Use of a basic oxygen furnace to produce granulated metallic units, and associated systems, devices, and methods

Patent metadata

Field	Value
Publication number	US-12403529-B2
Application number	US-202418882661-A
Country	US
Kind code	B2
Filing date	Sep 11, 2024
Priority date	Sep 11, 2023
Publication date	Sep 2, 2025
Grant date	Sep 2, 2025

Abstract

Systems and methods for using a liquid hot metal processing unit to produce granulated metallic units (GMUs) are disclosed herein. In some embodiments of the present technology, a liquid hot metal processing system for producing GMUs comprises a liquid hot metal processing unit including a granulator unit. The granulator unit can include a tilter positioned to receive and tilt a ladle, a controller operably coupled to the tilter to control tilting of the ladle, a tundish positioned to receive the molten metallics from the ladle, and a reactor positioned to receive the molten metallics from the tundish. The reactor can be configured to cool the molten metallics to form granulated metallic units (GMUs).

First claim

We claim:

1. A liquid hot metal processing system for producing granulated metallic units (GMUs), the system comprising:
a liquid hot metal processing unit including:
a granulator unit including:
a tilter positioned to receive a ladle,
a controller operably coupled to the tilter to control a tilt of the ladle,
a tundish positioned to receive molten metallics from the ladle, and
a reactor positioned to receive the molten metallics from the tundish, wherein the reactor is configured to cool the molten metallics and form the GMUs,
an ejector positioned to receive GMUs from the reactor, and
a lift line downstream of the reactor, wherein the lift line includes a rock box configured to receive and store a portion of the GMUs received by the ejector.

2. The system of claim 1 , wherein the liquid hot metal processing unit further includes:
the ladle configured to receive and store the molten metallics; and
an overhead crane configured to transfer the ladle to and from the tilter.

3. The system of claim 1 , wherein the liquid hot metal processing unit further includes:
a basic oxygen furnace (BOF) vessel configured to receive the molten metallics; and
an oxygen lance insertable into the BOF vessel to deliver oxygen gas to the molten metallics.

4. The system of claim 1 , wherein the liquid hot metal processing unit further includes an oxygen lance configured to deliver oxygen gas to the molten metallics, and wherein the oxygen gas is configured to react with carbon in or on the molten metallics to reduce a carbon content of the molten metallics.

5. The system of claim 1 , wherein the liquid hot metal processing unit further includes a desulfurization unit configured to reduce a sulfur content of the molten metallics, and wherein the desulfurization unit is configured to reduce the sulfur content of the molten metallics by providing at least one of calcium carbide or magnesium to the molten metallics.

6. The system of claim 1 , wherein the ladle comprises a first ladle, wherein the granulator unit comprises a first granulator unit, and wherein the liquid hot metal processing unit further includes a second ladle and a second granulator unit positioned adjacent to the first granulator unit, wherein the second granulator unit includes:
a second tilter positioned to receive and tilt the second ladle;
a second controller operably coupled to the second tilter to control tilting of the second ladle;
a second tundish positioned to receive the molten metallics from the second ladle; and
a second reactor positioned to receive the molten metallics from the second tundish, wherein the second reactor is configured to cool the molten metallics to form granulated metallic units (GMUs).

7. The system of claim 1 , wherein the granulator unit further includes a stopper rod assembly coupled to the tundish, wherein the stopper rod assembly include a stopper rod and an actuator operably coupled to move the stopper rod into and out of an outlet of the tundish.

8. The system of claim 1 , wherein the lift line includes a curved region, and wherein the rock box is at the curved region.

9. The system of claim 1 , wherein the granulator unit further includes a dewatering assembly positioned downstream of the reactor, wherein the dewatering assembly is configured to filter out GMU fines less than 1 millimeter in size.

10. The system of claim 1 , wherein the granulator unit further includes a dewatering assembly positioned downstream of the reactor, wherein the granulator unit further includes an imaging device positioned to capture images of the GMUs on the dewatering assembly, wherein the images captured by the imaging device are configured to be used in an optical granulometry feedback system to adjust a flow rate of the molten metallics into the reactor.

11. The system of claim 1 , wherein the granulator unit further includes a dewatering assembly positioned downstream of the reactor, wherein the granulator unit further includes a classifier assembly positioned downstream of the dewatering assembly, wherein the classifier assembly is configured to classify filtrate received from the dewatering assembly and output GMUs fines.

12. The system of claim 1 , wherein the liquid hot metal processing unit further includes a transfer vessel preparation unit configured to deslag and dekish the ladle.

13. The system of claim 1 , further comprising:
a blast furnace configured to melt iron ore to output the molten metallics; and
a torpedo car configured to transport the molten metallics from the blast furnace to the liquid hot metal processing unit.

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