Mineralogical Aspects of Reducing Lump Iron Ore, Pellets, and Sinter with Hydrogen

Angalakuditi, Veera Brahmacharyulu; Bhadravathi, Paramesha; Gujare, Ramarao; Ayyappan, Gowthaman; Singh, Lokendra Raj; Baral, Saroj Sundar

doi:10.1007/s11663-022-02442-4

Cited by 5 publications

(4 citation statements)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Heidari et al reported that impurities, such as CaO, SiO 2 , and MgO, promote reduction by forming microcracks on the pellet surface. However, CaO and SiO 2 also restrain surface fissures by forming low-melting binder phases. − Furthermore, SiO 2 densifies the generated metallic iron, and MgO reacts with the intermediate product FeO to produce (Mg, Fe)O, which is difficult to reduce . These factors hinder the reduction process.…”

Section: Physical Modelingmentioning

confidence: 99%

A Review on the Modeling and Simulation of Shaft Furnace Hydrogen Metallurgy: A Chemical Engineering Perspective

Fei,

Guan,

Kuang

et al. 2023

ACS Eng. Au

View full text Add to dashboard Cite

Hydrogen-based shaft furnace technology holds promise for low-carbon hydrogen metallurgy. Since hydrogen-assisted iron ore reduction is highly endothermic, inadequate heat supply relevant to the contact of gas and densely packed ores may reduce the rate and efficiency of reductions. The key to addressing this issue lies in understanding the competition among heat supply, heat transfer, and heat loss driven by the gas flow around ores and reactions within them. Modeling and simulation are crucial for revealing the underlying mechanisms and promoting process scale-up and intensification. This review summarizes previous efforts in physical modeling and model applications for improving the reduction performance. The discrete element method (DEM) and computational fluid dynamics (CFD)− DEM models have been used for particle-scale simulation to investigate inhomogeneous particle descent and relevant particle−particle interactions. For macroscale simulations, steady-state simplified models such as plug flow and REDUCTOR, as well as the Eulerian two-phase model, have been developed by considering heat and mass transfer. Based on these model applications, strategies including the optimization of operating conditions and gasfeeding methods have been proposed to improve the furnace performance. Further numerical efforts are needed to analyze the infurnace heat evolution and reduction and reveal the competitiveness of flow, transport, and reaction by incorporating multiscale physics in shaft furnaces. Additionally, attention could be paid to the effects of particle sticking and degradation on reduction, which may be more serious when the proportion of lump ores increases. When evaluating relative optimization strategies, comprehensive comparisons are expected in terms of iron ore reduction degree, gas utilization rate, energy consumption, and economic feasibility under various reducing and cooling gas operating conditions and furnace profiles to offer practical guidelines for industrial design and intensification.

show abstract

Section: Physical Modelingmentioning

confidence: 99%

A Review on the Modeling and Simulation of Shaft Furnace Hydrogen Metallurgy: A Chemical Engineering Perspective

Fei,

Guan,

Kuang

et al. 2023

ACS Eng. Au

View full text Add to dashboard Cite

show abstract

“…It is no longer news that coking coals can serve as an excellent reducing agent and high energy source for iron and steel production. But the under-utilized coke is produced as carbon monoxide gas which has an adverse climatic effect on our immediate environment [8]. The carbon monoxidegasmayalsoleadtoozonedepletion, the greenhouse effect, and global warming at large.…”

Section: Reduction Of Iron Ore By Hydrogen and Carbon-monoxide Gasmentioning

confidence: 99%

“…The focus of most research from the works of literature revolves around the production of iron metals through recycling or improving upon the existing method of production in the iron and steelmaking industry [2][3][4]. These methods include the Blast furnace/Blast Oxygen Furnace [5,6], Direct Reduction Method [7], Indirect Reduction Method [8,9], and Reducer-Smelter Process [10][11][12]. Thus, it is, therefore crucial to know that this processing technique has proven to have produced quality iron but not without a high cost of production, increased environmental pollution, and cumbersome production process [13,14].…”

