Note: Descriptions are shown in the official language in which they were submitted.
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Description
Title of the invention
Method and device for providing reduction gas from generator
gas
Technical field
The present invention relates to a method for providing
reduction gas for iron ore reduction by cooling and dry
dedusting generator gas produced in a melter gasifier for pig
iron production, and also to a device for carrying out the
method.
Prior art
In a number of melt reduction methods for iron ores, for
example COREX or FINEX , the reduction gas required is
provided from what is known as generator gas produced in a
melter gasifier by gasifying carbon carriers in the presence of
oxygen and pre-reduced iron carriers. The generator gas is
excessively dust-laden for use as reduction gas in a reduction
reactor, and is at a temperature which lies above a temperature
range that is favorable for the use thereof for reducing iron
ore. The temperature of the generator gas is not constant, but
instead fluctuates on account of pressure shocks in the melter
gasifier in a range of up to 50 C about an average value of
approximately 1030 C to 1070 C. So that it can be used as
reduction gas in a reduction reactor, the generator gas
therefore has to be dedusted and cooled. Within the context of
this application, generator gas is designated as reduction gas
only once dedusting and cooling have been effected. Here,
cooling does not concomitantly encompass a reduction in
temperature which arises in the form of heat loss upon passage
through conduits.
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It is known, for example from W09801587, to free the generator
gas of entrained dust by means of dry dedusting in a cyclone.
The generator gas is cooled in that a partial quantity of the
reduction gas emerging from the cyclone is wet dedusted and
cooled in a washer and, following subsequent compression, is
supplied to the generator gas as so-called cooling gas before
the
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dry dedusting. A dedusted and cooled so-called reduction gas
thus emerges from the cyclone.
The cooling by means of the cooling gas circuit disclosed in
W09801587 has the disadvantage that it is very complex in terms
of outlay on apparatus and required space. The plant parts
required for realizing the cooling gas circuit, such as washers
and compressors, shut-off valves and control valves, shut-off
flaps and control flaps, noise protection and buildings
including cranes, have to be provided, operated with a high
energy consumption and maintained - the compressors in
particular cause considerable maintenance costs in this case.
In addition, the washers make a considerable contribution to
the required design size of the wastewater system of a pig iron
production plant as per W09801587. The energy removed from the
reduction gas by the washers in a cooling gas circuit is
carried away unexploited with the washing water, and further
discharged to the surroundings via cooling towers.
Summary of the invention
Technical object
It is an object of the present invention to provide a method in
which the generator gas is reliably cooled without a cooling
gas circuit according to the prior art, and therefore the
disadvantages of the prior art mentioned are avoided when said
method is carried out. Similarly, the intention is to provide a
device for carrying out the method.
Technical solution
This object is achieved by a method for providing reduction gas
for iron ore reduction by cooling and dry dedusting generator
gas produced in a melter gasifier for pig iron production,
characterized in that
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the generator gas is cooled both by water injection and by heat
exchange after it has been discharged from the melter gasifier
and before the dry dedusting thereof.
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Advantageous effects of the invention
The terms melter gasifier, generator gas and reduction gas are
to be understood as defined above in the introduction. As is
generally known, pre-reduced iron carriers are additionally
completely reduced in the melter gasifier for producing
generator gas, and the pig iron which forms is melted down. In
order to provide a reduction gas, the generator gas, which - in
addition to carbon dioxide C02r steam H2O and nitrogen N2 -
consists primarily of reducing components such as carbon
monoxide CO, hydrogen H2 and methane CH4, is subjected to dry
dedusting and cooling, as in the prior art.
According to the invention, the generator gas is cooled here
both by water injection and by heat exchange after it has been
discharged from the melt reduction unit and before the dry
dedusting thereof.
Since the cooling is no longer effected by introducing cooling
gas produced from a partial quantity of the reduction gas, the
complex cooling gas circuit according to the prior art is
dispensed with here.
The cooling is effected already before the dry dedusting, in
order to cool the particles of the dust and to keep the thermal
loading of the device for dry dedusting as low as possible.
