Modeling a Compact Sintering Process Based on Biomass Fuels

2014 ◽  
Vol 902 ◽  
pp. 33-40 ◽  
Author(s):  
Jose Adilson de Castro ◽  
Alexandre Furtado Ferreira ◽  
Marcos Flavio de Camps ◽  
Ivaldo Leão Ferreira
Keyword(s):  
Blast Furnace ◽  
Solid Fuel ◽  
Chemical Species ◽  
Coke Oven ◽  
Reaction Rates ◽  
Furnace Operation ◽  
Base Case ◽  
Fuel Gas ◽  
Sintering Machine ◽  
Gas Utilization

This paper is focused on the numerical simulation of a new technology of small size iron ore sintering machine using gaseous fuel and oxygen injections to produce high quality of sinter product for the blast furnace operation. The proposed methodology is to partially replace the solid fuel (coke breeze) by steelworks gases in a compact machine to enhance heat and mass transfer. A multiphase mathematical model based on transport equations of momentum, energy and chemical species coupled with chemical reaction rates and phase transformations is proposed to analyze the inner process parameters. A base case representing a possible actual industrial operation of the sintering machine is used in order to compare different scenarios of possible operations which represents advanced operations techniques. The model was used to predict four cases of fuel gas utilization: a) 3% of the wind boxes inflow from N01-N10 wind boxes of natural gas (NG) and oxygen, b) same condition with coke oven gas (COG) and c) mixture of 80% COG and 20% blast furnace gas (BFG). The model predictions indicated that for all cases, the sintering zone is enlarged and the solid fuel consumption is decreased about 12kg/t of sinter product for the best combination. In order to maximize the steelworks gas utilization it is recommended the use of mixture of COG and BFG with optimum inner temperature distribution within a compact sintering machine, which enhance the productivity and obviously, decrease the investment cost of the sintering facilities.

Iron Ore Sintering Process Based on Alternative Gaseous Fuels from Steelworks

2012 ◽  
Vol 535-537 ◽  
pp. 554-560 ◽  
Author(s):  
José Adilson de Castro ◽  
Vagner Silva Guilherme ◽  
Alexandre Boscaro França ◽  
Yasushi Sazaki
Keyword(s):  
Solid Fuel ◽  
Iron Ore ◽  
Chemical Species ◽  
Reaction Rates ◽  
Base Case ◽  
Temperature Pattern ◽  
Sintering Process ◽  
Fuel Gas ◽  
Gas Utilization ◽  
Model Predictions

This paper deals with the numerical simulation of the new technology of gaseous fuel utilization on the sintering process of iron ore. The proposed methodology is to partially replace the solid fuel(coke breeze) by steelworks gases. A multiphase mathematical model based on transport equations of momentum, energy and chemical species coupled with chemical reaction rates and phase transformations is proposed to analyze the inner process parameters. A base case representing the actual industrial operation of a large sintering machine is used with thermocouples inserted into the sintering bed to record the inner bed temperatures and compare with model predictions in order to obtain model validation and parameters adjustment. Good agreement of the temperature pattern was obtained for the base case and thus, the model was used to predict four cases of fuel gas utilization: a) 2% of the wind boxes inflow from N01-N15 wind boxes of natural gas(NG), b) same condition with coke oven gas(COG), c) same condition with blast furnace gas(BFG) and d) mixture of 50% COG and 50% BFG. The model predictions indicated that for all cases, except only BFG, the sintering zone is enlarged and the solid fuel consumption is decreased about 8kg/t of sinter product. In order to maximize the steelworks gas utilization it is recommended the use of mixture of COG and BFG with optimum inner temperature distribution

scholarly journals Numerical Investigation of Blast Furnace Operation with Scrap Charging

Metals ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1666
Author(s):  
Zhu Liu ◽  
Zi Yu ◽  
Xuefeng She ◽  
Huiqing Tang ◽  
Qingguo Xue
Keyword(s):  
Blast Furnace ◽  
Numerical Investigation ◽  
Basic Oxygen Furnace ◽  
Furnace Operation ◽  
Partial Replacement ◽  
Base Case ◽  
Gas Temperature ◽  
Negative Effects ◽  
Basic Oxygen ◽  
Gas Utilization

