Computational Fluid Dynamics Simulation of the Hydrogen Reduction of Magnetite Concentrate in a Laboratory Flash Reactor
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A transformational technology for alternate ironmaking is under development at the University of Utah. In this novel ironmaking process, iron is produced by the direct gaseous reduction of iron oxide concentrate in a flash reduction process by utilizing hydrogen, natural gas, or coal gas as the reducing agent and fuel. This process aims at significant energy saving and reduction of CO2 emissions compared with the conventional blast furnace (BF) ironmaking process. The gases used in the process undergo partial oxidation to generate the process heat while providing a reducing atmosphere for the reduction of iron oxide. A number of experimental and simulation studies relevant to this novel process have been performed by Sohn and coworkers[1–10] aimed at generating a database to be used for the design of a flash ironmaking reactor. Choi and Sohn[3] investigated the kinetic feasibility of the proposed process and proved that the H2 reduction rate of magnetite concentrate particles was fast enough to obtain 90 to 99 pct reduction within 1 to 7 seconds in the temperature range of 1473 K to 1773 K (1200 C to 1500 C). Process simulation and economic feasibility analysis carried out by Pinegar et al.[4,5] demonstrated that energy consumption can be reduced significantly by this novel process compared with the BF process. Detailed rate expressions of H2 and CO reduction of DE-QIU FAN, Ph.D. Student, H.Y. SOHN, Distinguished Professor, YOUSEF MOHASSAB, Research Associate, and MOHAMED ELZOHIERY, Ph.D. Student, are with the Department of Metallurgical Engineering, University of Utah, Salt Lake City, UT 84112. Contact e-mail: [email protected] Manuscript submitted April 1, 2016. METALLURGICAL AND MATERIALS TRANSACTIONS B
hematite concentrate particles in the temperature range of 1423 K to 1623 K (1150 C to 1350 C) were developed by Chen et al.[8,10] Fan et al.[9] analyzed the H2 reduction rate of magnetite concentrate particles with the aid of CFD and developed a rate expression for the H2 reduction of magnetite concentrate particles in the temperature range of 1423 K to 1623 K (1150 C to 1350 C). A CFD model was developed by Sohn and Perez-Fontes[11] to investigate the H2 partial combustion, and obtained good agreements with experimental results reported in the literature. A large pilot-scale flash reactor has been constructed,[12] and its commissioning has just been completed. Along with the experimental data, CFD models are useful tools in process design and optimization of an industrial reactor. The CFD model can also be used to investigate the various transport phenomena taking place in the new process. Numerous examples of using CFD as an effective tool in industrial metallurgical furnaces have been reported in the literature. Ariyama and coworkers[13–16] developed a three-dimensional computation fluid dynamics and discrete element method (CFD-DEM) model to analyze the gas phase flow and solid movement in the blast furnace. The model was used to investigate the effect of gas injection at different shaft levels. Lekakh an
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