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CFD高炉数学模型综述:挑战、发展世代与展望

Critical review on CFD-based blast furnace mathematical models: challenges, developments and prospects

  • 摘要: 高炉是当前全球铁水生产的主流反应器,但其内部高温、高压、多相耦合的“黑箱”本质使得其直接测量和实验室研究极为困难。全高炉尺度的计算流体力学(computational fluid dynamics,CFD)模型因此成为解析炉内现象、支撑操作决策和开发低碳高炉技术的重要工具。本文系统综述了基于多流体模型框架的CFD高炉数学模型的发展历程,并将其发展划分为3个世代。第一世代为稳态模型,经历了从一维气-固体系到三维气-固-液-粉多相体系的持续拓展,纳入了全面的化学反应与相变过程。该代模型的重要里程碑是在全炉范围内引入矿焦分层化学反应结构,为矿石层和焦炭层分别赋予独立的化学反应体系,显著提升了其对软熔带形貌和气流分布的描述精度。第二世代为瞬态模型,能够模拟操作参数变化后的动态响应过程,如风温骤降、湿炉料装入和氢气喷吹等工况带来的时序变化。该代模型实现了时-空维度与物理保真度的同步提升。第三世代为CFD融合机器学习的智能模型,以高保真CFD模拟数据为训练源,构建能够快速预测炉内全场状态分布的代理模型,为高炉数字孪生奠定了基础。在实际工业应用中,应根据具体需求选择适用的模型类型。同时需要指出的是,前沿高炉模型的开发代表了大学科研人员数年专注研发的成果,通常具有较高的开发门槛并依赖长期系统性积累,工业可以通过与大学合作的方式开展高炉数学模型开发和部署以及应用。本文还梳理了模型发展面临的关键挑战,包括保真度与计算效率的平衡,以及验证手段不足、模型可持续性及物理约束下人工智能(artificial intelligence,AI)融合框架的构建等,并展望了面向工业部署的智能化高炉模拟平台的发展方向。

     

    Abstract: The blast furnace(BF) remains the dominant reactor for global hot metal production, yet its internal high-temperature, high-pressure, multiphase-coupled "black box" nature renders direct measurement extremely difficult. Computational fluid dynamics (CFD) full-scale blast furnace models have therefore become an indispensable tool for revealing in-furnace phenomena details and supporting operational decision-making. This paper systematically reviews the development history of CFD blast furnace mathematical models based on the transient/steady multi-fluid model framework, categorising their evolution into three generations. The first generation comprised steady-state models, which underwent continuous expansion from one-dimensional gas-solid systems to three-dimensional gas-solid-liquid-powder multiphase systems, incorporating dozens of chemical reactions and phase transformation processes. A key milestone of this generation was the introduction of a layered reacting structure across the entire furnace, assigning independent chemical reaction systems to ore layers and coke layers, respectively, which significantly improved the descriptive accuracy of cohesive zone morphology and gas flow distribution. The second generation was the transient model capable of simulating the dynamic response of the BF internal state following changes in operating parameters, such as sudden blast temperature drops, wet burden charging and hydrogen injection. This generation achieved simultaneous advancement in spatial dimensionality and physical fidelity. The third generation comprised intelligent models integrating machine learning, which used high-fidelity CFD simulation data as training sources to construct surrogate models capable of near-real-time prediction of full in-furnace state distributions, laying the foundation for the next version and real blast furnace digital twins. In practical applications, the selection of blast furnace models should be guided by specific industrial requirements. It should also be noted that the development of high-fidelity blast furnace models typically represents years of dedicated research efforts by academic institutions and is associated with a high barrier to reproduction, relying on long-term systematic accumulation of knowledge. As such, collaboration between industry and universities provides an effective pathway for the development and application of blast furnace mathematical models. This paper also identifies key challenges facing model development, including the balance between fidelity and computational efficiency, insufficient validation methods, model sustainability, and the construction of physics-constrained AI(artificial intelligence) integration frameworks, and provides an outlook on the development direction of intelligent blast furnace simulation platforms oriented towards industrial deployment.

     

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