含多金属硫酸渣制备预还原球团工艺及机理研究
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摘要
近年来,我国铁矿石资源短缺已经严重制约了钢铁工业的发展。作为一种富含铁元素的二次资源,硫酸渣还含有少量的铜、铅、锌等有色金属,具有重要的综合利用价值,是一种典型的难选难冶二次资源铁矿。我国化工行业每年排放数千万t的硫酸渣,且在全国各地堆存量上亿t无法得到有效利用。传统的回转窑高温氯化焙烧工艺,要求含多金属硫酸渣的FeO含量小于5%,且制备出的氧化球团铁品位低；而用还原焙烧工艺处理含多金属的硫酸渣,则无法脱除铜等有色金属。本研究以河南灵宝地区的含铜铅锌和高FeO含量的硫酸渣混合矿为原料,开发了预热氯化-直接还原“一步法”新工艺,并进一步开展了相关机理的研究,为含多金属硫酸渣综合利用提供理论依据及有效途径。
系统研究了含多金属硫酸渣生球制备、球团的预热固结和氯化焙烧、球团预热还原焙烧等工艺,优化了工艺参数。研究结果表明：所开发的含多金属硫酸渣球团预热氯化-直接还原“一步法”新工艺,可制备出铁品位高,机械强度好,具有一定的金属化率和铜铅锌含量低的预还原球团矿,是一种优质的高炉炉料。针对含Fe61.24%、CuO.22%、Pbl.79%和Zn0.20%的硫酸渣混合矿,在链篦机-回转窑模拟装置上进行了该工艺的扩大试验,取得的主要指标为：预还原球团全铁含量73.17%、金属化率46.18%、Cu、Pb和Zn含量分别为0.18%、0.16%和0.065%,抗压强度1069N/个,转鼓强度64%,总还原度90.97%,还原膨胀指数-3.7%,还原粉化指数RDI+3.15为98.83%。结果表明：该工艺能有效的实现铁和铜、铅、锌的分离,在大幅提高铁品位同时,预还原球团的机械强度、冶金性能和铜、铅、锌等杂质的含量均能满足高炉要求。
深入开展了硫酸渣球团氯化焙烧基础研究。①氯化热力学基础研究表明：添加CaCl2的球团中铜、铅、锌的氧化物、硫化物、铁酸盐和硅酸盐均容易被氯化,而铁氧化物和硅铝等脉石矿物均难以被氯化,这是实现铁和铜、铅、锌氯化挥发分离的理论依据。②氯化焙烧动力学研究表明：在1025℃～1175℃的温度范围内,CuO、Cu2O、ZnO和ZnFe2O4的氯化反应均受界面化学反应控制,而PbO的氯化反应则受扩散控制。铜、铅、锌的氯化反应速率非常快,这为硫酸渣中铜、铅、锌在链篦机上预热过程快速脱除提供了动力学支持。③铜、铅和锌的氯化焙烧行为研究结果表明：在氯化焙烧过程中,硫化物最容易脱除,氧化物次之,而铁酸盐和硅酸盐最难脱除,脉石成分对铜、铅、锌矿物的氯化脱除有很大影响。④氯化焙烧过程中预热球团的微观结构变化发现,氯化焙烧可促进预热球团内铁氧化物的结晶。
进一步研究了含多金属硫酸渣球团还原行为。①还原焙烧热力学基础研究表明：铜氧化物最容易被还原成金属铜而残留在球团中；铅氧化物也易被还原而挥发；锌氧化物最难被还原,但还原后容易挥发。②还原动力学研究表明：在800-1100℃的还原温度范围内,硫酸渣球团中的铁氧化物还原受界面化学反应控制。在还原温度为950～1100℃时,铁酸锌和氧化铅的还原也均受界面化学反应控制。氧化铅还原最快,锌氧化物次之,铁氧化物还原最慢。③硫酸渣球团直接还原过程固结机理和微观结构特征研究表明：预热球团充分固结和铁氧化物充分结晶,是保证直接还原球团强度的前提。④铅、锌氧化物还原焙烧行为研究表明：提高还原温度及维持强还原气氛有利于加快铅和锌的脱除。
Shortage of iron ore resource has seriously restricted the development of iron and steel industry in China recently. It is significant to utilize the secondary resources which are rich of iron, such as pytite cinder, comprehensively. Pyrite cinder, also containing considerable nonferrous metals, is a kind of important secondary resources which are difficult to upgrade and smelt. Tens of millions of tons of pyrite cinder are discharged in chemical industry annually. In addition, there are more than100million tons of the accumulated waste cinder in storage that cannot be efficiently utilized. However, there are some limitations for comprehensive utilization of the pyrite cinder containing nonferrous metals. As an example, it is required that FeO content of cinder is less than5%with traditional technology of high temperature chlorination roasting for pyrite cinder. The iron grade of oxidized pellet which is prepared by high temperature chlorination roasting is low for the blust furnace. Furthermore, the nonferrous metal elements, such as copper, cannot be removed by the traditional reduction technology. Therefore, This paper developed a "one step" technology of preheating chorination-direct reduction. The raw material used is namely pyrite cinder mixture from Lingbao with Cu, Pb, Zn and high FeO content. Moreover, the mechanism was studied, which supplied the theory basis and effective process for the comprehensive utilization of pyrite cinder containing nonferrous metals.