The combination of water injection and heat exchange makes it
possible to ensure that the generator gas is cooled setting a
degree of oxidation of the reduction gas which is favorable for
the following iron ore reduction and setting a constant
temperature of the reduction gas. The term constant temperature
here is to be seen in connection with industrial iron ore
reduction plants and the operation thereof, and therefore does
not exclude small control deviations from a desired temperature
value.
Cooling by water injection alone would provide a reduction gas,
by water evaporation and the reaction of steam with carbon
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monoxide, which would have a considerably higher degree of
oxidation compared to the procedure according to the invention
- this is because the abandonment of cooling by heat exchange
would mean that significantly more water would have to be
injected to achieve a specific desired temperature for the
reduction gas, which is why the degree of oxidation of the
generator gas would be increased to a greater extent as a
result.
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Here, the degree of oxidation is defined by the relationship
(C02+H20) / (CO+CO2+H2+H2O) .
On account of the inertia of a heat exchanger system when it
reacts to temperature fluctuations of a gas stream to be
cooled, there is the problem that the reduction gas temperature
would likewise fluctuate given a greatly fluctuating generator
gas temperature. Reliable cooling at a maximum temperature by
heat exchange alone would make it necessary to design the plant
parts required for the maximum temperature peaks and volume
throughputs of the generator gas which occur. This in turn
would create the problem of reliably avoiding excessive cooling
of the generator gas at temperatures of the generator gas which
lie below the temperature peaks.
The combination according to the invention of water injection
and heat exchange for cooling the generator gas avoids these
disadvantages of the two individual cooling concepts. The inert
reacting cooling by heat exchange is supplemented by the
rapidly reacting water injection, and the negative influence of
the water injection on the degree of oxidation of the reduction
gas is reduced by the fact that not all of the cooling is
effected by water injection, but instead heat exchange also
removes some of the heat which is to be dissipated during the
cooling.
According to an advantageous embodiment of the method according
to the invention, the heat exchange is effected with at least
one liquid heat exchange medium. A liquid heat exchange medium
is used so that it is possible to reliably keep the surface
temperature of the heat exchanger below 450 C. Cooling by gas
or vapor, by contrast, has the disadvantage that the heat
transfer coefficient would be lower, and therefore there would
be an increased risk of higher surface temperatures of the heat
exchanger. A surface temperature of the heat exchanger below
450 C is preferred, in order to avoid the risk of metal dusting
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corrosion of the heat exchanger by reaction with components of
the generator gas.
The liquid heat exchange medium is, for example, water, which
may be pressurized and may also have been specially treated -
for example demineralized or desalinated water -, or thermal
oil, produced for example from synthetic oils or organic oils.
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In steel, petrochemical and ORC plants, use is made, for
example, of the commercially available thermal oil
THERMINOL 66 for heat displacement or waste heat recovery.
The major advantage of thermal oil over water is the
significantly higher boiling point, which can lie at
temperatures above 300 C. Furthermore, the use of thermal oil
is easier to manage in terms of apparatus, since it is
generally used at atmospheric pressure and therefore, in
contrast to water-carrying plants, the plants do not have to be
designed for an excess pressure. Specifically, water is often
used at an excess pressure, and therefore the plants have to be
designed to be more stable. It is of course possible according
to the invention for thermal oil to also be used at excess
pressure, however.
The disadvantage compared to water is the need to couple the
heat obtained via thermal oil into another product medium if
the heat is to be utilized. Furthermore, thermal oil generally
has a smaller heat capacity than water, and the heat of
evaporation cannot be utilized in the case of saturated steam
operation.
The water injection can be effected before, during or after the
heat exchange. It is advantageous for the water injection to be
effected before and/or during the heat exchange. In this way,
it is possible to provide a sufficient evaporation distance for
injected water and to achieve temperature equalization of the
generator gas stream more easily before the dry dedusting.
