Magnitogorsk Iron and Steel Works (MMK) has developed an original method for the direct reduction of iron and other iron-containing titaniferous raw material sources with promising metallurgical technology of third generation ITmk3, told an international conference on the TMS-2013 in San Antonio, TX (USA), a leading specialist of the future development of CMI Nicholas Panishev .
Until two years ago at the CMI opened a project to find promising areas of oxidized (hematite) and titanomagnetite ores extraction of different components. Currently, CMI less than a third provided with its own iron ore, which is mined in the field Small Kuybas (Magnitogorsk ore field), and comes from the processing of slag. Development of new technologies allows us to engage in the processing of ore with a high content of magnesium, titanium, vanadium and increase plant availability of raw materials, as reserves of titanomagnetite ores only in the Chelyabinsk region are estimated at several billion tons.
Using titaniferous in traditional blast furnace process is limited high titania slag imparts high viscosity. Therefore, it was decided to appeal to a new breakthrough technology ITmk3, developed in Japan. The technology of direct reduction is a simple process with a one-step operation in the furnace. Unlike previous technologies of direct reduction of iron in the technology ITmk3 recovery, melting and slag separation occur within 9-12 minutes, not hours. In addition, you can replace expensive coke of coal rank and file names, including energy, and even brown.
The experimental fusion were performed in a chamber furnace, located in the shop magnesia-dolomite refractories Refractory Company (part of the IMC). Careful preparatory work on the selection of qualitative and quantitative composition of the material in the shortest time possible to carry out experiments and successfully obtain a granular iron (nuggets) with an iron content of about 97%, which can be used as scrap in electric furnaces. CMI has developed a unique technology with its own parameters, which has already received two positive solutions for a patent.
Speaking about the benefits of the new technology, we can also mention the possibility of using not only titanomagnetite, but also any other low-grade iron-containing materials — blast furnace and converter sludge, flue dust contaminated with impurities of zinc ore and other metals. In this case, the same zinc (as oxide) can be separated, captured and sold as raw material zinc plants.
Calculations show that the specific capital costs of a project to build an industrial plant using new technology to 20% lower capital costs for conventional metallurgical facilities of similar capacity, lower operating costs by 30%. Thus, the return on such a plant may be only 2.5 years. Most importantly — a new technology (due to non-participation in it of blast furnace coke and sinter plants) gives a large environmental impact. It is assumed that carbon dioxide, sulfur dioxide, nitrogen oxide and other noxious substances will decrease by about 30% compared to conventional metallurgical techniques.
Currently, MMC is considering the construction of an industrial plant, working on technology ITmk3. The introduction of new technology will allow the company to reduce dependence on purchased iron ore, scrap and significantly reduce anthropogenic impacts on the environment.