The study of this thesis focused on the preparation of green balls, preheating and chloridizing roasting of pellets and reduction roasting of pre-heated pellets. It is shown that blast furnace burdens of high quality, which possess high grade of iron, good mechanical strength, some metallization degree and low content of copper, lead and zinc, have been acquired by "one step" technology of chloridizing and reduction roasting from pyrite cinder containing nonferrous metals. Based on the above research, the tests, using the pyrite cinder mixture contaning Fe61.24%、 Cu0.22%、Pb1.79%and Zn0.20%, were conducted in a grate-kiln at a pilot scale. The main quality results of pre-reduced pellets were as follows:total iron content of73.17%、metallization degree of46.18%、the Cu、Pb and Zn content of0.18%,0.16%and0.065%, the compressive strength of1069N per pellet, tumbler strength of64%, the reducibility index of30.12%, the reduction swelling index of-3.7%, reduction disintegration index of (RDI+3.15)98.83%。The test results show that this new process can effectively separate copper, lead, zinc form iron, and greatly increase the iron grade. The mechanical strength and metallurgical property of pre-reduced pellets and the content of copper, lead and zinc in them also can meet the requirement of blast furnace burden.
The chloridizing roasting behaviors of pyrite cinder pellets were investigated.①It can be seen from the research of chlorination thermodynamics that it is easy for oxides, sulfides, ferrite and silicates of copper, lead and zinc to chloridize with the addition of CaCl2in pellets, but hard for the iron oxide and the gangue like silicon and alumina. This is the basis for separation of copper, lead, zinc from iron.②It is shown from the research of chlorination kinetic that the chlorination reactions of CuO, Cu2O, ZnO and ZnFe2O4are controlled by interface chemical reaction from1025℃to1175℃, while PbO is controlled by diffusion. The chlorination reaction rates of copper, lead and zinc are very fast, which support the removal of copper, lead and zinc inside pyrite cinder well at the chain grate in preheating.③Form the chlorination behavior of copper, lead and zinc, it is found out that it is the easiest to remove sulfides in the chloridizing roasting, then the oxides. Furthermore, it is most difficult for ferrites and silicates to remove. The gangue has a great effect on the removal of copper, lead and zinc.④The microstructure change of preheated pellets shows that oxidizing and chloridizing roasting can pomote the crystallization of iron oxides.
It was further investigated of the reduction mechanism of pyrite cinder pellets and reduction volatilization behaviors of lead and zinc. The following results are obtained.①It can be seen from the research of reduction thermodynamics that the copper oxides are the easieat to reduce, zinc oxides are most difficulty to reduce, lead oxides are middle. Metallic zinc and lead volatilize into flue gas, while the metallic copper is remained in pellets.②It is found out from the research of reduction kinetic that reduction of iron oxides is controlled by interface chemical reaction inside pyrite cinder pellets within the temperature range of800-1100℃, and the reduction reaction rate is fast. The reduction reactions of zinc ferric and lead oxide are also controlled by interface chemical reaction at950-1100℃. The lead oxide is the fastest to reduce, iron oxides are the slowest to reduce, and zinc oxides are in the middle.③From the research of solidification mechanism pyrite cinder pellets and microstructure feature in reduction, it is proved that fully solidification of pellets and sufficient crystallization of iron oxides are the premise to obtain high strength of reduced pellets.④The reduction volatilization behaviors of lead and zinc show that the high reduction temperature and the high concentration of CO promote the removal of zinc and lead.
