Experimental Investigation and Computational Fluid Dynamics Simulation of the Magnetite Concentrate Reduction Using Meth
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THERE has been much effort devoted to reducing the emissions of greenhouse gas (GHG) in all industries. The steel industry has been achieving significant reduction in GHG emissions during the past few decades by improving the energy efficiency through technologies. According to the International Energy Association (IEA), the iron and steel industry accounts for 6.7 pct of the world CO2 emissions in 2017.[1] A transformational technology for alternate ironmaking has been developed at the University of Utah aimed at greatly reducing the energy consumption and GHG emission compared with the conventional blast furnace (BF) process. In this novel ironmaking process, iron is
MOHAMED ELZOHIERY, DEQIU FAN, YOUSEF MOHASSAB, and H. Y. SOHN are with the Department of Metallurgical Engineering, University of Utah, Salt Lake City, Utah 84112,. Contact e-mail: [email protected] Manuscript submitted October 27, 2019.
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produced by the direct gaseous reduction of iron oxide concentrate in a flash reactor by utilizing hydrogen, natural gas, or coal gas as the reducing agent and fuel. Little work had been done on the reduction of iron oxide in a flash process before the development effort at Utah. Themelis and Zhao[2] investigated the flash reduction of iron oxides, but it was concluded that the reaction was not amenable to the high-intensity flash process as the reaction rate was too slow. This conclusion was based on experimental results of the reduction of iron oxide particles ranging from 70 to 42,000 lm in the temperature range of 873 K (600 °C) to 1273 K (1000 °C). Johnson and Davison[3] studied the reduction of taconite concentrate particles ranging in size from 5 to 45 lm in a heated cyclone. The cyclone system was preheated from 1273 K (1000 °C) to 1473 K (1200 °C) prior to switching to a plasma system to maintain an average operating temperature of 1773 K (1500 °C) or higher. The iron ore concentrate particles were reduced using CO as the reducing gas, and a reduction degree of 80 to 95 pct were achieved.
Most of the experimental and simulation work on flash reaction processes were focused on the smelting and converting of sulfide concentrates. Perez-Tello et al.[4,5] investigated the copper converting reaction in terms of converting rate, converting quality, particle size change, morphology, and mineralogy in a laboratory flash rector. A three-dimensional computational fluid dynamics (CFD) model was developed to model the converting process. Reasonable agreement between the experimental results and the computed result was obtained in terms of the fractional completion of the oxidation reaction and sulfur remaining. Different experiments were conducted by Jokiaakso et al.[6] in a laboratory flash reactor aiming to treating complex copper and nickel concentrates in the Outotec flash smelting process. The work was focused on the removal of arsenic and antimony from the complex copper concentrates. CFD models were also developed aimed at improving the energy efficiency of the Outotec flash smelting pr
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