount of a nitrogen gas were adjusted to perform adjustment so that a treatment temperature was 1000° C., a CO/CO2 ratio was 2.02 to 2.05, and a nitrogen partial pressure was 0.8 atm. A temperature measurement and a gas composition analysis were performed at a location of the charged sample after a lapse of 15 minutes. Respective concentrations of carbon monoxide (CO) and carbon dioxide (CO2) in the gas were measured using an infrared gas analyzer, and a residual component of the gas was treated as the nitrogen gas. Further, an oxygen partial pressure was calculated from the CO/CO2 ratio determined from the respective concentrations of CO and CO2 based on reactions (h) to (j) expressed by formulae below. Furthermore, respective compositions of iron ore and manganese ore used are as shown in Table 1 above.
Regarding an operation in which the reducing gas unit consumption x×Q was made to vary, Tables 2 to 3 show treatment conditions and results thereof where the reduction treatment temperature Tr 1000° C., an amount of iron ore was 2 t, and a reduction treatment time was one or two hours, and Tables 4 to 5 show treatment conditions and results thereof where an amount of iron ore was 4 t and a reduction treatment time was one or two hours.
In inventive Examples 1 to 20 of the present invention shown in Tables 2 to 5 in which the reduction treatment was performed first, a phosphorus removal ratio is improved by performing the reduction treatment as compared with Comparative Example 1 of the present invention in which the reduction treatment was not performed, with any value of the reducing gas unit consumption x×Q, Furthermore, in Inventive Examples 1 to 20 of the present invention in which the reducing gas unit consumption x×Q is 1.5 to 6.0, as compared with Comparative Examples 2 to 17, the phosphorus removal ratio is as high as about 70%. Conceivably, the reason why an increase in phosphorus removal ratio is small when the reducing gas unit consumption x×Q is less than 1.5 is that Fe2O3 still remained after the reduction treatment, and thus the above-described reaction (a) was suppressed until the above-described reaction (e) progressed. Conceivably, the reason why the phosphorus removal ratio is low when the reducing gas unit consumption x×Q is larger than 6.0 is that a metallic iron resulting from progress of the above-described reaction (b) absorbed vaporized phosphorus, resulting in lowering the phosphorus removal ratio.
Furthermore, regarding an operation in which the reducing gas unit consumption x×Q was made to vary, Tables 6 to 7 show, along with results thereof, treatment conditions that the reduction treatment temperature Tr=1000° C., an amount of iron ore was 2 t, and a flow rate of a reducing gas was 25 L/min or 100 L/min., and Tables 8 to 9 show, along with results thereof, treatment conditions that an amount of iron ore was 4 t and a flow rate of the reducing gas was 25 L/min or 100 L/min. In inventive Examples 21 to 40 of the present invention shown in Tables 6 to 9, for any value of the reduction treatment temperature Tr, as compared with Comparative Example 1 in which the reduction treatment was not performed, a phosphorus removal ratio is improved by performing the reduction treatment. Furthermore, in Inventive Examples 21 to 40 of the present invention in which the reducing gas unit consumption x×Q is 1.5 to 6.0, as compared with Comparative Examples 18 to 33, the phosphorus removal ratio is as high as about 70%. Conceivably, the reason why an increase in phosphorus removal ratio is small when the reducing gas unit consumption x×Q is less than 1.5 is that Fe2O3 still remained after the reduction treatment, and thus the reaction (a) was suppressed until the reaction (e) progressed. Further, conceivably, the reason why the phosphorus removal ratio is low when the reducing gas unit consumption x×Q is larger than 6.0 is that a metallic iron resulting from progress of the reaction (b) absorbed vaporized phosphorus, resulting in lowering the phosphorus removal ratio.
Regarding an operation in which the reduction treatment temperature Tr was made to vary, Tables 10 to 11 show treatment conditions and results thereof where the reducing gas unit consumption x×Q was 3.0 or 5.0, an amount of iron ore was 2 t and a reduction treatment time was one hour. In Inventive Examples 41 to 52 of the present invention shown in Tables 10 to 11, for any value of the reducing gas unit consumption x×Q, as compared with Comparative Example 1 shown in Table 2, the phosphorus removal ratio ΔP is improved by the reduction treatment under a condition that the reduction treatment temperature Tr is not higher than 1300° C. The phosphorus removal ratio ΔP is high particularly in Inventive Examples 41 to 52 of the present invention in which the reduction treatment was performed at 300 to 1300° C. Furthermore, conceivably, the reason why an increase in the phosphorus removal ratio ΔP is small in Comparative Examples 34 to 35 and Comparative Examples 38 to 39 in which the reduction treatment was performed at a temperature lower than 300° C. is that Fe2O3 was stable at lower than 300° C., and thus a reduction using carbon monoxide did not progress. As a result, Fe2O3 remained after the reduction treatment at lower than 300° C., and thus the above-described reaction (a) was suppressed until the above-described reaction (e) progressed, resulting in lowering the phosphorus removal ratio. Conceivably, the reason why the phosphorus removal ratio is low in Comparative Examples 36 to 37 and Comparative Examples 40 to 41 in which the reduction treatment was performed at a temperature higher than 1300° C. is that a melting point of iron ore used this time was 1370° C., so that the iron ore was in a semi-molten or molten state at the reduction treatment temperature Tr of 1350 or 1400° C. and as a result of aggregation of a sample, gaps and pores between iron ore particles disappeared to significantly reduce an interfacial area for contacting gas. A melting point Tm used in this example was measured based on the first method described above in paragraph.
