CFD Modeling and Analysis of Particle Size Reduction and Its Effect on Blast Furnace Ironmaking
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BLAST furnace (BF) ironmaking is the most important technology for reducing hot metal (HM) from ferrous materials rapidly and efficiently. This process accounts for over 70 pct of the iron for steelmaking in the world. In an integrated steelwork, BFs together with the associated units (e.g., pelletizing–sintering machine and coke oven) represent about 90 percent of the CO2 emission and 70 percent of the energy consumption.[1] Therefore, high operational efficiency is in high demand for BF production, especially under the rising economic and environmental pressures. Generally, BF performance is dependent on a range of variables related to material properties, geometric configurations and operational conditions. Among them, one of the most
LULU JIAO, SHIBO KUANG, LINGLING LIU, and AIBING YU are with the ARC Research Hub for Computational Particle Technology, Department of Chemical Engineering, Monash University, VIC 3800, Australia. Contact e-mails: [email protected]; [email protected] YUNTAO LI and XIAOMING MAO are with the Ironmaking Division, Research Institute (R&D Center), Baoshan Iron & Steel Co., Ltd, Shanghai 201900, China. HUI XU is with the Ironmaking Plant, Baoshan Iron &Steel Co., Ltd, Shanghai 201900, China. Manuscript submitted June 21, 2020; accepted October 6, 2020.
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important factors is the degradation of sinter and coke particles, which changes the bed permeability, the associated ascending gas flow, hereby the contact between reducing gas and ferrous materials, further process stability, and efficiency. Sinter and coke particles inside a BF have different degradation mechanisms. Specifically, coke particle size reduces mainly due to reactions, although the mechanical stress and abrasion may contribute to this phenomenon, to some extent.[2] This mechanical degradation also occurs to sinter particles as they are reduced. However, in this reduction process, the crystal structure change from hematite (Fe2O3) to magnetite (Fe3O4) plays a crucial role in sinter size reduction. Such structure change occurs in the low-temperature region of a BF, and thus the resulting degradation is called low-temperature reduction disintegration. Usually, the reduction degradation index (RDI) is introduced to describe the extent of the size reduction resulting from the crystal structure change. The low-temperature reduction disintegration of ferrous materials has attracted much interest. For example, Takada et al.[3] studied the reduction degradation behavior of sinter samples at various RDI values by inserting a sample of sinter particles into a real BF and recovering it. Iwanaga[4] carried out extensive experiments on the degradation of sinter during reduction and correlated the degree of size degradation with reduction parameters. Nakajima et al.[5] carried out laboratory
tests on the reduction degradation behavior of sinter under similar temperature conditions in a real BF. Wu et al.[6] compared the reduction degradation characteristics of typical sinter, pellet and lu
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