Experimental Study on Charging Process in the COREX Melter Gasifier
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BLAST furnace ironmaking, which has a long history and high energy efficiency, is the main technology for hot metal production. Recently, mainly due to the diminishing of high-quality coking-coal resources and increasingly strict environmental regulations, various new alternative processes such as COREX, FINEX, and HIsmelt have been developed.[1–4] Among these processes, COREX is the earliest commercialized smelting reduction ironmaking process.[5–7] It is a two-stage process that includes pre-reduction in a shaft furnace and final reduction in a melter gasifier (MG). In comparison with the blast furnace that is usually equipped with a bell or bell-less type top, there are two charging systems on the top of the MG, i.e., one GIMBAL distributor surrounded by eight DRI-flap distributors. In practice, the direct reduced iron (DRI)
ZHIGUO LUO, HAIFENG LI, and ZONGSHU ZOU are with the School of Metallurgy, Northeastern University, Shenyang, 110819, Liaoning, China. YANG YOU is with the School of Metallurgy, Northeastern University and also with the School of Materials Science and Engineering, University of New South Wales, Sydney, NSW 2052, Australia. Contact e-mail: [email protected] HENG ZHOU is with the School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China. Manuscript submitted July 20, 2017.
METALLURGICAL AND MATERIALS TRANSACTIONS B
with a metallization ratio of around 80 pct from the shaft furnace and lump coal are charged into the MG by the DRI-flap and GIMBAL distributors, respectively. The lump coal is used as fuel and reducing agent, and the DRI is finally reduced to hot metal in the MG. As the burden distribution directly affects the gas flow in the MG and then determines the further reduction degree of DRI, it is therefore of considerable importance to investigate and clarify the influence of burden charging on its distribution in the MG, in order to maintain high operational stability and energy efficiency for the COREX process. In the past, both experimental and mathematical studies were conducted on the burden distribution in the blast furnace and shaft furnace, involving the aspects of falling trajectory of particles,[8–11] burden profile and structure,[12–16] and the descent of burden layer.[17,18] As for the COREX MG, however, most of the related studies were based on mathematical modeling probably due to the short history and the lack of corresponding experimental apparatuses.[19–25] Li et al.[26] developed a three-dimensional (3D) discrete element method (DEM) model to investigate the particle trajectory, falling location, and burden profile in the MG. Han et al.[27] established a 2D slot DEM model to analyze the influence of cohesive zone shape on solid flow, and the distribution of particle mass, velocity, normal force, and porosity were analyzed. Wang et al.[28] developed a 2D two-fluid CFD model to evaluate the gas flow under different solid bed conditions in a MG. Recently,
authors of the present work[29] established a 1/7.5 scale experimental appara
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