Mathematical simulation of hot metal desulfurization during KR process coupled with an unreacted core model

A three-dimensional mathematical model was established to predict the multiphase flow,motion and dispersion of desulfurizer particles,and desulfurization of hot metal during the Kanbara reactor(KR)process.The turbulent kinetic energy-turbulent dissipation rate(k-ε)turbulence model,volume-of-fluid multiphase model,discrete-phase model,and unreacted core model for the reaction between the hot metal and particles were coupled.The measured sulfur content of the hot metal with time during the actual KR process was employed to validate the current mathematical model.The distance from the lowest point of the liquid level to the bottom of the ladle decreased from 3170 to2191 mm when the rotation speed increased from 30 to 110 r/min,which had a great effect on the dispersion of desulfurizer particles.The critical rotation speed for the vortex to reach the upper edge of the stirring impeller was 70 r/min when the immersion depth was 1500 mm.The desulfurization rate increased with the increase in the impeller rotation speed,whereas the influence of the immersion depth was relatively small.Formulas for different rotation parameters on the desulfurization rate constant and turbulent energy dissipation rate were proposed to evaluate the variation in sulfur content over time.

Mathematical Model for Growth of Inclusion in Deoxidization on the Basis of Unreacted Core Model

Controlling inclusion composition, from the point of view of thermodynamics, only explains the probability and limit of reaction. However, kinetics makes the nucleation and the velocity of growth of inclusions clear, and these kinetic factors are very important to the quality of slab. The basic kinetic theory of unreacted core model was used to build the mathematical model for the growth of inclusions and the concerned software was developed through Visual Basic 6.0. The time that different radius inclusions attain saturation was calculated to determine the controlling step of reaction between steel and inclusions. The time for the growth of inclusion obtained from the model was in good agreement with the data measured by Japanese Okuyama G, which indicated that the model is reasonable.

Effect of FeO concentration in sinter iron ore on reduction behavior in a hydrogen-enriched blast furnace

Japan started the national project“COURSE 50”for CO_(2) reduction in the 2000s.This project aimed to establish novel technologies to reduce CO_(2) emissions with partially utilization of hydrogen in blast furnace-based ironmaking by 30%by around 2030 and use it for practical applications by 2050.The idea is that instead of coke,hydrogen is used as the reducing agent,leading to lower fossil fuel consumption in the process.It has been reported that the reduction behavior of hematite,magnetite,calcium ferrite,and slag in the sinter is different,and it is also considerably influenced by the sinter morphology.This study aimed to investigate the reduction behavior of sinters in hydrogen enriched blast furnace with different mineral morphologies in CO-CO_(2)-H2 mixed gas.As an experimental sample,two sinter samples with significantly different hematite and magnetite ratios were prepared to compare their reduction behaviors.The reduction of wustite to iron was carried out at 1000,900,and 800℃ in a CO-CO_(2)-H2 atmosphere for the mineral morphology-controlled sinter,and the following findings were obtained.The reduction rate of smaller amount of FeO led to faster increase of the reduction rate curve at the initial stage of reduction.Macro-observations of reduced samples showed that the reaction proceeded from the outer periphery of the sample toward the inside,and a reaction interface was observed where reduced iron and wustite coexisted.Micro-observations revealed three layers,namely,wustite single phase in the center zone of the sample,iron single phase in the outer periphery zone of the sample,and iron oxide-derived wustite FeO and iron,or calcium ferritederived wustite'FeO'and iron in the reaction interface zone.A two-interface unreacted core model was successfully applied for the kinetic analysis of the reduction reaction,and obtained temperature dependent expressions of the chemical reaction coefficients from each mineral phases.

Modelling and numerical simulation of isothermal oxidation of an individual magnetite pellet based on computational fluid dynamics

A mathematical model based on the computational fluid dynamics method,heat and mass transfer in porous media and the unreacted shrinking core model for the oxidation reaction of an individual magnetite pellet during preheating was established.The commercial software COMSOL Multiphysics was used to simulate the change in the oxidation degree of the pellet at different temperatures and oxygen concentrations,and the simulated results were compared with the exper-imental results.The model considered the influence of the exothermic heat of the reaction,and the enthalpy change was added to calculate the heat released by the oxidation.The results show that the oxidation rate on the surface of the pellet is much faster than that of the inside of the pellet.Temperature and oxygen concentration have great influence on the pellet oxidation model.Meanwhile,the exothermic calculation results show that there is a non-isothermal phenomenon inside the pellet,which leads to an increase in temperature inside the single pellet.Under the preheating condition of 873-1273 K(20%oxygen content),the heat released by the pellet oxidation reaction in a chain grate is 7.8×10^(6)-10.8×10^(6) kJ/h,which is very large and needs to be considered in the magnetite pellet oxidation modelling.

Effect of MgO on Oxidation Process of Fe_3O_4 in Pellets

Induration process of oxidized pellets involves the oxidation of Fe3O4 and re-crystallization of Fe2O3.The oxidation process of Fe3O4 is significant for pellets to obtain better ambient strength.Thus,the effect of MgO on oxidation process of Fe3O4 was investigated.The unreacted core model was applied to analyze the oxidizing induration process of pellets.The experimental results show that MgO plays a negative role in the oxidation process of Fe3O4.The oxidation rate of Fe3O4 in MgO-fluxed pellets（95.0% Fe3O4 ＋5.0% MgO）is slower than that in standard acid pellets（100% Fe3O4）.The relation between oxidation ratio of Fe3O4 and time was calculated based on the unreacted core model for both MgO-fluxed pellets and standard acid pellets.According to verification experiments,the values calculated by model coincide well with the experimental values.Therefore,the unreacted core model could be applied to describe the oxidizing induration process of pellets.

Theoretical Foundation of Carbonation Pellet Process for Ferrous Sludge Recycling

For the recycling of ferrous sludge from steel industry,the carbonation pellet process should be considered as a ＂green＂ process,since no impurities are added as well as CO2 can be sequestrated and consumed.Through the thermodynamic calculation,the carbonation reaction can occur spontaneously and is an exothermic reaction.Based on the kinetic analysis through unreacted core model,the interfacial chemical reaction was the rate controlling step in the initial fast stage of carbonation,and the CO2 diffusion through the CaCO3 product layer was the rate controlling step in the following extremely slow stage.For the carbonation bonded mechanism,the pellet strength was gained by the formation and growing of CaCO3 product layer.Since the interfacial chemical reaction was the critical stage of the entire carbonation process,the emphasizes should be focused on the improvement of sorbent activity and the optimization of process parameters,such as pore structure,pore surface area,and total pressure,CO2 partial pressure,reaction temperature,etc to accelerate the reaction rate and to improve the quality of carbonation pellets.