Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

Abstract

A large‐scale bench reactor (LSBR) is operated at the University of Utah to develop a novel flash ironmaking process. The reactor vessel is a refractory‐lined furnace with 0.8 m in diameter and 2.1 m in length, with a capacity of processing 1–7 kg h−1 of magnetite concentrate. Natural gas is partially oxidized with oxygen in a uniquely designed burner, producing a short flame that provides heat (1423–1873 K) and a reducing gas mixture (hydrogen and carbon monoxide). The reducing gas reacts with magnetite (Fe3O4) concentrate particles to produce metallic iron. A computational fluid dynamics (CFD) model is developed to simulate the LSBR runs, in which the kinetics of magnetite concentrate reduction, separately determined in a drop‐tube reactor, is incorporated. The reduction degrees and composition of the off‐gas obtained from the CFD model show reasonable agreements with the experimental results.

Design of Novel Flash Ironmaking Reactors for Greatly Reduced Energy Consumption and CO2 Emissions

“…This reactor was simulated by CFD to optimize the operating conditions to achieve high reduction degree at the optimum conditions and reactor sizes to be used in an industrial reactor [29]. The results obtained from the developed CFD model were compared to the actual results of the reactor operation and good agreement was achieved.…”

A Computational Fluid Dynamics Simulation Method to Optimize the Structure Parameters of Coal‐Based Flash Ironmaking Reactors

“…However, due to the apparent kinetic study under corresponding conditions was adopted, the measured kinetic parameters already included the effects of morphological changes. The problem of particle adhesion in the high temperature process was already observed in the bench‐scale practise, [ 22 ] but not included into the consideration in this research. A complex comprehensive model including particle sticking and wall reaction was under development.…”

Numerical Analysis of the Dust Control Performance of a Counter-current Swirling Configuration in the Flash Ironmaking Reactor

“…Different fuels have different combustion mechanisms and gas compositions. [6][7][8][9][10] It is assumed that the upper cavity of the settler can be used as the location of gas generation, which is outside the computational zone. Therefore, the gas generation process was not considered in this study, and a simplified gas composition with pure H 2 : CO ratio was directly used as Fig.…”