Particularly if the water injection is effected before and/or
during the heat exchange, it is advantageous
if the inlet temperature of the liquid heat exchange medium
lies within a temperature range
with a minimum temperature of 70 C, preferably 100 C,
and
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with a maximum temperature which is lower than the lowest
temperature at which metal dusting corrosion occurs by reaction
with generator gas on the material of the device for heat
exchange, preferably lower than 450 C, particularly preferably
150 C.
It is preferable for the inlet temperature to lie within a
temperature range of 100 C to 150 C.
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This is because, if water injection is effected before and/or
during the heat exchange, the steam content of the generator
gas rises, and therefore the surfaces of the device for heat
exchange should be at temperatures which make it possible to
reliably avoid condensation of steam. Such a condensation
entails the risk of the formation of undesirable caking of dust
entrained in the generator gas. At a minimum temperature of
70 C, preferably 100 C, the risk of condensation is largely
averted.
The maximum temperature should be lower than the lowest
temperature at which metal dusting corrosion occurs by reaction
with generator gas on the material of the device for heat
exchange, preferably lower than 450 C, in order to avoid the
risk of metal dusting corrosion, which typically occurs in the
range of approximately 450 C - 900 C in the case of common
materials for devices for heat exchange, as a result of
excessively high surface temperatures in the device for heat
exchange.
It is preferable for the water injection to be regulated in
accordance with the temperature of the generator gas after the
heat exchange. It is advantageous for the water injection to be
regulated in accordance with the temperature of the reduction
gas produced by the dry dedusting. In this way, it is possible
to promptly react to changes in the temperature of the
reduction gas.
In any event, the temperature used for regulating the water
injection should be a temperature of the generator gas - or of
the reduction gas - after water injection has been effected.
According to a preferred embodiment, this regulation is
effected with the inclusion of information relating to the
cooling power which can be provided by heat exchange - in
addition to the cooling power by water injection.
If it is foreseeable, for example, that the cooling being
effected given an adjustment A of the water injection leads to
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a temperature of the generator gas subjected to the heat
exchange which cannot be cooled down to a desired temperature
for the reduction gas by the heat exchange, the adjustment of
the water injection is regulated to an adjustment B, which
makes it possible to set the desired temperature with the
cooling power of the heat exchange.
According to one embodiment of the method according to the
invention, the quantity of heat withdrawn from the generator
gas per unit of time during the heat exchange, i.e. the
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cooling power, is regulated by changing the temperature of the
heat exchange medium and/or the quantity of heat exchange
medium supplied per unit of time. This regulation, too, can be
effected in accordance with the temperature of the reduction
gas produced by the dry dedusting. It is also possible to use
the temperature of the generator gas downstream of the heat
exchanger before the dry dedusting for regulation. In any
event, the temperature used for regulation should be a
temperature of the generator gas - or of the reduction gas -
after heat exchange has been effected.
According to a preferred embodiment, a specific basic quantity
of heat energy is withdrawn from the generator gas by means of
heat exchange, and quantities of heat additionally to be
withdrawn are withdrawn by water injection. On account of the
fluctuations in the generator gas temperature, these additional
quantities of heat vary over time. The water injection allows
for easier and quicker adaptation of the cooling power to the
fluctuations in the generator gas temperature than regulation
of the cooling power by way of the heat exchange.
As opposed to a cooling gas circuit according to the prior art,
a further advantage of the present invention consists in the
fact that the water injection contributes, by a gasification
reaction of coal dust entrained in the generator gas with the
injected water, to the formation of reducing compounds such as
CO and H2, in accordance with the heterogeneous reaction
C+H2O CO+H2.
Correspondingly converted coal dust from the generator gas then
does not have to be separated during the dry dedusting - which
relieves the burden on the dry dedusting device - and
contributes to the reduction capacity of the reduction gas.
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The present invention also relates to a device for carrying out
a method according to the invention, comprising
a reduction reactor for reducing iron ore by means of a
reduction gas, and a melter gasifier for producing generator
gas by gasifying carbon carriers in the presence of oxygen and
pre-reduced iron carriers,
wherein the melter gasifier and the reduction reactor are
connected by a gas line, in which a dry dedusting device is
present, characterized in that
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both a device for water injection and a device for heat
exchange are present in the gas line between the melter
gasifier and the dry dedusting device.
