Continuous granulated metallic units production, and associated systems, devices, and methods

Patent metadata

Field	Value
Publication number	US-12427569-B2
Application number	US-202418882638-A
Country	US
Kind code	B2
Filing date	Sep 11, 2024
Priority date	Sep 11, 2023
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

Systems for continuous granulated metallic unit (GMU) production, and associated devices and methods are disclosed herein. In some embodiments, a continuous GMU production system includes a furnace unit, a desulfurization unit, a plurality of granulator units, and a cooling system. The furnace unit can receive input materials such as iron ore and output molten metal. The desulfurization unit can reduce a sulfur content of the molten metallics received from the furnace unit. Each of the plurality of granulator units can include a tundish that can control the flow of molten metallics and a reactor that can granulate the molten metallics to form GMUs. The cooling system can provide cooled water to the reactor. Continuous GMU production systems configured in accordance with embodiments of the present technology can produce GMUs under continuous operations cycles for, e.g., at least 6 hours.

First claim

We claim:

1. A method for producing granulated metallic units (GMUs), the method comprising:
reducing a sulfur content of molten metallics to produce desulfurized molten metallics;
feeding the desulfurized molten metallics to one of first or second granulator units, wherein feeding comprises:
transferring the desulfurized molten metallics into a tundish of one of the first or second granulator units,
directing the desulfurized molten metallics from the tundish into a reactor of one of the first or second granulator units, and
granulating the desulfurized molten metallics in the reactor to form GMUs;

filtering the GMUs in a dewatering assembly to form a filtrate and transferring filtrate from the dewatering assembly to a classifier assembly of one of the first or second granulator units, and
classifying, at the classifier assembly, the filtrate to output GMU fines having an average size of less than 1 mm.

2. The method of claim 1 , wherein granulating comprises ejecting the desulfurized molten metallics via a vibrating nozzle of the tundish.

3. The method of claim 1 , wherein granulating comprises extruding the desulfurized molten metallics.

4. The method of claim 1 , wherein granulating comprises applying a pressurized stream of water to the desulfurized molten metallics.

5. The method of claim 1 , wherein reducing the sulfur content comprises adding at least one of calcium carbide or magnesium to the molten metallics.

6. The method of claim 1 , further comprising dithering a stopper rod to control a flow rate of the molten metallics out of an outlet of the tundish.

7. The method of claim 1 , further comprising:
ejecting the GMUs to a dewatering assembly of one of the first or second granulator units; and
drying and filtering by size the GMUs at the dewatering assembly.

8. The method of claim 1 , further comprising:
transporting the desulfurized molten metallics to one of the first or second granulator units using a torpedo car; and
deslagging and/or dekishing the torpedo car after the torpedo car has transported the desulfurized molten metallics to one of the first or second granulator units.

9. The method of claim 1 , wherein granulating comprises forming, via the first and/or second granulator units, the GMUs for at least 6 hours continuously.

10. The method of claim 1 , wherein granulating comprises forming, via the first and/or second granulator units, the GMUs for at least 12 hours continuously.

11. A method for producing granulated metallic units (GMUs), the method comprising:
feeding molten metallics to one of first or second granulator units, wherein feeding comprises:
transferring the molten metallics into a tundish of one of the first or second granulator units,
directing the molten metallics from the tundish into a reactor of one of the first or second granulator units, and
granulating the molten metallics in the reactor to form GMUs;

filtering the GMUs in a dewatering assembly to form a filtrate and transferring filtrate from the dewatering assembly to a classifier assembly of one of the first or second granulator units; and
classifying, at the classifier assembly, the filtrate to output GMU fines.

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