Into a rotary hearth furnace having a scale of 5 ton/hr, 4 t of iron ore or 4 t of manganese ore were charged together with a carbonaceous material, and a reduction treatment thereof was performed for two hours by adjusting respective amounts of fuel and oxygen to be supplied to a heating burner. Then, a nitriding dephosphorization treatment was carried out for 30 minutes by adjusting the respective amounts of fuel and oxygen to be supplied to the heating burner, a ratio therebetween, and an amount of a nitrogen gas to be supplied to perform adjustment so that the treatment temperature TDP=1000° C., a CO/COD ratio: a range of 2.02 to 2.05, and a nitrogen partial pressure PN2=0.80 atm. A temperature measurement and a gas composition analysis were performed at a location of the charged sample after a lapse of 15 minutes in the nitriding dephosphorization treatment.
Tables 12-1 to 12-7 show treatment conditions and results in a case of treating iron ore. Treatment No. 1 is a comparative example in which a reduction treatment was not performed. Treatments Nos. 2 to 49 show results of operations in which the reduction treatment temperature Tr was set to 300, 800, 1000, and 1300° C. and the reducing agent ratio M/O on an amount-of-substance basis to iron ore was made to vary. In Treatments Nos. 2 to 49, under any of reduction treatment conditions, as compared with Treatment No. 1 as the comparative example, the phosphorus removal ratio ΔP by a nitriding dephosphorization treatment is improved. The phosphorus removal ratio ΔP is as high as about 70% particularly under a condition that the reducing agent ratio M/O on an amount-of-substance basis is ⅓ to 1.0, Conceivably, the reason why an increase in phosphorus removal ratio is small when the reducing agent ratio M/O on an amount-of-substance basis is less than ⅓ is as follows. That is, under the conditions of this example, a carbonaceous material is used as a solid reducing agent, and thus an amount of substance y of an oxygen atom that reacts with 1 mol of the solid reducing agent is 1 mol. The reducing agent ratio M/O on an amount-of-substance basis required for the above-described reaction (e) to completely progress rightward (a reduction reaction) is expressed as ⅓y ⅓. That is, conceivably, when the reducing agent ratio M/O on an amount-of-substance basis was less than ⅓, Fe2O3 remained after the reduction treatment, and thus in a subsequent nitriding dephosphorization treatment, a dephosphorization reaction of the above-described reaction (a) was suppressed until the above-described reaction (e) was completed. On the other hand, conceivably, the reason why the phosphorus removal ratio ΔP is low when the reducing agent ratio M/O on an amount-of-substance basis is larger than 1.0 is as follows. That is, the reducing agent ratio M/O on an amount-of-substance basis required for a reaction (k) expressed by Chemical Formula 12 below to completely progress rightward (a reduction reaction) is expressed as 1/y=1. That is, when the reducing agent ratio M/O on an amount-of-substance basis is more than 1.0, the above-described reaction (b) progresses rightward (a reduction reaction) to cause metallic iron to be formed, Therefore, it was considered that phosphorus was absorbed by the metallic iron, resulting in lowering the phosphorus removal ratio ΔP.
[Chemical Formula 12]
2Fe2O3(s)=4FeO(s)+O2(g) (k)
Treatment Conditions Nos. 50 to 88 in Tables 12-5 to 12-7 show results of operations in which the reducing agent ratio M/O on an amount-of-substance basis was set to 0.33, 0.78, and 1.0 and the reduction treatment temperature Tr was made to vary. Under a reduction treatment condition that the treatment temperature is not higher than Tr=1300° C., as compared with the result of Treatment No. 1 as the comparative example, the phosphorus removal ratio ΔP based on a nitriding dephosphorization treatment is improved. The phosphorus removal ratio ΔP based on the nitriding dephosphorization treatment is high particularly when the reduction treatment temperature Tr is 300 to 1300° C. Conceivably, the reason why an increase in the phosphorus removal ratio ΔP is small when a reduction treatment is performed at lower than Tr=300° C. is that Fe2O3 was stable at lower than 300° C., and thus a reduction using carbon did not progress, as a result of which Fe2O3 remained after the reduction treatment at lower than 300° C., so that in a subsequent nitriding dephosphorization treatment, a dephosphorization reaction of the reaction (a) was suppressed until the reaction (e) was completed. On the other hand, conceivably, the reason why the phosphorus removal ratio ΔP is low when the reduction treatment is performed at a temperature higher than Tr 1300° C. is that the melting point Tm of iron ore used this time was 1370° C., so that the iron ore was in a semi-molten or molten state at the reduction treatment temperature Tr of 1350 or 1400° C., which is higher than 0.95×Tm, and as a result of aggregation of a sample, gaps and pores between iron ore particles disappeared to significantly reduce an interfacial area for contacting a nitrogen gas.