One approach to reduce CO2 emission in the steelmaking industry is to recycle scrap to the blast furnace/basic oxygen furnace (BF/BOF) production system. This paper performed a numerical investigation on the BF operation with scrap charging. The investigated BF was with an inner volume of 820 m3, producing 2950 tons of hot metal per day (tHM/d). The simulated results indicated the following: Extra scrap addition in BF causes the decrease of shaft temperature, the decrease of local gas utilization, and the lowering of cohesive zone position, leading to an unstable BF running. The partial replacement of sinter with scrap in BF can mitigate the negative effects induced by scrap charging. The optimal scrap rate in the BF is 178 kg/tHM, under which the BF reaches a productivity of 3310 tHM/d, a top-gas utilization of 48.5%, and a top-gas temperature of 445 K. Compared to the base case, in the BF operation with scrap charging, the BF productivity is increased by 360 kg/tHM, its pulverized-coal rate and coke rate are decreased by 16.3 kg/tHM and 39.8 kg/tHM, respectively.

scholarly journals The Mini Blast Furnace Process: An Efficient Reactor for Green Pig Iron Production Using Charcoal and Hydrogen-Rich Gas: A Study of Cases

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1501
Author(s):  
Jose Adilson de Castro ◽  
Giulio Antunes de Medeiros ◽  
Elizabeth Mendes de Oliveira ◽  
Marcos Flavio de Campos ◽  
Hiroshi Nogami
Keyword(s):  
Blast Furnace ◽  
Process Efficiency ◽  
Rate Equations ◽  
Base Case ◽  
Pig Iron ◽  
Blast Furnace Process ◽  
Reference Case ◽  
Fuel Gas ◽  
Furnace Process ◽  
Operational Conditions

The mini blast furnace process is an efficient route to produce pig iron based on the burden with granulated charcoal. New, improved technologies have recently been introduced in the mini blast furnace process, such as pulverized charcoal and gas injections, new burden materials, and peripheral devices that improve the overall process efficiency. In this paper, we revise the new injection possibilities and discuss new aspects for further developments. The analysis is carried out with a comprehensive multiphase multicomponent mathematical model using mass, momentum, and energy conservation principles coupled with the rate equations for chemical reactions, multiphase momentum, and heat exchanges. We analyze new technological possibilities for the enhancement of this process as follows: (i) a base case of pulverized charcoal injection with industrial data comparison; (ii) a set of scenarios with raceway injections, combining pulverized charcoal with hydrogen-rich fuel gas, replacing granular charcoal in the burden; (iii) a set of scenarios with hydrogen-rich gas injection at the shaft level, replacing reducing gas in the granular zone of the reactor; and the possible combination of both methodologies. The simulated scenarios showed that a considerable decrease in granular charcoal consumption in the burden materials could be replaced by combining a pulverized charcoal injection of 150 kg/tHM and increasing rich gas injections and oxygen enrichment values, decreasing the specific blast injection and granular charcoal. The productivity of the mini blast furnace process was increased for all scenarios compared with the reference case. We review the aspects of these operational conditions and present an outlook for improvements on the process efficiency.

Model Predictions for New Iron Ore Sintering Process Technology Based on Biomass and Gaseous Fuels

2014 ◽  
Vol 918 ◽  
pp. 136-144 ◽  
Author(s):  
Jose Adilson de Castro
Keyword(s):  
Solid Fuel ◽  
Iron Ore ◽  
Sintering Process ◽  
Sintering Machine ◽  
Gaseous Fuels ◽  
Rich Mixture ◽  
Iron Ore Sintering ◽  
Gas Utilization ◽  
Model Predictions ◽  
Ore Sintering

