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The present investigation was aimed at elucidating solid particle behaviour in a new design COREX shaft furnace using a new technique called areal gas distribution (AGD). The measurement of solid flow profile was performed with a semi-cylindrical model. To guarantee similarity of conditions, a modified Froude number was taken into consideration in the physical model constructed. The solid flow characteristics in this new furnace with different blast volumes were analysed, and the effect of discharge rate as well as abnormal conditions on solid flow behaviour have also been investigated. The work reveals that solid flow profile in the shaft furnace model progresses through a FlatRWaveRW shape profile as the burden descends. Blast volume has little influence on solid particle behaviour. However, increasing the discharge rate has an effect of decreasing the quasi-stagnant zone size and with the increasing discharge rate, the cross-section of AGD channel increases. For asymmetric flow, particles descend from the top and move to the discharging outlet and a very big stagnant zone is formed on the opposite side of the discharging outlet.

COREX is an industrially and commercially proven smelting reduction process. The shaft furnace (SF) for the direct reduction of iron ore is one of the two major reactors of COREX. In the new design of COREX-3000 SF in Baosteel, China, a new technique called areal gas distribution (AGD) has been adopted. With the installation of two AGD beams, the cross-sectional area varies in a complicated manner, which will affect the burden descending behaviour. This work uses a slot model to investigate the solid flow behaviour in the SF by discrete element method. The applicability of the discrete element method model is validated. The results confirm that the flow profile in SF with AGD evolves from a flat to wave and finally to W profile as the solids descend. A triangle shaped free area is observed under the AGD beam, which is the main channel for gas flow into the shaft centre. Increasing the discharging rate has an effect of decreasing the quasi-stagnant zone size, but does not affect the macroscopic motion of particles and flow pattern above the bustle. The cross-section of AGD channel increase with the increase in the discharging rate. Under the asymmetric condition, the solid flow pattern is asymmetric. The influence of AGD on macro-and microscope properties of solid flow in SF is also evaluated. This investigation reveals that AGD beams affect the particle uniform descending in bustle zone and increase the complexity of normal force distribution.

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