Table 13 collectively shows treatment conditions and operation results in a case of treating manganese ore. Here, a reduction ratio of iron oxide and manganese oxide refers to a ratio of an amount of reduced oxygen to total oxygen in the iron oxide and manganese oxide. In Treatments Nos. 90 to 109 in which the reduction treatment temperature Tr is in a range of 200 to 1350° C., as compared with Treatment No. 89 as a comparative example in which a reduction treatment is not performed, the phosphorus removal ratio ΔP is improved. Particularly under treatment conditions (Nos. 96 to 98, 101 to 103, and 106 to 108) that the reducing agent ratio M/O on an amount-of-substance basis is in a range of ⅓ to 1.0 among conditions that the reduction treatment temperature Tr is in a range of 300 to 1350° C., as compared with treatment conditions (Nos. 95, 99, 100, 104, 105, and 109) that the reduction treatment temperature Tr is in the same range and the reducing agent ratio M/O on an amount-of-substance basis is 0.22 or 1.11, the phosphorus removal ratio ΔP is high. Conceivably, the reason why an increase in the phosphorus removal ratio ΔP is small when the reducing agent ratio on an amount-of-substance basis is less than ⅓ is as follows. That is, under the conditions of this example, a carbonaceous material is used as a solid reducing agent, and thus the amount of substance y of an oxygen atom that reacts with 1 mol of the solid reducing agent M is 1 mol. Accordingly, the reducing agent ratio M/O on an amount-of-substance basis required for the above-described reaction (e) and reaction (f) to completely progress rightward (a reduction reaction) is expressed as ⅓y=⅓. That is, conceivably, when the reducing agent ratio M/O on an amount-of-substance basis was less than ⅓, Fe2O3 and Mn2O3 remained after the reduction treatment, and thus in a subsequent nitriding dephosphorization treatment, a dephosphorization reaction of the above-described reaction (a) was suppressed until the above-described reaction (e) and reaction (f) were completed. On the other hand, conceivably, the reason why the phosphorus removal ratio ΔP is low when the reducing agent ratio M/O on an amount-of-substance basis is more than 1.0 is as follows. That is, the reducing agent ratio M/O on an amount-of-substance basis required for the above-described reaction (k) and a reaction (l) expressed by Chemical Formula 13 below to completely progress rightward (a reduction reaction) is expressed as 1/y=1 when considered similarly to the above, That is, conceivably, when the reducing agent ratio M/O on an amount-of-substance basis was more than 1.0, the above-described reaction (b) and reaction (c) progressed rightward (a reduction reaction) to cause metallic iron and metallic manganese to be formed, so that phosphorus was absorbed by the metallic iron or metallic manganese, resulting in lowering the phosphorus removal ratio ΔP.
[Chemical Formula 13]
2Mn2O3(s)=4MnO(s)+O2(g) (1)
Furthermore, conceivably, the reason why an increase in the phosphorus removal ratio ΔP is small when a reduction treatment is performed at lower than the reduction treatment temperature Tr=300° C. is that Fe2O3 and Mn2O3 were stable at lower than 300° C., and thus a reduction using carbon did not progress, as a result of which Fe2O3 remained after the reduction treatment at lower than 300° C., so that in a subsequent nitriding dephosphorization treatment, a dephosphorization reaction of the reaction (a) was suppressed until the reaction (e) and the reaction (f) were completed. On the other hand, conceivably, the reason why the phosphorus removal ratio ΔP is low when the reduction treatment is performed at a temperature higher than Tr=1350° C. is that the melting point Tm of manganese ore used this time was 1425° C. so that the manganese ore was in a molten state at the reduction treatment temperature Tr of 1450° C., which is more than 0.95×Tm, and as a result of aggregation of a sample, gaps and pores between manganese ore particles disappeared to significantly reduce an interfacial area for contacting a nitrogen gas.
The dephosphorization method according to the present invention is not only a method for preferentially removing phosphorus from a phosphorus-containing substance but also a technique for preferentially reducing oxide, and this idea is applicable not only to the field of smelting and refining described merely as an example but also to other technical fields.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-117307 | Jun 2019 | JP | national |
| 2019-117329 | Jun 2019 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2020/018445 | 5/1/2020 | WO |
