Analysis of performance of an iron-bath reactor using computational fluid dynamics

Panjković, Vladimir; Truelove, J.S.; Ostrovski, Oleg

doi:10.1016/s0307-904x(01)00056-7

Cited by 14 publications

(4 citation statements)

References 16 publications

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“…However, quantification of heats specially overall excess heat were not mentioned in the discussion. Several researchers have analyzed heat transfer aspects of the steelmaking process in terms of (a) quantifying the temperature of the metal droplets; [20][21][22] (b) calculating the heat released and transferred from the postcombustion reaction in a foaming slag; [23][24][25][26] (c) improving the energy efficiency of the process by increasing the scrap melting (by 3 to 6%) using the heat of post-combustion; [27][28][29] and (d) investigating the heat transfer mechanism of scrap melting and dissolution. [30][31][32][33][34][35][36][37] The industrial, experimental, and model studies show that the BOF process has been reasonably understood through dynamic kinetic models in terms of predicting refining profiles, achieving various end composition, and tap temperature.…”

Section: Analytical Evaluation Of Heat Flow In Oxygen Steelmakingmentioning

confidence: 99%

Analytical Evaluation of Heat Flow in Oxygen Steelmaking

et al. 2022

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Dynamic models for a BOF (Basic oxygen furnace) process have been developed to quantitatively capture the variation in refining kinetics and heat flow during the blowing period. Previous studies have developed extensive models to understand the kinetics and reaction mechanisms for a BOF process. The understanding of heat flow during the refining period helps in optimizing the process interms of energy consumption and minimizing the overall excess heat (heat losses). The present work aims to develop an approach that will capture the heat flow during the blowing period once the refining profiles are known. In the present calculation the instantaneous heats were calculated based on the refining profiles from Cicutti et al. 1) industrial trial and Imphos pilot plant data.2) The developed model reveals different possibilities for process optimization by identifying the periods of overall excess energy formation. It was observed by compiling Cicutti's data that an average of 7.5 MJ/min/t of hot metal excess heat is generated during the blowing period spanning from 6 to 14 minutes. Moreover, the present study demonstrates that the parameters such as scrap quantity, flux added, and oxygen flowrate can play a vital role in optimizing the process in terms of the utilization of the overall excess energy during the refining period.

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Section: Analytical Evaluation Of Heat Flow In Oxygen Steelmakingmentioning

confidence: 99%

Analytical Evaluation of Heat Flow in Oxygen Steelmaking

et al. 2022

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“…In this work, the oxygen lance nozzle was modeled based on the Cartesian coordinate system. Since the nozzles are distributed symmetrically, the calculation domain was set to consider only one-third of the entire model for the six-hole oxygen lance and one-fifth of the entire model for the five-hole oxygen lance to simplify the calculation and increase the convergence speed [15][16][17][18]; the model mainly includes two Laval nozzles and a sufficiently large space. e latter consists of a segment of one-third of a cylinder with a radius of 1.2 m and a height of 3 m. e geometric model is shown in Figure 2.…”

Section: Geometric Modeling and Mesh Generationmentioning

confidence: 99%

Turbulence Calculations of a Dual-Structure Oxygen Lance for Converter Based on Hydrodynamics

Jia

Han

et al. 2021

Mathematical Problems in Engineering

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The oxygen lance is a piece of special equipment in the converter steelmaking process for blowing oxygen into the molten steel. After more than 80 years of development, the structure and function of the oxygen lance have undergone many changes. In this paper, based on the theory of hydrodynamics, the jet behavior characteristics of a dual-structure oxygen lance for the converter are determined and optimized by CFD simulations and compared with those of the traditional-structure oxygen lance. The research results show that multiple jets deflect to the central axis of the oxygen lance during movement and the inclination angle of the nozzle holes influences the jet deflection. A decrease in the nozzle hole angle results in an increase in the mutual suction between the streams. With the increasing flow rate through the large holes in the new dual-structure oxygen lance, the dynamic radial pressure increases at the middle of the jet. The jet flow characteristics of the new dual-structure oxygen lance are better than those of the traditional oxygen lance. Its impact on the molten pool includes greater momentum, a larger impact area, and a more uniform and powerful stirring of the molten pool. A nozzle angle of 14° combined with a flow rate ratio of 65% and a nozzle angle of 17° combined with a flow rate ratio of 35% are the optimal parameters for the new dual-structure oxygen lance.

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“…As is well known, the gas utilisation ratio in the reduction reaction of wüstite to iron is <30%, 2 as is shown in equation (29). Thus, according to the theory of mass balance and reduction potential demand for wüstite reduction, the minimum flowrate of inlet gas is calculated by the following equations The heat balance of the MIDREX shaft furnace is evaluated by the following relationship 3 Thus, according to equations (22)–(28), the minimum flowrate of inlet gas can be calculated by the following equation …”

Section: Heat and Mass Balance Modelmentioning

confidence: 99%

“…To simulate the reaction rate of a pellet in the shaft scale, the unreacted shrinking core model was used at each step of the reduction: haematite to magnetite, magnetite to wüstite and wüstite to iron, as the following 2 The combustion rates of CO and H 2 are given by a generalised form of the eddy dissipation model as 3 The combustion rate of CH 4 is given by the following equation 4 …”

Section: Kinetic Modelmentioning

confidence: 99%

Discussion on chemical energy utilisation of reducing gas in reduction shaft furnace

Liu

Zong-shu

et al. 2013

Ironmaking & Steelmaking

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The reduction shaft furnace is a countercurrent moving bed cylindrical reactor in which hematite pellets are reduced by a gas mixture of H 2 and CO. Most of the reduction shaft furnaces use hydrogen rich gas as reducing gas. The materials and heat balances show that the heat balance determines the gas consumption. Compared with the gas requirement by reduction reaction, a much greater quantity of gas has to be blown into the furnace to satisfy the heat balance, leading to a high energy consumption and high excess of reduction potential of top gas. To solve this problem, a new approach is proposed where some oxygen is blown into the upper zone of the shaft furnace. As the feasibility study of such an approach, a static model was developed first to calculate input gas flowrate and oxygen rate. Then, based on conservations of mass and heat, a kinetic model for a typical MIDREX shaft furnace was developed to investigate the proper position for oxygen blowing. The model predictions were validated by comparison with production data. Finally, a kinetic model was developed to investigate the process of shaft furnace with oxygen blowing. The results show that the gas consumption can be reduced from 1897 to 1405 N m 3 tDRI 21 with oxygen blowing of 20?3 N m 3 tDRI 21 . After oxygen blowing, the temperature increases sharply, the concentration of CO and H 2 decreases, and reduction potential of top gas decreases from 1?48 to 0?69, showing that the gas utilisation is greatly improved. These models can be used for process optimisation development. List of symbolsA cross-section area, m 2 C P specific heat capacity, J mol 21 K 21

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Analysis of performance of an iron-bath reactor using computational fluid dynamics

Cited by 14 publications

References 16 publications

Analytical Evaluation of Heat Flow in Oxygen Steelmaking

Analytical Evaluation of Heat Flow in Oxygen Steelmaking

Turbulence Calculations of a Dual-Structure Oxygen Lance for Converter Based on Hydrodynamics

Discussion on chemical energy utilisation of reducing gas in reduction shaft furnace

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