Section: Introduction 11 Study Backgroundmentioning

confidence: 99%

Recent Trends in the Technologies of the Direct Reduction and Smelting Process of Iron Ore/Iron Oxide in the Extraction of Iron and Steelmaking

Ogbezode¹,

Ajide²,

Oluwole³

et al. 2023

Iron Ores and Iron Oxides - New Perspectives

View full text Add to dashboard Cite

The blast furnace and direct reduction processes have been the major iron production routes for the past few decades, but the challenges of maintaining the iron and steel-making processes are enormous. The challenges, such as cumbersome production routes, scarcity of metallurgical coke, high energy demands, and a high cost of production, cannot be overemphasized. This study provides a systematic overview of the different ironmaking routes, and the challenges involved. Subsequently, strategic ways towards improving the production efficiency and product quality of metallic iron produced in the recent iron processing routes were suggested. The study reiterated that the non-contact direct reduction and reduction-smelting routes are the faster ironmaking and steelmaking processes that can utilise alternative energy sources efficiently with little or no carbon deposition. Both processes also have promising features based on their requirements in terms of fewer energy demands, time-saving, cost-effectiveness, and operational efficiency. Thus, in today's iron and steelmaking processes, non-contact direct reduction and reduction-smelting processes remain viable alternative iron production routes.

show abstract

“…One of the characteristics of metallurgical reaction kinetics is its greater dependence on the mechanism of the reaction rather than on the rate of the entire multiphase process. The reduction of iron ore is composed of different rate-controlling processes such as gas external diffusion, internal diffusion, and chemical reactions, among which chemical reactions have the slowest rate [8][9][10][11][12]. However, these findings are semiquantitative because the transition points of different rate-controlling processes at the early and later stages and the relevant kinetic parameters cannot be obtained from reaction simulations.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Reaction Kinetics of a Sinter-Reduction Process in the Thermal Reserve Zone of a Blast Furnace Using a Modified Sectioning Method

Zhu

Wenlong

et al. 2022

Metals

View full text Add to dashboard Cite

With the development of large-scale and high-performing blast furnaces, it is necessary to extensively study the reaction characteristics and related kinetic parameters of sinters in their heat reserve area. Under reducing atmosphere conditions, the reduction of iron oxide in sinter is closely related to the gasification reaction of coke. Based on a simulation experiment, the transition point from chemical reactions to diffusion and the related kinetic parameters were determined through a sectioning method. The results showed that increasing the proportion of low-grade coke increased the chemical-reaction rate, but it slightly decreased the mass-transfer and diffusion rates. An increase in the coke particle size increased the chemical-reaction, mass-transfer, and diffusion rates. However, an increase in the CO2 volume fraction in gas reduced the chemical-reaction, diffusion, and mass-transfer rates. The mixing ratio of coke and sinters increased the chemical-reaction rate, but it decreased the mass-transfer and diffusion rates. The rate constant of the chemical reactions in the early stage was three orders of magnitude higher than that of the diffusion and mass-transfer coefficients, and the fitting degree was obviously better than that of the molecular diffusion in the later stage. Based on the thermodynamics of irreversible processes, the interference of the chemical reactions with the diffusion and mass transfer in the near-equilibrium region was tentatively established, the method of controlling coke diffusion and mass transfer in the later reaction stage was given and related kinetic parameters were corrected, and further improvement of the modified sectioning method was completed.

show abstract

Mineralogical Aspects of Reducing Lump Iron Ore, Pellets, and Sinter with Hydrogen

Cited by 5 publications

References 28 publications

A Review on the Modeling and Simulation of Shaft Furnace Hydrogen Metallurgy: A Chemical Engineering Perspective

A Review on the Modeling and Simulation of Shaft Furnace Hydrogen Metallurgy: A Chemical Engineering Perspective

Recent Trends in the Technologies of the Direct Reduction and Smelting Process of Iron Ore/Iron Oxide in the Extraction of Iron and Steelmaking

Investigation of the Reaction Kinetics of a Sinter-Reduction Process in the Thermal Reserve Zone of a Blast Furnace Using a Modified Sectioning Method

Contact Info

Product

Resources

About