The reduction reactor for reducing iron ore can be a fixed bed
reactor or a fluidized bed reactor, for example. A plurality of
such reduction reactors can also be present in series or
connected in parallel. In the reduction reactor, iron ore is at
least partially reduced by means of a reduction gas.
In a melter gasifier, as is known for example from COREX or
FINEX , generator gas is produced. The melter gasifier and the
reduction reactor are connected by a gas line. A dry dedusting
device, for example a cyclone or a ceramic hot gas filter, is
present in said gas line and dedusts the generator gas fed into
the gas line from the melter gasifier.
Both a device for water injection and a device for heat
exchange are present in the gas line between the melter
gasifier and the dry dedusting device.
The generator gas fed into the gas line from the melter
gasifier flows in the direction of the reduction reactor. In
this case, it passes through both the device for water
injection and the device for heat exchange, by means of which
it is cooled, and the dry dedusting device, by means of which
the dust load thereof is reduced. The gas emerging from the dry
dedusting device, which gas is cooled to a temperature
favorable for carrying out the reduction in the reduction
reactor and dedusted, is designated within the context of this
application as reduction gas. The reduction gas is supplied to
the reduction reactor via the gas line.
The device for water injection may consist, for example, of one
to three water nozzles per generator gas line. The water
nozzles are preferably two-fluid nozzles which atomize water
with nitrogen or steam or process gas as atomization gas. As a
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result, the droplet size is minimized, which ensures a short
evaporation distance for evaporation of the injected water in
the generator gas stream, and a sufficient mixing distance for
mixing the injected water in the generator gas stream.
Evaporation within a
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short distance and mixing in this case help to exploit the
cooling action of the injected water.
A device for heat exchange is to be understood to mean one or a
plurality of indirect heat exchangers per generator gas line. A
typical COREX or FINEX plant has 4 generator gas lines.
The heat exchangers can be operated as water preheaters or as
water evaporators. Operation as superheaters would generally be
disadvantageous, because in this case a poor transfer of heat
from the heat exchanger to vapor, the heat exchange medium,
would make metal dusting corrosion possible on account of high
surface temperatures of the heat exchanger which are
consequently present. If the material of the heat exchangers is
resistant to metal dusting corrosion under the conditions of
operation as superheaters, however, it is also possible for the
heat exchangers to be operated as superheaters or as gas-gas
heat exchangers.
The device for heat exchange advantageously has a plurality of
heat exchangers which, with respect to feed lines and discharge
lines for heat exchange medium, are connected in parallel or in
series. This affords advantages in production and assembly, and
has the effect that instances of thermal expansion in the
installed state present fewer problems - here, the advantages
are applicable if use is made, instead of a large heat
exchanger with a specific surface area for heat exchange, of a
plurality of smaller heat exchangers whose surface areas for
heat exchange correspond in total to that of the large heat
exchanger.
According to a preferred embodiment, the device for heat
exchange is in the form of a cooling jacket heat exchanger. In
this case, it preferably has a smooth surface on the inner side
and has no fittings on the inner side. This serves for largely
avoiding problems such as caking and abrasion resulting from
dust.
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It is advantageous for the cooling jacket heat exchanger to
have a cooling jacket with a helical guide for heat exchange
medium. This allows for particularly efficient cooling.
The device for heat exchange can be arranged, for example,
within a pipeline for conducting generator gas. However, it can
also itself form said pipeline.
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Pipelines for conducting generator gas generally comprise a
layer of anti-wear masonry, facing toward the generator gas,
for protection against wear resulting from the hot generator
gas and the dust load thereof, said layer of anti-wear masonry
being surrounded toward the outside by a layer of insulating
masonry for thermal insulation. If the device for heat exchange
is arranged within a pipeline for conducting generator gas, it
is fitted at the site of the anti-wear masonry. It is
preferably fitted movably within the insulating masonry; by way
of example, a spacing can be left free between the device for
heat exchange and the insulating masonry and is sealed off
against penetration by gases by means of a seal, for example
silicone-sheathed ceramic sealing beads.
