Numerical simulation analysis of direct reduction of gas-based shaft furnace

BAI Chenchen; SHI Xuefeng; WANG Mingyang; YU Hao; HU Changqing; HAN Tao

doi:10.13228/j.boyuan.issn0449-749x.20230201

PDF(2289 KB)

Iron and Steel ›› 2024, Vol. 59 ›› Issue (1) : 41-48. DOI: 10.13228/j.boyuan.issn0449-749x.20230201

Raw Material and Ironmaking

Numerical simulation analysis of direct reduction of gas-based shaft furnace

Author information +

History +

Abstract

Aiming at the difficulty that the operation degree of the reduction reaction cannot be directly observed during the direct reduction process of the gas-based shaft furnace, based on the three-interface unreacted nuclear model, a direct reduction model of the gas-based shaft furnace is established under the condition of ignoring the internal temperature of the model pellet and assuming that the thermal effect of the pellet reduction reaction completely occurs in the solid phase, and the valence state transformation of iron oxide is numerically simulated and verified. The results show that since the established gas-solid model contains three interfaces, the reaction radius of each interface eventually tends to zero with the stepwise reduction of iron oxides, and the reduction reaction rate increases first and then decreases with the increase of shaft furnace depth. When the pellets descend to a depth of 3 m in the shaft furnace, a FeO reaction interface with a radius of 15 mm appears, where the pellet reduction rate is about 28%. As the pellets continue to descend about 2 m in the shaft furnace to a depth of 5 m, the radius of the interface of Fe₃O₄ decreases to 0, at which point the iron oxide completely transforms into the floatite form, and the pellet reduction rate is about 34%. By changing different process parameters for simulation, it can be found that the metallization rate and reduction rate of the reducing pellet increase with the increase of gas temperature. When the gas temperature increases at 50 ℃ and the reducing gas flow rate increases at a gradient of 5 040 m³/h, the corresponding pellet metallization rate increases by about 8% and 4%, respectively. In contrast, the metallization rate of the pellets is much more affected by the cutting speed than the gas temperature and reducing gas flow, which is manifested as follows: when the cutting speed increases by 0.02 t/h, the metallization rate decreases by about 0.07%. When the pellet size decreases, the metallization rate will show an increasing trend, and the pellet size decreases by 1 mm, and the pellet metallization rate increases by 2.23%.

Key words

gas based shaft furnace / gas based method / direct reduced / numerical simulation / reduction rate / metallization rate

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

BAI Chenchen, SHI Xuefeng, WANG Mingyang, et al. Numerical simulation analysis of direct reduction of gas-based shaft furnace[J]. Iron and Steel, 2024, 59(1): 41-48 https://doi.org/10.13228/j.boyuan.issn0449-749x.20230201

