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Direct Reduction Process

Process Description

In the case of direct reduction methods, such as QSL methods, flash smelting, TSL (ausmelt / isasmelt) or Kivcet, roasting and reduction of the feed material take place in one step. This reduces environmental pollution and increases economic efficiency. The melting units used in the processes have single burners or burner field systems for auxiliary firing.   

Gas-Application

Oxyfuel Process

In the Oxyfuel process, the combustion processes are carried out by means of an oxygen burner (Oxyfuel burner) which is operated with pure oxygen or oxygen-enriched air as an oxidising agent. Messer has developed the family of Oxipyr burners for this purpose.   

In comparison to burners which use air as an oxidant, Oxipyr burners provide a range of process technology advantages: 

  • Higher combustion efficiency
  • Higher melting rate
  • Faster heating-up times
  • Lower fuel consumption
  • Higher processing temperatures possible
  • Faster reaction speeds
  • Lower exhaust gas levels
  • Less dust
  • Lower emissions
  • Lower production costs

Oxygen Enrichment

The oxidising agent fed to the combustion process is enriched with oxygen, with the flow of oxygen being carefully regulated.

Messer Solution

In addition to the gases required for your process, Messer offers a variety of equipment for its optimisation under the brand names Oxipyr and Oxijet. 

In order to select the optimum system, experts from Messer first carry out a comprehensive process analysis. Following calculations and basic engineering, suggestions are made for optimisation and further procedures.

Oxipyr – Burner Technology

The characteristics of the burner types are multi-faceted and range from low to high momentum burners, oxyfuel to oxygen/air mixing burners and burners for different fuels or fuel combinations. The systems are controlled manually, semi- or fully automatically following compositions or temperature.

Oxipyr

Fuel

 

Burner protection

Flame

Burner Technology

gas

liquid

solid

low NOx

refractory material

traversing devices

cooling

monitoring

ignition

Oxipyr – P

X

 

 

 

X

X

X

X

X

Oxipyr – F

X

X

X

X

X

X

X

X

X

Oxipyr – Flex

X

X

X

X

X

X

X

X

X

Oxipyr – Air

X

X

X

X

X

X

X

X

X

Oxipyr – SVNR

X

X

X

X

X

X

 

X

X

 

Oxipyr- IPC (internal post-combustion)  

The combustion ratio of fuel and oxidising agent is selectively altered, with the oxygen flow regulated as a function of exhaust gas parameters. As a result, through the post-combustion of pollutants in the exhaust gas high-quality fuels can be relieved especially of the burden of volatile organic components (VOC).  Messer developed the Oxipyr-IPC process for this purpose.  When using the Oxipyr-IPC process, oxygen and fuel requirements are controlled automatically. Oxygen is always supplied via Oxipyr burners; with Oxijet oxygen lances used for certain types of furnace.

Advantages:

  • Lower fuel consumption
  • Use of cheaper alternative fuels
  • Reduces post-combustion burden
  • Higher output due to recycling of plastic-adhering lead during battery cycling
  • Savings in waste-disposal costs during battery recycling
  • Lowering of production costs