The feed lines and discharge lines for heat exchange medium are
preferably provided with compensators in order to avoid
stresses and instances of material fracture, caused by
instances of thermal expansion, in the region of the inlet or
of the outlet of the feed lines and discharge lines into that
part of the device for heat exchange which provides the surface
area for heat exchange.
According to various embodiments of the invention, the device
for heat exchange can be operated as a preheater for heat
exchange medium and/or as an evaporator for heat exchange
medium.
According to one embodiment, the device for heat exchange is
provided with a feed line for liquid heat exchange medium,
preferably water or thermal oil.
The device for water injection can be arranged between the
melter gasifier and the device for heat exchange, in the device
for heat exchange or between the device for heat exchange and
the dry dedusting device.
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According to a preferred embodiment, the device for water
injection is arranged between the melter gasifier and the end -
as seen in the direction of flow of the generator gas - of the
device for heat exchange.
According to a preferred embodiment, the device for water
injection is arranged in the device for heat exchange.
It is particularly preferable for the device for water
injection to be arranged between the melter gasifier and the
start - as seen in the direction of flow of the generator gas -
of the device for heat exchange.
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The actually selected site at which the device for water
injection is arranged depends, for example, on where in a given
device for carrying out a method according to the invention
optimum turbulence of the injected water can be achieved.
The vapor which may be produced in the device for heat exchange
can be used, for example, in a COREX or FINEX process for the
substitution of smelter vapor for trace heating, or for vapor
injection systems for oxygen nozzles. The exploitation of the
energy withdrawn from the generator gas by heat exchange makes
it possible for the method for iron ore reduction or for
producing pig iron to be carried out more economically overall.
Brief description of the drawings
Embodiments of the present invention are explained hereinbelow
by way of example with reference to schematic figures.
Figure 1 shows a device for iron ore reduction by means of a
reduction gas obtained from a melter gasifier according to the
prior art.
Figure 2 shows a device according to the invention analogous to
figure 1.
Figure 3 is a schematic illustration of a section through a gas
line portion which conducts generator gas and is provided with
a cooling jacket heat exchanger.
Description of the embodiments
Figure 1 shows a device for carrying out a method for providing
reduction gas for iron ore melt reduction by cooling and dry
dedusting generator gas produced in a melter gasifier for pig
iron production according to the prior art, in accordance with
the COREX method.
Iron ore 2 is introduced into a reduction reactor 1, in this
case a fixed bed reactor, and reduced by a reduction gas.
Carbon carriers 4, pre-reduced iron carriers 5 obtained in the
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reduction reactor during the reduction of the iron ore and
oxygen 6 are introduced into a melter gasifier 3. The pig iron
obtained from the pre-reduced iron carriers 5 in the melter
gasifier 3 as a result of the complete reduction thereof is
melted down, and can be removed from the melter gasifier 3. The
generator gas formed in the melter gasifier 3 by gasification
reactions of the
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carbon carriers 4 with the oxygen 6 in the presence of the pre-
reduced iron carriers 5 is discharged from the melter gasifier
3 through the gas line which connects the melter gasifier 3 to
the reduction reactor 1. The gas line portion 7a of the gas
line conducts generator gas. The dust load of the generator gas
is reduced in a dry dedusting device 8, here a cyclone, present
in the gas line. Dust separated in the cyclone is returned into
the melter gasifier 3. A partial quantity of the reduction gas
emerging from the dry dedusting device 8 is subjected to wet
washing in a washer 9 and in the process is largely freed of
remaining dust and cooled. A partial quantity of the gas taken
from the washer 9 is fed to the generator gas, after
compression, before it enters the dry dedusting device 8. This
reduces the temperature of the generator gas entering the dry
dedusting device 8, i.e. the generator gas is cooled.