References

[1] 苏长永, 李新宇, 林严, 等. 钢铁行业固废绿色低碳高质量发展路径[J]. 烧结球团, 2022, 47(6): 1.(SU C Y, LI X Y, LIN Y, et al. Green, low-carbon and high-quality development route of solid waste in the iron and steel industry[J]. Sintering and Pelletizing, 2022, 47(6): 1.)
[2] 刘夏青, 赵立华. 欧盟碳边境调节机制对中国钢铁行业的影响:基于产品碳足迹视角[J]. 中国冶金, 2023, 33(2): 135.(LIU X Q, ZHAO L H. Impact of EU carbon border adjustment mechanism on China's steel industry: Based on product carbon footprint perspective[J]. China Metallurgy, 2023, 33(2): 135.)
[3] 张寿荣, 潘国友, 柳萌. “双碳”目标下我国炼铁技术发展路径[J]. 炼铁, 2022, 41(6): 1.(ZHANG S R, PAN G Y, LIU M. Development route of China's ironmaking technology under the "dual carbon" goal[J]. Ironmaking, 2022, 41(6): 1.)
[4] 田恬, 路光杰, 马丽. 2021年脱硫脱硝行业发展评述及展望[J]. 中国环保产业, 2022,285(3): 14. (TIAN T, LU G J, MA L. Review and prospects of the development of desulfurization and denitration industry in 2021[J]. China Environmental Protection Industry, 2022, 285(3):14.)
[5] 潘刚, 王子杰, 李义科, 等. 白云鄂博矿含碳球团直接还原过程的实验及数值模拟研究[J]. 烧结球团, 2016, 41(4): 24. (PAN G, WANG Z J, LI Y K, et al. Experiment and numerical simulation of direct reduction process of carbon-containing pellets of Baiyunebo mine[J]. Sintering and Pelletizing, 2016, 41(4): 24.)
[6] 邱梓洋, 王淇, 王义松, 等. 典型的气基竖炉直接还原工艺[C]//第十一届全国能源与热工学术年会论文集. 北京:中国金属学会能源与热工分会, 2021: 604. (QIU Z Y, WANG Q, WANG Y S, et al. Typical gas-based shaft furnace direct reduction process[C]//The 11th Conference on Energy and Thermal Engineering. Beijing:Energy and Thermal Engineering Branch of the Chinese Society for Metals, 2021:604.)
[7] HU B, HU P, LU B, et al. NO_x Emission reduction by advanced reburning in grate-rotary kiln for the iron ore pelletizing production[J]. Processes, 2020, 8(11): 1470.
[8] 刘然, 张智峰, 刘小杰, 等. 低碳绿色炼铁技术发展动态及展望[J]. 钢铁, 2022, 57(5): 1. (LIU R, ZHANG Z F, LIU X J, et al. Development trend and prospect of low carbon green ironmaking technology[J]. Iron and Steel, 2022, 57(5):1.)
[9] 王敏, 任荣霞, 董洪旺, 等. 熔融还原炼铁最新技术及工艺路线选择探讨[J]. 钢铁, 2020, 55(8): 145. (WANG M, REN R X, DONG H W, et al. Latest technology of melting reduction ironmaking process and discussion of process route choice[J]. Iron and Steel, 2020, 55(8): 145.)
[10] 朱仁良. 未来炼铁技术发展方向探讨以及宝钢探索实践[J]. 钢铁, 2020, 55(8): 2. (ZHU R L. Discussion on future development direction of ironmaking technology and exploratory practice of Baosteel[J]. Iron and Steel, 2020, 55(8): 2.)
[11] SUOPAJÄRVI H, UMEKI K, MOUSA E, et al. Use of biomass in integrated steelmaking-Status quo, future needs and comparison to other low-CO₂ steel production technologies[J]. Applied Energy, 2018, 213: 384.
[12] 张福明. 首钢绿色低碳炼铁技术的发展与展望[J]. 钢铁, 2020, 55(8): 11. (ZHANG F M. Development and prospect of green and low carbon ironmaking technologies in Shougang[J]. Iron and Steel, 2020, 55(8): 11.)
[13] 王新东, 金永龙. 高炉使用高比例球团的战略思考与球团生产的试验研究[J]. 钢铁, 2021, 56(5): 7. (WANG X D, JIN Y L. Strategy analysis and testing study of' high ratio of pellet utilized in blast furnace[J]. Iron and Steel, 2021, 56(5): 7.)
[14] 王新东, 李建新, 胡启晨. 基于高炉炉料结构优化的源头减排技术及应用[J]. 钢铁, 2019, 54(12): 104. (WANG X D, LI J X, HU Q C. Application practice of source and process sulfur nitrate reduction technology based on optimization of blast furnace charge structure[J]. Iron and Steel, 2019, 54(12): 104.)
[15] 徐少兵, 许海法. 熔融还原炼铁技术发展情况和未来的思考[J]. 中国冶金, 2016, 26(10): 33.(XU S B, XU H F. Development of smelting reduction iron making technology and future thinking[J]. China Metallurgy, 2016, 26(10): 33.)
[16] 王国栋. 钢铁行业技术创新和发展方向[J]. 钢铁, 2015, 50(9): 1. (WANG G D. Technology innovation and development direction of iron and steel industry[J]. Iron and Steel, 2015,50(9):1.)
