Process and device for producing pig iron or liquid steel precursors

1. A process for producing pig iron or liquid primary steel products in a melter gasifier and a smelting reduction unit, comprising:

at least partially reducing iron-ore-containing charge materials in at least one reduction unit by means of a reducing gas,

melting a first fraction of the at least partially reduced charge materials in the melter gasifier and also supplying carbon carriers, and oxygen-containing gas to the melter gasifier for simultaneous formation of the reducing gas,

feeding the reducing gas to the at least one reduction unit and, after the reducing gas has passed through the reduction unit, drawing off the reducing gas which has passed through the reduction unit, as top gas or as export gas, and

feeding a second fraction of the at least partially reduced charge materials, Fe carriers other than the second fraction of the at least partially reduced charge materials, and carbon containing reducing materials to the smelting reduction unit for reducing the second fraction of the at least partially reduced charge materials and smelting it, wherein the amount of the second fraction of the at least partially reduced charge materials is 10-60%, with reference to an iron fraction of all Fe carriers that are charged into the smelting reduction unit.

2. The process as claimed in claim 1 , wherein the amount of the second fraction of the at least partially reduced charge materials is established in accordance with at least one of: a selected amount of top gas, the amount of export gas, and the quality of the export gas.

3. The process as claimed in claim 1 , wherein an amount of the second fraction of the at least partially reduced charge materials (LRI) is up to 1.2 times an amount of pig iron obtained in the melter gasifier.

4. The process as claimed in claim 1 , wherein a degree of reduction in at least one of: (1) the second fraction of the at least partially reduced charge materials and (2) the charge materials used in the melter gasifier is set to 40-95%.

5. The process as claimed in claim 1 , wherein the at least partial reduction of the iron-ore-containing charge materials is performed in a row of 2 to 6 reduction units connected in series, the reducing gas being conducted in countercurrent in relation to the iron-ore-containing charge materials to be reduced.

6. The process as claimed in claim 1 , wherein the reduction of the iron-ore-containing charge materials is performed in at least two mutually parallel rows of the reduction units, the reduction units in each row of the at least two mutually parallel rows being connected in series.

7. The process as claimed in claim 1 , further comprising passing along the at least partially reduced charge material from the at least one reduction unit and then compacting it.

8. The process as claimed in claim 1 , further comprising charging the second fraction of the at least partially reduced charge materials into the smelting reduction unit in place of sinter.

9. The process as claimed in claim 1 , further comprising introducing the at least partially reduced charge materials into at least one of: (1) the melter gasifier and (2) the smelting reduction unit in a hot state.

10. The process as claimed in claim 1 , further comprising hot compacting the at least partially reduced charge materials then cooling the at least partially reduced charge material to avoid oxidation processes.

11. The process as claimed in claim 1 , wherein the reduction of the charge materials is performed in a fluidized bed in the at least one reduction unit.

12. The process as claimed in claim 1 , wherein the reduction of the charge materials takes place in a reducing shaft furnace, a rotary tubular furnace or a rotary hearth furnace, and wherein the charge materials are in the form of at least one of: (1) pellets, (2) lump ore, and (3) sinter.

13. The process as claimed in claim 1 , wherein the reduction of the charge materials takes place on levels lying one above the other in a multi-level reduction furnace, and the charge materials undergo restricted guidance by means of a clearer.

14. The process as claimed in claim 1 , further comprising dedusting the reducing gas drawn off from the melter gasifier, in a dedusting device, and feeding the dedusted reducing gas to the at least one reduction unit.

15. The process as claimed in claim 1 , further comprising partially combusting the reducing gas in the at least one reduction unit while supplying oxygen to set a temperature of the reduction unit.

16. The process as claimed in claim 1 , further comprising mixing the charge materials with additives, selected from the group consisting of limestone, burnt lime, hydrated lime, dolomite, burnt or hydrated dolomite and quartz, and drying the mixture before charging it into the at least one reduction unit, wherein the charge materials and the additives have approximately the same grain size.

17. A process for producing pig iron or liquid primary steel products in a melter gasifier and a smelting reduction unit, comprising:

at least partially reducing iron-ore-containing charge materials in at least one reduction unit by means of a reducing gas,

melting a first fraction of the at least partially reduced charge materials in the melter gasifier and also supplying carbon carriers, and oxygen-containing gas to the melter gasifier for simultaneous formation of the reducing gas,

feeding the reducing gas to the at least one reduction unit and, after the reducing gas has passed through the reduction unit, drawing off the reducing gas which has passed through the reduction unit, as top gas or as export gas,

feeding a second fraction of the at least partially reduced charge materials and Fe carriers other than the second fraction of the at least partially reduced charge materials to the smelting reduction unit for reducing and smelting, wherein the amount of the second fraction of the at least partially reduced charge materials is 10-60%, with reference to an iron fraction of all Fe carriers that are charged into the smelting reduction unit,

dedusting the reducing gas drawn off from the melter gasifier, in a dedusting device, and feeding the dedusted reducing gas to the at least one reduction unit, and

dedusting and scrubbing excess reducing gas and compressing the reducing gas as recycled gas, feeding the recycled gas to a CO 2 separation unit and separating at least some CO 2 from the recycled gas, and subsequently passing the recycled gas as a product gas into the dedusting device or directly into the reduction unit.

18. The process as claimed in claim 17 , further comprising setting the pressure in the melter gasifier by a setting means of a scrubber for scrubbing the excess reducing gas.

19. The process as claimed in claim 17 , further comprising heating the product gas before it is returned into the dedusting device or directly into the at least one reduction unit.

20. The process as claimed in claim 17 , further comprising cooling and scrubbing the top gas before mixing the top gas with the excess, dedusted reducing gas, removing heat from the top gas and using the removed heat for heating the product gas before it is returned into the dedusting device or into the at least one reduction unit.

21. The process as claimed in one of claims 17 , wherein the separated CO 2 is discharged together with top gas as export gas.

22. The process as claimed in claim 17 , further comprising setting the amount of recycled gas and the amount of carbon carriers in the melter gasifier in accordance with the amount of the at least partially reduced charge materials.