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Advanced Minerals Engrng Presentation1F-1

The Finmet process reduces iron ore using a multi-staged fluidized bed reactor system with hydrogen gas. Iron ore concentrate is dried and fed into the bottom of four reactors where it undergoes step-wise reduction as it moves counter-currently against reducing gases to produce hot briquetted iron (HBI). Reducing gases are produced from steam reforming of natural gas and recycled from the reactor off-gases after scrubbing. The high pressure operation of 12 bars allows for a high degree of metallization to over 93% iron. The HBI product is then briquetted above 650°C before cooling.

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67 views25 pages

Advanced Minerals Engrng Presentation1F-1

The Finmet process reduces iron ore using a multi-staged fluidized bed reactor system with hydrogen gas. Iron ore concentrate is dried and fed into the bottom of four reactors where it undergoes step-wise reduction as it moves counter-currently against reducing gases to produce hot briquetted iron (HBI). Reducing gases are produced from steam reforming of natural gas and recycled from the reactor off-gases after scrubbing. The high pressure operation of 12 bars allows for a high degree of metallization to over 93% iron. The HBI product is then briquetted above 650°C before cooling.

Uploaded by

Lorraine
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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FINMET

Reduction of Iron ore


Process background

The Finmet process is a multiple fluidized bed process which


utilizes a hydrogen rich gas to reduce iron ores. Hydrogen is
sourced from a steam reforming process and the reduction
process is carried out at intermediate reduction temperatures,
with a higher operating pressure than most direct reduction
processes. The process produces hot briquetted iron, HBI.
Process description

The first processing step involves the removal of gangue


from the ore in the beneficiation plant.
Beneficiation plant

Iron fines containing 62-63% total Fe (most in the form of hematite,


Fe2O3) and approximately 5 % silica (silicon dioxide, Si2O3) and 2.5%
Al2O3 are processed by standard gravity and magnetic separation
means to yield a concentrate of greater or equal to 67% total Fe and
approximately 2% Si2O3 and 2% Al2O3. The concentrate produced has
a wide size range of approximately 6.3 mm too 10 µm.
Buffer stockpiles

Buffer stockpiles exist between the beneficiation and hot briquetted iron, HBI plants.
Drying

Concentrate reclaimed from the stockpile is fed into a fluid


bed ore dryer where the ore is dried between 90-100 ºC prior
injection into the feed system day bins. The iron oxide fines
are dried to 0.2% moisture and stored in day bins close to the
reactors.
Injection

From the day bins, the feed is lifted to the top of the FINMET reactor
structure and is charged to the reactor train via a pressurized lock
hopper system. The upper lock hoppers cycle continuously from
ambient to reactor pressure and the ore is fed continuously to the
reactors out the lower lock hopper, which is always maintained at
reactor pressure. The reactor system operates at high pressure, about
11-13 bars gauge, in order to increase the productivity.
FINMET process
The process uses a train of four fluid bed reactors, with
counter current gas/solid contacting down the reactor train.
Conditions within each fluid bed are maintained to ensure
adequate solids mixing and efficient gas/solid contacting.
The process is characterized by the solids path down the
reactor and the gas path from the gas plant up the reactor
train.
Solids flow

Solids flow downwards from reactor 4 to reactor 1 with


subsequent reduction processes involved in each reactor.
Hematite is reduced using hydrogen to give Fe through a
counter current reduction process involving the use of the 4
reactors.
R4 to R3
The feed concentrate enters the topmost reactor (R4) where it
is preheated to 550-570 ºC by reducing gas leaving reactor
R3. preheating is accompanied by ore dehydration,
decrepitation and reduction of hematite (Fe2O3) to
magnetite (Fe3O4). The beneficiated ore is transferred
downward between reactors via standpipes and is
progressively reduced first to FeO, and then finally to
metallic Fe.
Reduction reaction R4 to R3
R2 to R1

The temperature in the bottom reactor (R1) is in the range 780-800 ºC and the final reduction
to 93% metallization is accompanied by carburization of some of the Fe to Fe3C (iron carbide).
The carbon content of the product exist between 1 to 3 %, and can be varied by adjusting the
composition of the recycle gas entering R1.
Reduction reaction R2 to R1
Briquetting
The hot, directly reduced iron is then transported by a sealed, pneumatic
lift system to the briquette area where it is briquetted at temperatures
above 650 ºC in double roll briquetting machines to a density of about 5
g/c m3 . Strings of briquettes emerging from the presses are separated into
individual briquettes in the revolving drum screen or trommels. Fines
separated out in the trommels are recycled to the briquetting presses. The
briquettes are then air cooled on a cooling conveyor and sent to product
stockpile.
Gas flow

The gas required for the reduction process is supplied by a mixture


or recycled top gas and fresh reformer makeup gas provided by a
standard steam reformer. The recycle gas is tapped from the top of
R4, this gas still contains significant quantities of H2 and CO due to
incomplete conversions in single passes. The gas is first quenched to
40-50 ºC and scrubbed in wet scrubber to remove dust and water
produced by the hydrogen reduction reactions.
Benfield CO2 removal system

A small bleed is removed from this stream to limit the buildup of inert

components, primarily N2 and CH4. however this bleed has enough fuel

power to b used in the reducing gas heater burners.

The recycle gas is compressed in a centrifugal compressor before a

portion is passed through a Benfield CO2 removal system to control the

CO2 levels in the reducing gas.


Removal of H2S

The system also removes H2S from the gas therefore a small amount of

H2S is injected into the recycle loop before the reducing gas heater to

protect the heater tubes from corrosion by carburization (metal dusting)


Make up gas

The gas required to balance gas consumed in the reactions and that purged

for fuel, is supplied from a conventional steam reformer system. Natural

gas is preheated and mixed with superheated steam before first passing

through a pre-former where the reforming reaction is initiated. It is further

preheated in the reformer recuperator before passing through the reformer

tubes where the reforming reactions occur over catalyst.


Make up gas

The gas leaves the reformer tubes at approximately 825 ºC and is cooled in

a heat exchanger which produces part of the process steam requirements.

Part of the reformed gas is then passed through CO shift converter to

adjust the H2 /CO ratio prior further cooling to remove water. The

reformed gas can then enter the gas recycle loop either through the

Benfield CO2 removal system or bypass around it.


Reducing gas

The combined recycle gas and fresh reformed gas stream returning
from the CO2 removal system is then preheated to about 810-830 ºC
in the reducing gas heater prior to re-entering the reactor train
through the bottom of reactor R1.
Process advantages

 Direct use of low cost iron ore fines

 The process uses proven fluid bed technology

 High process and plant flexibility through separate gas production,


fines reduction and briquetting.
Disadvantages

 An operating pressure as high as 12 bars is used to ensure higher


degree of metallization, which causes maintaining an operating
atmosphere highly costly in terms of energy and maintenance.
Compiled by:

Chikati Descent N01519542L


Mabhena Hlengiwe N01519032V
Mupararano Tendai N01522360X
Nhira Ellen N01521806X
Shumba Nyasha N01523511C
Tshuma Bret N01518969T

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