National University of Science and Technology MISiS, Moscow, Russia
G. S. Sborshchikov, Dr. Eng., Prof., Dept. of Energy-Efficient and Resource-Saving Industrial Technologies, e-mail: g.sborshikov@mail.ru
A. Yu. Solodova, Cand. Eng., Associate Prof., Dept. of Energy-Efficient and Resource-Saving Industrial Technologies, e-mail: terekhova.nastya@mail.ru
K. S. Shatokhin, Cand. Eng., Associate Prof., Dept. of Energy-Efficient and Resource-Saving Industrial Technologies, e-mail: shatohin_ks@mail.ru

From a thermal physics perspective, a liquid-phase iron reduction furnace (LPIRF) offers significant potential as a multifunctional metallurgical unit. This is due to the fact that the process takes place in a melt with high density, allowing for the control of its chemical composition. Conversely, high density ensures high volumetric heat content at a given temperature, which predetermines intensive heat exchange and a compact unit size for a given throughput. The main drawback of LPIRFs is the high specific oxygen and fuel consumption per ton of primary metal produced. The objective of this study was to identify ways to reduce specific fuel consumption. A Romelt pilot plant was used as the object of study. It was found that for the selected unit, the limiting factor preventing an increase in the specific furnace productivity and a reduction in the specific costs of producing primary metal is the heat generation method used, which involves the afterburning of exhaust gases in the freeboard. A fuel combustion method that eliminates the afterburning of exhaust gases in the freeboard is proposed. This method, previously implemented in the non-ferrous metallurgy industry, involves burning fuel in remote combustion chambers installed on the side tuyeres of a liquid-phase reduction furnace. In this case, high-temperature combustion products of the fuel, rather than an oxygen-air mixture, are injected into the bubbling bed. Implementing this method in the furnace under study will completely eliminate the use of oxygen in the process and reduce the specific fuel consumption per ton of hot metal from 593 to 312 kilograms. At the same time, the furnace exhaust gas temperature will decrease from 1680 °C to 1400 °C, further contributing to a reduction in specific fuel consumption in the process.

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