系统研究了含多金属硫酸渣生球制备、球团的预热固结和氯化焙烧、球团预热还原焙烧等工艺,优化了工艺参数。研究结果表明：所开发的含多金属硫酸渣球团预热氯化-直接还原“一步法”新工艺,可制备出铁品位高,机械强度好,具有一定的金属化率和铜铅锌含量低的预还原球团矿,是一种优质的高炉炉料。针对含Fe61.24%、CuO.22%、Pbl.79%和Zn0.20%的硫酸渣混合矿,在链篦机-回转窑模拟装置上进行了该工艺的扩大试验,取得的主要指标为：预还原球团全铁含量73.17%、金属化率46.18%、Cu、Pb和Zn含量分别为0.18%、0.16%和0.065%,抗压强度1069N/个,转鼓强度64%,总还原度90.97%,还原膨胀指数-3.7%,还原粉化指数RDI+3.15为98.83%。结果表明：该工艺能有效的实现铁和铜、铅、锌的分离,在大幅提高铁品位同时,预还原球团的机械强度、冶金性能和铜、铅、锌等杂质的含量均能满足高炉要求。
深入开展了硫酸渣球团氯化焙烧基础研究。①氯化热力学基础研究表明：添加CaCl2的球团中铜、铅、锌的氧化物、硫化物、铁酸盐和硅酸盐均容易被氯化,而铁氧化物和硅铝等脉石矿物均难以被氯化,这是实现铁和铜、铅、锌氯化挥发分离的理论依据。②氯化焙烧动力学研究表明：在1025℃～1175℃的温度范围内,CuO、Cu2O、ZnO和ZnFe2O4的氯化反应均受界面化学反应控制,而PbO的氯化反应则受扩散控制。铜、铅、锌的氯化反应速率非常快,这为硫酸渣中铜、铅、锌在链篦机上预热过程快速脱除提供了动力学支持。③铜、铅和锌的氯化焙烧行为研究结果表明：在氯化焙烧过程中,硫化物最容易脱除,氧化物次之,而铁酸盐和硅酸盐最难脱除,脉石成分对铜、铅、锌矿物的氯化脱除有很大影响。④氯化焙烧过程中预热球团的微观结构变化发现,氯化焙烧可促进预热球团内铁氧化物的结晶。
进一步研究了含多金属硫酸渣球团还原行为。①还原焙烧热力学基础研究表明：铜氧化物最容易被还原成金属铜而残留在球团中；铅氧化物也易被还原而挥发；锌氧化物最难被还原,但还原后容易挥发。②还原动力学研究表明：在800-1100℃的还原温度范围内,硫酸渣球团中的铁氧化物还原受界面化学反应控制。在还原温度为950～1100℃时,铁酸锌和氧化铅的还原也均受界面化学反应控制。氧化铅还原最快,锌氧化物次之,铁氧化物还原最慢。③硫酸渣球团直接还原过程固结机理和微观结构特征研究表明：预热球团充分固结和铁氧化物充分结晶,是保证直接还原球团强度的前提。④铅、锌氧化物还原焙烧行为研究表明：提高还原温度及维持强还原气氛有利于加快铅和锌的脱除。
Shortage of iron ore resource has seriously restricted the development of iron and steel industry in China recently. It is significant to utilize the secondary resources which are rich of iron, such as pytite cinder, comprehensively. Pyrite cinder, also containing considerable nonferrous metals, is a kind of important secondary resources which are difficult to upgrade and smelt. Tens of millions of tons of pyrite cinder are discharged in chemical industry annually. In addition, there are more than100million tons of the accumulated waste cinder in storage that cannot be efficiently utilized. However, there are some limitations for comprehensive utilization of the pyrite cinder containing nonferrous metals. As an example, it is required that FeO content of cinder is less than5%with traditional technology of high temperature chlorination roasting for pyrite cinder. The iron grade of oxidized pellet which is prepared by high temperature chlorination roasting is low for the blust furnace. Furthermore, the nonferrous metal elements, such as copper, cannot be removed by the traditional reduction technology. Therefore, This paper developed a "one step" technology of preheating chorination-direct reduction. The raw material used is namely pyrite cinder mixture from Lingbao with Cu, Pb, Zn and high FeO content. Moreover, the mechanism was studied, which supplied the theory basis and effective process for the comprehensive utilization of pyrite cinder containing nonferrous metals.
