Operation and Design of Scrap Melting Process of the Packed Bed Type

A coke Packed bed type Scrap Melting process (PSM)with simultaneous high-rate injection of oxygen and pulverized coal was proposed which aims to achieve high heat efficiency, high productivity, high Fe yield and low refractory erosion with using not only shaft type furnaces but also basic oxygen converter (BOF) vessel. The experiments were made to verify the usefulness of the proposed process using the modified experimental blast furnace of 1 ton pig per tap scale and the modified experimental BOF of 10 ton pig per tap scale. A 3-dimensional mathematical simulation model was also developed in order to elucidate the physical and chemical conditions inside the furnace on the basis of transport phenomena and to make a basic design of commercial scale plant. Obtained results were summarized as follows: 1) 100% steel scrap can be melted into well carburized and well desulpherized pig iron using both 1 ton scale blast furnace and 10 ton scale BOF. 2) The heat efficiency of about 80%, the productivity per unit furnace volume of about 50t/d.m 3 , Fe yield of more than 99% and the erosion rate of refractory of less than 0.5 mm/charge were achieved throughout the experiments. 3) These results were well justified by the 3-dimensional mathematical simulation model. 4) A basic design of commercial scale plant was also performed by the use of the model.