In this paper a new technology for a compact iron ore sintering machine is analyzed. The compact sintering process is based on the massive injection of gaseous fuels and the solid fuel is only agglomerated fine charcoal obtained by biomass. The solid fuel used in this study is obtained by agglomeration of fine charcoal produced from elephant glass which has very short period for production and CO2 capture (less than 6 months in tropical climate). To overcome the lower heat supply into the combustion front of the sintering process the simultaneous injection of oxygen and gaseous fuel is proposed. The proposed methodology is to combine the solid fuel (agglomerated fines charcoal) and steelworks gases in a compact machine to enhance heat and mass transfer with high productivity (about 5 times the conventional large machine). A multiphase mathematical model based on transport equations of momentum, energy and chemical species coupled with chemical reaction rates and phase transformations is used to analyze the inner process parameters. A base case representing a possible actual industrial operation of the sintering machine is used in order to compare different scenarios of practicable operations which represents advanced operations techniques. The model was used to predict six cases of combined operation with biomass and fuel gas utilization: a) Scenario 01 and 02: Wind boxes inflow from N01-N10 of rich mixture of natural gas (NG) +Air +O2, b) Scenario 03 and 04: Wind boxes inflow from N01-N10 of rich mixture of coke oven gas (COG)+Air + O2, c) Scenario 05 and 06: Wind boxes inflow from N01-N10 of mixture of COG+BFG+Air+O2. The model predictions indicated that for all cases, the sintering zone is enlarged and the solid fuel consumption is decreased. In order to maximize the steelworks gas utilization it is recommended the use of mixture of COG and BFG with optimum inner temperature distribution within a compact sintering machine (in this study was the scenario 05), which enhance the productivity keeping good inner temperature distribution which promotes formation of calcium ferrites of structural shape which confers adequate metallurgical properties for blast furnace sinter. This technology is also expected to decrease considerably the specific CO2 emissions, as demonstrated by scenarios simulated. It worthy to mention that, although the solid fuel considered in this work is produced from biomass the gas utilization is attractive due to decrease of the CO2 emissions and the gas mixtures can easily be obtained by using inner steelworks gas.

scholarly journals Development of iron ores sintering machine for blast furnace process

2021 ◽  
Vol 15 (2) ◽  
pp. 64-75
Author(s):  
Femi Akinfolarin ◽  
Buliaminu Kareem ◽  
Oladunni Oyetola Alabi
Keyword(s):  
Blast Furnace ◽  
Refractory Material ◽  
Iron Ore ◽  
Research Work ◽  
Palm Kernel ◽  
Furnace Operation ◽  
Sintering Machine ◽  
Palm Kernel Shell ◽  
Iron Ore Sintering ◽  
Steel Material

There must be proper means to sinter and, agglomerated iron ore concentrate before it can be further processed in the blast furnace. A Sintering machine of 5kg capacity of agglomerated ore was designed and fabricated using mild steel material, which was locally sourced. The machine was fabricated with a combustion chamber of 30 by 30 cm and with 15cm depth. It was also lined with refractory material to reduce the chamber to the volume of 3375 cm3. However, the sintering chamber was designed to have a truncated square pyramid shape to the volume of 2150 cm3 after lining with refractory material. The design was made to utilize coke and palm kernel shell char as fuel which will be ignited to produce heat into the sintered material by suction of the heat into the agglomerated sintered ore. Tests such as tumbler index, abrasion, and porosity test were carried out on the sintered products in agreement with ASTM E276 and E389 standards. The results from the test gave a tumbler index of 70.2% and 65.7% for coke and palm kernel shells respectively. Also, abrasion index of 5.1% and 4.6% for coke and palm kernel char, and porosity of 6.8% and 6.5% for coke and palm kernel char respectively. The results from the experimental test were in agreement with other research work. Therefore, the developed iron ore sintering machine has a better efficiency of producing sinter for blast furnace operation.   

Investigation of the Influence of Alkali Circulation on the Blast Furnace Operation

1979 ◽  
Vol 65 (12) ◽  
pp. 1663-1672 ◽  
Author(s):  
Michiharu HATANO ◽  
Tomio MIYAZAKI ◽  
Yuji IWANAGA
Keyword(s):  
Blast Furnace ◽  
Furnace Operation ◽  
Blast Furnace Operation
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