The study of this thesis focused on the preparation of green balls, preheating and chloridizing roasting of pellets and reduction roasting of pre-heated pellets. It is shown that blast furnace burdens of high quality, which possess high grade of iron, good mechanical strength, some metallization degree and low content of copper, lead and zinc, have been acquired by "one step" technology of chloridizing and reduction roasting from pyrite cinder containing nonferrous metals. Based on the above research, the tests, using the pyrite cinder mixture contaning Fe61.24%、 Cu0.22%、Pb1.79%and Zn0.20%, were conducted in a grate-kiln at a pilot scale. The main quality results of pre-reduced pellets were as follows:total iron content of73.17%、metallization degree of46.18%、the Cu、Pb and Zn content of0.18%,0.16%and0.065%, the compressive strength of1069N per pellet, tumbler strength of64%, the reducibility index of30.12%, the reduction swelling index of-3.7%, reduction disintegration index of (RDI+3.15)98.83%。The test results show that this new process can effectively separate copper, lead, zinc form iron, and greatly increase the iron grade. The mechanical strength and metallurgical property of pre-reduced pellets and the content of copper, lead and zinc in them also can meet the requirement of blast furnace burden.
The chloridizing roasting behaviors of pyrite cinder pellets were investigated.①It can be seen from the research of chlorination thermodynamics that it is easy for oxides, sulfides, ferrite and silicates of copper, lead and zinc to chloridize with the addition of CaCl2in pellets, but hard for the iron oxide and the gangue like silicon and alumina. This is the basis for separation of copper, lead, zinc from iron.②It is shown from the research of chlorination kinetic that the chlorination reactions of CuO, Cu2O, ZnO and ZnFe2O4are controlled by interface chemical reaction from1025℃to1175℃, while PbO is controlled by diffusion. The chlorination reaction rates of copper, lead and zinc are very fast, which support the removal of copper, lead and zinc inside pyrite cinder well at the chain grate in preheating.③Form the chlorination behavior of copper, lead and zinc, it is found out that it is the easiest to remove sulfides in the chloridizing roasting, then the oxides. Furthermore, it is most difficult for ferrites and silicates to remove. The gangue has a great effect on the removal of copper, lead and zinc.④The microstructure change of preheated pellets shows that oxidizing and chloridizing roasting can pomote the crystallization of iron oxides.
It was further investigated of the reduction mechanism of pyrite cinder pellets and reduction volatilization behaviors of lead and zinc. The following results are obtained.①It can be seen from the research of reduction thermodynamics that the copper oxides are the easieat to reduce, zinc oxides are most difficulty to reduce, lead oxides are middle. Metallic zinc and lead volatilize into flue gas, while the metallic copper is remained in pellets.②It is found out from the research of reduction kinetic that reduction of iron oxides is controlled by interface chemical reaction inside pyrite cinder pellets within the temperature range of800-1100℃, and the reduction reaction rate is fast. The reduction reactions of zinc ferric and lead oxide are also controlled by interface chemical reaction at950-1100℃. The lead oxide is the fastest to reduce, iron oxides are the slowest to reduce, and zinc oxides are in the middle.③From the research of solidification mechanism pyrite cinder pellets and microstructure feature in reduction, it is proved that fully solidification of pellets and sufficient crystallization of iron oxides are the premise to obtain high strength of reduced pellets.④The reduction volatilization behaviors of lead and zinc show that the high reduction temperature and the high concentration of CO promote the removal of zinc and lead.
引文
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