Low-sulfur granulated metallic units

Patent metadata

Field	Value
Publication number	US-12397346-B2
Application number	US-202418882191-A
Country	US
Kind code	B2
Filing date	Sep 11, 2024
Priority date	Sep 11, 2023
Publication date	Aug 26, 2025
Grant date	Aug 26, 2025

Abstract

A low-sulfur granulated metallic unit having a mass fraction of sulfur between 0.0001 wt. % and 0.08 wt. % is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt. %, a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %, a mass fraction of manganese of at least 0.2 wt. %, a mass fraction of carbon of at least 0.8 wt. %, and/or a mass fraction of iron of at least 94.0 wt. %.

First claim

What is claimed is:

1. A plurality of granulated metallic units, individual granulated metallic units comprising:
a mass fraction of phosphorous of at least 0.025 wt. %;
a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %;
a mass fraction of manganese of at least 0.2 wt. %;
a mass fraction of carbon of at least 0.8 wt. %;
a mass fraction of sulfur between 0.0001 wt. % and 0.08 wt. %; and
a mass fraction of iron of at least 94.0 wt. %,
wherein the plurality of granulated metallic units has a size distribution such that at least 50 wt. % of the plurality of granulated metallic units is at least 6 millimeters, and
wherein a specific gravity of the plurality of granulated metallic units is between 5.0 and 6.5.

2. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of sulfur is between 0.0001 wt. % and 0.05 wt. %.

3. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of sulfur is between 0.0001 wt. % and 0.01 wt. %.

4. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of carbon is between 0.8 wt. % and 4.0 wt. %.

5. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of sulfur is between 0.0001 wt. % and 0.01 wt. % and the mass fraction of carbon is between 0.8 wt. % and 4.0 wt. %.

6. The plurality of granulated metallic units of claim 1 , wherein the plurality of granulated metallic units is a plurality of granulated pig irons.

7. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of phosphorous is between 0.025 wt. % and 0.085 wt. %.

8. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of silicon is between 0.25 wt. % and 0.75 wt. %.

9. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of manganese is between 0.2 wt. % and 0.4 wt. %.

10. The plurality of granulated metallic units of claim 1 , wherein the mass fraction of iron is between 94.0 wt. % and 96.0 wt. %.

11. The plurality of granulated metallic units of claim 1 , wherein an average particle size of the plurality of granulated metallic units is between 6 and 25 millimeters.

12. The plurality of granulated metallic units of claim 1 , wherein the size distribution is such that at least 50 wt. % of the plurality of granulated metallic units is between 6 and 10 millimeters.

13. The plurality of granulated metallic units of claim 1 , wherein the size distribution is such that at most 2.5 wt. % of the plurality of granulated metallic units is less than 4 millimeters.

14. The plurality of granulated metallic units of claim 1 , wherein the size distribution is such that:
at most 0.41 wt. % of the plurality of granulated metallic units is less than 2 millimeters;
at most 1.31 wt. % of the plurality of granulated metallic units is between 2 and 4 millimeters;
at most 7.24 wt. % of the plurality of granulated metallic units is between 4 and 6 millimeters;
at most 7.53 wt. % of the plurality of granulated metallic units is between 6 and 8 millimeters;
at least 53.46 wt. % of the plurality of granulated metallic units is between 8 and 12 millimeters;
at least 18.79 wt. % of the plurality of granulated metallic units is between 12 and 16 millimeters;
at least 10.92 wt. % of the plurality of granulated metallic units is between 16 and 25 millimeters; and
at least 0.07 wt. % of the plurality of granulated metallic units is more than 25 millimeters.

15. The plurality of granulated metallic units of claim 1 , wherein a bulk density of the plurality of granulated metallic units is between 200 and 350 pounds per cubic foot.

16. The plurality of granulated metallic units of claim 1 , wherein the plurality of granulated metallic units has a melting point between 1000° C. and 1250° C.

17. The plurality of granulated metallic units of claim 1 , wherein the plurality of granulated metallic units is produced at a production rate of at least 1000 tons per day.

18. The plurality of granulated metallic units of claim 1 , wherein the plurality of granulated metallic units has a melting point of at least 1100° C.

19. A plurality of granulated metallic units, individual granulated metallic units comprising:
a mass fraction of phosphorous of at least 0.025 wt. %;
a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %;
a mass fraction of manganese of at least 0.2 wt. %;
a mass fraction of carbon of at least 0.8 wt. %;
a mass fraction of sulfur between 0.0001 wt. % and 0.08 wt. %; and
a mass fraction of iron of at least 94.0 wt. %,
wherein the plurality of granulated metallic units has a size distribution such that at least 50 wt. % of the plurality of granulated metallic units is at least 6 millimeters, and
wherein a bulk density of the plurality of granulated metallic units is between 200 and 350 pounds per cubic foot.

20. A plurality of granulated metallic units, individual granulated metallic units comprising:
a mass fraction of phosphorous of at least 0.025 wt. %;
a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %;
a mass fraction of manganese of at least 0.2 wt. %;
a mass fraction of carbon of at least 0.8 wt. %;
a mass fraction of sulfur between 0.0001 wt. % and 0.08 wt. %; and
a mass fraction of iron of at least 94.0 wt. %,
wherein the plurality of granulated metallic units has a size distribution such that at least 50 wt. % of the plurality of granulated metallic units is at least 6 millimeters, and
wherein the plurality of granulated metallic units has a melting point between 1000° C. and 1250° C.

Assignees

• Suncoke Tech & Development Llc

Inventors

• Quanci John Francis
• RICHARDSON John Michael
• Mullarkey Patrick James
• Schwake David James
• Butor Andrew Michael
• Perkins Jonathan Hale
• Choi Chun Wai

Classifications

• C22C33/0257

  characterised by the range of the alloying elements · CPC title

• C21C5/527

  Charging of the electric furnace · CPC title

• C21B5/008

  Composition or distribution of the charge · CPC title

• C02F2209/40

  Liquid flow rate · CPC title

• C02F2103/10

  from quarries or from mining activities · CPC title