Novel Flash Ironmaking Technology Based on Iron Ore Concentrate and Partial Combustion of Natural Gas: A CFD Study
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RODUCTION
A novel flash ironmaking technology (FIT) was developed for direct production of iron from iron oxide concentrate using reducing gases generated from the partial combustion of natural gas with oxygen (H2 + CO). The CFD approach has been actively used for the advancement of that novel technology, starting from the kinetic determination step on the small experimental reactor followed by the lab-scale reactor and ending with the LSBR. The process is very complex, involving complicated reactor configuration, turbulent flow of an expanding and recirculating gas-particle jets, numerous gas phase and gas-particle chemical reactions, and heat transfer processes, including radiation phenomena. Thus, it is not possible to use other conventional modeling approaches to describe and analyze important aspects of such a complex process, and thus the CFD technique must be adopted to model this and other similar processes. Thus, the approach used in this work is expected to have broader applications in other industrial fields.
AMR ABDELGHANY is with the Department of Materials Science & Engineering, University of Utah, 135 S 1460 E, RM 412, Salt Lake City, UT, 84112 and also with the Department of Chemical Engineering, Faculty of Engineering, Cairo University, Giza, 12613, Egypt. Contact e-mail: [email protected] DE-QIU FAN and H.Y. SOHN are with the Department of Materials Science & Engineering, University of Utah. Manuscript submitted March 6, 2020.
METALLURGICAL AND MATERIALS TRANSACTIONS B
Fan et al.[1] used the CFD approach to develop and improve the kinetics of the small experimental drop-tube reactor (DTR) developed by Elzohiery et al.[2,3] by taking into consideration the variation of particle temperature and velocity in the DTR. Fan et al.[4,5] developed a three-dimensional CFD model using ANSYS FluentÒ to study the reduction of magnetite concentrate particles in a lab-scale reactor called the Utah Flash Reactor (UFR) in the presence of H2and H2O mixture. The mixture was produced from the combustion of H2 with oxygen, which makes the reactor reach 1175±25 °C with the help of six electrical heating elements. The UFR achieved a reduction degree as high as 91 pct under the operating conditions tested. They compared temperature profiles and reduction degrees obtained from CFD with the experimental results and obtained a satisfactory agreement. The final stage of the development of this technology was the operation of an LSBR described by Abdelghany et al.[6,7] where a CFD model was created and validated by experimental data. In that model, the operating conditions did not allow the incorporation of a comprehensive heat transfer through the wall because the operation had to be time-dependent as far as the heat transfer through the wall was concerned. The LSBR is heated solely by the complete combustion of natural gas with oxygen without electrical heating elements, and its operating temperature can reach 1873 K. When the reactor reaches the required operating temperature, then partial combustion is maintained to provide r
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