针对目前熔融还原设备无法将煤气二次燃烧氧化区与铁氧化物还原区隔离而导致能耗偏高的问题,提出了一种两步三段式厚渣层铁浴熔融还原炼铁工艺,以期利用厚渣层冶炼的方法使得氧化区与还原区的梯度隔离.设计了主反应器铁浴炉尺寸与产能,并建立了工艺的整体静态模型,考察了球团金属化率与铁浴炉炉顶煤气氧化度对工艺煤耗、氧耗以及能耗的影响.在选定的适宜操作参数,即煤气氧化度55％,球团金属化率80％条件下,冶炼1t铁水,消耗球团矿1869.83kg,煤粉674.07kg,同时得到还原度71％的改质煤气898.44kg.结合反应器的设计产能,反应器可处理球团矿3793.66kg/(h·m2).
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