Accordingly, reduction gas emerges from the dry dedusting
device 8, in accordance with the definition of the present
application. Accordingly, generator gas is conducted in the gas
line portion 7a, and reduction gas is conducted in the gas line
portion 7b. The gas line consists of the two gas line portions
7a and 7b. After washing in the washer 10, top gas emerging
from the reduction reactor 1 is supplied, together with a
partial quantity of the reduction gas treated in the washer 9,
as export gas 11 to further consumers, for example power plants
or pelletizing systems, as an energy provider.
The device parts which are utilized for the wet washing, for
compression and for feeding wet-washed, compressed reduction
gas into the generator gas are referred to as the cooling gas
circuit.
Figure 2 shows a device according to the invention which is
comparable to figure 1. Comparable parts of the device are
provided with the same reference signs as in figure 1. In
contrast to the device according to the prior art shown in
figure 1, there is no cooling gas circuit with a washer 9 and a
compressor. For cooling the generator gas, both a device for
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water injection 12 and a device for heat exchange 13 are
present in the gas line instead between the melter gasifier and
the dry dedusting device 8, here a cyclone.
The device for heat exchange 13 is provided with a feed line
for liquid heat exchange medium 14, in this case pressurized
water. The
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device for heat exchange 13 is in the form of a cooling jacket
heat exchanger, with the cooling jacket heat exchanger having a
helical guide for the heat exchange medium - the pressurized
water.
The device for water injection 12 is arranged between the
melter gasifier and the device for heat exchange 13. The water
injection is regulated in accordance with the temperature of
the reduction gas produced by the dry dedusting. To this end, a
valve 15 and a temperature sensor 16 are connected to one
another on the gas line portion 7b via a regulating device 17.
Figure 3 is a schematic illustration of a section through part
of the gas line portion 7a, which is connected to a cooling
jacket heat exchanger 18 as the device for heat exchange 13.
The cooling jacket heat exchanger 18 is provided with a helical
guide for the heat exchange medium, which is indicated by
dashed lines within the cooling jacket heat exchanger 18. The
cooling jacket heat exchanger is arranged within the pipeline
for conducting generator gas 19 of the gas line portion 7a. In
the portions without a cooling jacket heat exchanger, the
pipeline for conducting generator gas 19 has a layer of anti-
wear masonry 21, facing toward the generator gas 20, which is
illustrated by wavy arrows in the direction of flow, for
protection against wear resulting from the hot generator gas
and the dust load thereof, said layer of anti-wear masonry
being surrounded toward the outside by a layer of insulating
masonry 22 for thermal insulation. Where the cooling jacket
heat exchanger 18 is arranged within the pipeline for
conducting generator gas 19, it is fitted at the site of the
anti-wear masonry 21. An intermediate space 23 between the
cooling jacket heat exchanger 18 and the insulating masonry 22
is left free, as a result of which the cooling jacket heat
exchanger 18 is fitted movably within the insulating masonry
22. For reasons of clarity, seals which are present for the
intermediate space 23 against the penetration of gases have not
been illustrated.
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The feed line 24 and discharge line 25 for heat exchange
medium, in this case water - shown by dashed arrows -, are
provided with compensators (not shown) in order to avoid
stresses and instances of material fracture, caused by
instances of thermal expansion, in the region of the inlet or
of the outlet of the feed lines and discharge lines into that
part of the cooling jacket heat exchanger 18 which provides the
surface area for heat exchange.
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List of reference signs
1 Reduction reactor
2 Iron ore
3 Melter gasifier
4 Carbon carriers
Iron carriers
6 Oxygen
7a Gas line portion
7b Gas line portion
8 Dry dedusting device
9 Washer
Washer
11 Export gas
12 Device for water injection
13 Device for heat exchange
14 Liquid heat exchange medium
Valve
16 Temperature sensor
17 Regulating device
18 Cooling jacket heat exchanger
19 Pipeline for conducting generator gas
Generator gas
21 Anti-wear masonry
22 Insulating masonry
23 Intermediate space
24 Feed line
Discharge line
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List of citations
Patent literature
WO9801587
