Numerical Investigation of the Inner Profiles of Ironmaking Blast Furnaces: Effect of Throat-to-Belly Diameter Ratio
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urnace (BF) ironmaking is the most important technology by which hot metal (HM) is continuously and rapidly reduced from iron-bearing materials. This process accounts for over 96 percent of the total HM production for steelmaking in the world.[1] It is recognized that in order to achieve high-level performance, BF inner profile or geometry has to meet the physical and chemical requirements of counter-, co-, and/or cross-current flows of descending solids and liquid as well as ascending gas over the region from the hearth to the top.[2] However, because of the complexity of BF, it is extremely difficult if not impossible to measure the details of inner flow and thermochemical phenomena and then consider them at the design phase. Consequently, for a long time, the inner profile has evolved through experience, of which the calculation is more or less empirical.[2] Moreover, such calculation cannot fully take into account the effects of operational condition, material property, and their variations. However, these effects are very useful for obtaining an optimum inner profile and for avoiding ZHAOYANG LI, Ph.D. Candidate, SHIBO KUANG, Research Fellow, and AIBING YU, Professor, are with the Laboratory for Simulation and Modelling of Particulate Systems, Department of Chemical Engineering, Monash University, Clayton, Melbourne, VIC 3800, Australia. Contact e-mail: [email protected] DINGLIU YAN and YUANHONG QI, Professors, are with the State Key Laboratory for Advanced Iron and Steel Processes and Products, Central Iron and Steel Research Institute, Beijing 100081, China. Manuscript submitted June 15, 2016. Article published online October 17, 2016. 602—VOLUME 48B, FEBRUARY 2017
possible rapid changes of BF inner states with varying material and/or operational conditions. Additionally, the problem associated with determination of BF geometry can become more serous by the uncertainties from the implementation of new technologies. Therefore, with either a short-term or long-term view, there are needs to reveal the effects of furnace profiles under different conditions, particularly at a quantitative level. In the past years, various experimental studies have been conducted to study the effects of BF inner profiles.[3-6] Although useful to better know the impact of furnace profile, the previous studies were mainly based on scaled-down cold models and largely confined to the visual observation of particle flow patterns. In fact, at this stage of development, it is yet difficult to measure the local solid structures, multiphase flows, and related phenomena which are critical for understanding BFs and other particle-fluid systems.[7-9] Moreover, real BFs are operated under extremely harsh environment, involving intensive interactions among gas, solid, and liquid in terms of flow, and heat and mass transfer at high temperature and pressure. They are therefore not easy to simulate experimentally. This problem may, to some extent, be overcome by a small experimental BF (e.g., 9-m3 LKAB BF[10]), which in principle functions in a similar way to a rea
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