Modelling of Mass and Thermal Balance and Simulation of Iron Sintering Process with Biomass

Abstract

This paper specifies the mathematical and physical modelling of the iron sintering process in laboratory conditions. The aim is to get the simplest approach (using thermodynamic software “HSC Chemistry”, version 9, Outokumpu Research Oy, Pori, Finland) that allows one to predict the output parameters based on the initial composition analysis. As a part of the application of mathematical modelling, a mass and thermal balance of combustion of carbonaceous fuels (including biomass) and a mass and thermal balance of high-temperature sintering of an agglomeration charge were determined. The objective of the paper was to point out the advantages of modelling using thermodynamic software and apply the results into a simulation of the sintering process. The outcome of mathematical modelling correlates to the outcome of physical modelling for fuel combustion and the agglomerate production in a laboratory sintering pan. The energy required to reach the desired sintering temperatures and acquire the standard quality of agglomerate was calculated using 4.97% of coke breeze. In a real experiment with the laboratory sintering pan, 4.35% of coke was used. When a biomass fuel with a lower calorific value (lignin) is used in the agglomeration charge, the amount of fuel has to be increased to 5.52% (with 20% substitution of coke). This paper also aimed at predicting methodological tools and defining thermodynamic conditions for creating an interactive simulation. In addition, kinetics should be considered to improve the predicting capabilities of the current model and therefore in further research it will be required to optimise the computational program pursuant to the results of the kinetics experiments.

Advances in Sintering of Iron Ores and Concentrates

“…the major sintering products. By changing the basic condition of the thermodynamic system, it is feasible to find the optimum operating conditions of the sintering process and minimize the consumption of raw materials and energy [11]. For mathematical modeling the basic chemical reactions with standard Gibbs energy and mass and thermal balance were calculated.…”

“…HSC Chemistry offers powerful calculation methods for studying the effects of different variables on the chemical system at equilibrium. The aim is to get the simplest approach (using this software to calculate equilibrium) which allows one to predict the output parameters (amounts, chemistry, mineralogical composition, and total heat) based on the initial composition analysis [11].…”

“…The said model allows the control of the overall thermal effect of the sintering process during individual instances of experimental laboratory sintering while it employed the prediction of sinter phase composition at the sintering temperatures in the calculations. Since the phase composition of the sinter is determined on samples of sinter after cooling, the computational model should bring a new perspective of the processes taking place during sintering [11]. Figure 8 shows the global method with modeling the mass and thermal balance of the sintering process.…”

“…Pursuant to the modeling of the sintering process in the Figure 8. Scheme presenting the global method with modeling the mass and thermal balance (modified by authors according [11]). laboratory conditions, it was feasible to specify the created model by the following parameters [11]:…”

“…The authors of this chapter have already carried out a large number of laboratory experiments [9][10][11], the results of which can be compared with the calculated thermodynamic models. It is apparent that the model calculations of added fuel in charge are highly correlated with the experimentally determined values, Figure 9a.…”