Numerical Investigation of Novel Oxygen Blast Furnace Ironmaking Processes
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(BF) ironmaking is the most important technology for reducing hot metal (HM) from ferrous materials rapidly and efficiently. This process generates the thermochemical energy required for the ZHAOYANG LI and AIBING YU are with the Center for Simulation and Modelling of Particulate Systems, Southeast University - Monash University Joint Research Institute, Suzhou 215123, P.R. China and also with the ARC Research Hub for Computational Particle Technology, Department of Chemical Engineering, Monash University, Clayton, Melbourne, VIC 3800, Australia. Contact e-mail: [email protected] SHIBO KUANG is with the ARC Research Hub for Computational Particle Technology, Department of Chemical Engineering, Monash University. Contact e-mail: [email protected] JIANJUN GAO, YUANHONG QI, and DINGLIU YAN are with the State Key Laboratory for Advanced Iron and Steel Processes and Products, Central Iron and Steel Research Institute, Beijing 100081, P.R. China. YUNTAO LI and XIAOMING MAO are with the Ironmaking Division, Research Institute (R&D Center), Baoshan Iron & Steel Co., Ltd., Shanghai 201900, P.R. China. Manuscript submitted August 4, 2017.
METALLURGICAL AND MATERIALS TRANSACTIONS B
smelting and reducing of burden materials mainly through combusting carbonaceous materials in the forms of coke and pulverized coal (PC), which are emitted to the atmosphere as CO2, finally. In an integrated steelwork, BFs together with the associated units (e.g., pelletizing–sintering machine and coke oven), represent about 90 pct of the CO2 emission[1–3] and 70 pct of the energy consumption.[4] On account of this, the conventional BF (CBF) ironmaking process has been facing growing social and environmental concerns. In the past decades, extensive efforts have been made to overcome this problem by developing various new techniques for CBFs, as reviewed by different investigators.[2,5–8] Nowadays, the efficiency of the CBF process is arguably believed to approach its limit.[7] In the process of oxygen blast furnace (OBF), room-temperature oxygen is used in place of hot blast. OBF has been regarded as a promising novel ironmaking technology because of its potential advantages over CBF, such as high productivity, high injection rates of auxiliary fuels, lower furnace allowing burden materials of various qualities, and ‘‘zero carbon footprint’’ production.[9–12] This ‘‘zero carbon footprint’’ benefits from
the fact that N2 is excluded from the furnace gas of OBF, and thus CO2 can be relatively easily sequestrated for storage or other disposal options rather than be released to the atmosphere directly. However, it is established that OBFs suffer from two major problems: ‘‘overheating’’ in the lower furnace and ‘‘thermal shortage’’ in the upper furnace.[13] The first problem is related to the high adiabatic flame temperature, which may be overcome by means of massive injection of auxiliary fuels in the tuyeres[13] and/or a newly designed oxygen–coal lance.[14] The second problem is that burden materials cannot be sufficiently heated up in the upper furna
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