Cogeneration process for production of energy and iron materials, including steel

• Main Author: LEHTO; JOHN M
• Format: Patent
• Language: English
• Published: 19.11.1991
• Subjects: BLASTING; CHEMISTRY; COMBUSTION ENGINES; COMBUSTION ENGINES IN GENERAL; CRACKING HYDROCARBON OILS; FUELS; HEATING; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS; INTERNAL-COMBUSTION PISTON ENGINES; LIGHTING; LUBRICANTS; MANUFACTURE OF IRON OR STEEL; MECHANICAL ENGINEERING; METALLURGY; METALLURGY OF IRON; MINERAL WAXES; PEAT; PETROLEUM, GAS OR COKE INDUSTRIES; PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OFWROUGHT-IRON OR STEEL; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVEHYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, ORGASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; TECHNICAL GASES CONTAINING CARBON MONOXIDE; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS; WEAPONS

A process and arrangement are provided for the efficient generation of energy from coal, while at the same time providing for a relatively inexpensive step in processing of iron or steel, and the extraction of valuable materials such as oils from coal. An advantage to the process is that relatively low quality coals can be utilized, since the coal is pretreated before any burning operation. Generally, the process involves three interacting stages. In the First Stage, a coal liquefaction/pyrolysis procedure is utilized to drive off volatiles, and form a very low volatile char. The volatiles can be collected and utilized as a valuable oil product, such as for diesel fuel or the like. The char material is preferably pelletized and utilized as a reductant, in a Second Stage of iron reduction and melting. Preferably the iron reduction and melting operation is conducted in a pressurized cupola and the high pressure hot product gases are utilized directly and/or indirectly, to generate electricity in Stage Three, and to produce hot steam for use in driving certain portions of Stages One and Two. High pressure product gases have a greater energy content than gases at atmospheric pressure and facilitate more efficient production of electricity in Stage Three. Problems of handling molten iron from a pressurized cupola are solved using the pressure to drive the molten iron up a vertical tap mechanism. The weight of the metal offsets the pressure as the metal rises so that the metal is driven up to a point at which the metal's pressure is decreased to atmospheric pressure. Also, preferably steel is formed from the reduced iron product of Stage Two. Also, preferably slag formed during the process is converted to a fiber product.