[17] 王新东, 王国栋. 以产学研用协同创新新模式助推钢铁行业技术进步[J]. 钢铁, 2017, 52(7): 1.(WANG X D, WANG G D. Promoting technical progress of iron and steel industry with anew mode of collaborative innovation[J]. Iron and Steel,2017, 52(7): 1.)
[18] 王新东, 闫永军. 智能制造助力钢铁行业技术进步[J]. 冶金自动化, 2019, 43(1): 1.(WANG X D, YAN Y J. Promoting the technical progress of steel industry with intelligent manufacturing[J]. Metallurgical Industry Automation, 2019, 43(1): 1.)
[19] 李宏扬, 刘小杰, 李欣, 等. 高炉炼铁工业互联网平台的应用[J]. 钢铁, 2021, 56(9): 10. (LI H Y, LIU X J, LI X, et al. Application of industrial internet platform for blast furnace iron making[J]. Iron and Steel, 2021, 56(9): 10.)
[20] 王新东, 郝良元. 现代炼铁工艺及低碳发展方向分析[J]. 中国冶金, 2021, 31(5): 1. (WANG X D, HAO L Y. Analysis of modern ironmaking technology and low-carbon development direction[J]. China Metallurgy, 2021, 31(5): 1.)
[21] 严珺洁. 超低二氧化碳排放炼钢项目的进展与未来[J]. 中国冶金, 2017, 27(2): 6.(YAN J J. Progress and future of ultra low CO steel making program[J]. China Metallurgy, 2017, 27(2): 6.)
[22] 潘建, 朱德庆, 韩基祥, 等. 磁铁矿氧化球团富氢气基直接还原的特性研究[J]. 烧结球团, 2022, 47(1): 48. (PAN J, ZHU D Q, HAN J X, et al. Study on hydrogen-rich gasbased direct reduction of oxide pellets made by magnetite concentrate[J]. Sintering and Pelletizing, 2022, 47(1): 48.)
[23] 张福明, 曹朝真, 徐辉. 气基竖炉直接还原技术的发展现状与展望[J]. 钢铁, 2014, 49(3): 1. (ZHANG F M, CAO C Z, XU H. Current status and prospects of gas based shaft furnace direct reduction technology[J]. Iron and Steel, 2014, 49(3): 1.)
[24] 邹敏, 王琪琳, 江文世. 煤基直接还原技术处理钛中矿富集钛资源研究[J]. 中国有色冶金, 2022, 51(4): 129. (ZOU M, WANG Q L, JIANG W S. Enriching titanium resources from titanium middling ore by coal-based direct reduction technology[J]. China Nonferrous Metallurgy, 2022, 51(4): 129.)
[25] 周颖, 周红军, 徐春明. 中国钢铁工业低碳绿色生产氢源思考与探索[J]. 化工进展, 2022, 41(2): 1073. (ZHOU Y, ZHOU H J, XU C M. Exploration of hydrogen sources for the low-carbon and green production in the steel industry in China[J]. Chemical Industry and Engineering Progress, 2022, 41(2): 1073.)
[26] 朱德庆, 薛钰霄, 潘建, 等. 气基直接还原工艺研究进展和发展思考[J]. 烧结球团, 2022, 47(1): 1. (ZHU D Q, XUE Y X, PAN J, et al. Research progress and development thinking of gas-based direct reduction process[J]. Sintering and Pelletizing, 2022, 47(1): 1.)
[27] 张奔, 赵志龙, 郭豪, 等. 气基竖炉直接还原炼铁技术的发展[J]. 钢铁研究, 2016, 44(5): 59.(ZHANG B, ZHAO Z L, GUO H, et al. Development of direct-reduction ironmaking technology in gas based shaft furnace[J]. Research on Iron and Steel, 2016, 44(5): 59.)
[28] 于恒, 周继程, 郦秀萍, 等. 气基竖炉直接还原炼铁流程重构优化[J]. 中国冶金, 2021, 31(1): 31. (YU H, ZHOU J C, LI X P, et al. Reconstruction optimization of gas based shaft furnace direct reduction ironmaking process[J]. China Metallurgy, 2021, 31(1): 31.)
[29] 龙鹄. 氢气直接还原竖炉内气固反应及运动行为研究[D]. 秦皇岛:燕山大学, 2017. (LONG H. Research of Reduction Reaction and Motion Behavior of Gas-solid in the Hydrogen Shaft Furnace[D]. Qinhuangdao: Yanshan University,2017.)
[30] 吕建超, 白明华, 徐宽, 等. 气基直接还原竖炉生产过程的数值模拟研究[C]//第十一届中国钢铁年会论文集:S01.炼铁与原料. 北京:中国金属学会, 2017: 1146. (LÜ J C, BAI M H, XU K, et al. Numerical simulation of gas-based direct reduction furnace production process[C]//Proceedings of the 11th CSM Steel Congress: S01. Ironmaking and Raw materials. Beijing:The Chinese Society for Metals, 2017:1146.)
[31] 王兆才, 陈双印, 储满生, 等. 含钒钛铁精矿氧化球团气基竖炉直接还原模拟试验[J]. 钢铁钒钛, 2012, 33(2): 34. (WANG Z C, CHEN S Y, CHU M S, et al. Simulation Experiment on direct reduction of oxidized pellets of vanadium and titanium-bearing iron concentrates by gas based shaft furnace[J]. Iron Steel Vanadium Titanium, 2012, 33(2): 34.)