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氢基直接还原炼铁的多尺度反应科学与工程

Multiscale reaction science and engineering of hydrogen-based direct reduction ironmaking

  • 摘要: 氢基直接还原(hydrogen-based direct reduction,HyDR)工艺用绿氢替代化石燃料,是钢铁工业实现深度脱碳的核心技术路径之一。该工艺涉及从电子/原子尺度的多相反应一直延伸到竖炉反应器的多物理场耦合,跨越多个尺度。然而,这些动态变化的多尺度行为与宏观反应之间究竟如何关联,目前仍缺乏充分认识,这也是完善氢冶金理论体系必须解决的关键科学问题。为此,本文沿“电子/原子-微观/介观-宏观反应器/工业流程”这一主线,系统综述了氢基直接还原炼铁全链条的多尺度研究进展。在原子/电子尺度,借助密度泛函理论阐明了H2与CO在铁氧化物表面解离吸附和界面反应的晶面依赖性及其控速环节,并结合深度学习势驱动的大规模分子动力学,以密度泛函理论计算的精度水平揭示了浮氏体的缺陷演化以及“非晶铁中间相→晶态铁”的成核-结晶过程。在微观/介观尺度,将X射线断层扫描、环境透射电子显微镜与深度学习相结合,定量解耦了孔隙-裂纹网络的动态演化,证实了空位驱动的非晶铁类流体聚集机制,并据此厘清了未反应收缩核模型、晶粒模型和随机孔模型等动力学模型的适用场景。在宏观反应器和工业流程尺度,系统比较了多孔介质连续模型、欧拉双流体以及计算流体力学-离散元法(computational fluid dynamics-discrete element method,CFD-DEM)耦合方法3类竖炉数值模拟框架,并针对纯氢还原强吸热的特点,提出了多热工参数协同的能量与流程优化策略。最后,本文从跨尺度耦合、通用机器学习势、原位定量表征和工业数据验证等方面展望了未来方向,以期完善氢冶金理论体系,为HyDR工艺从机制认知走向工程实践提供理论支撑。

     

    Abstract: Hydrogen-based direct reduction (HyDR), in which green hydrogen replaces fossil reductants, is one of the core technological routes for deep decarbonization of the steel industry. The process spans multiple scales, from atomic interfacial reactions to multiphysics coupling in the shaft furnace reactor, while the correlation between its dynamically evolving multiscale behavior and the macroscopic reaction behavior remains insufficiently understood, constituting a key scientific problem that must be resolved to refine the theoretical framework of hydrogen metallurgy. Following an "electron/atom-micro/meso-macro reactor" framework, this review systematically summarizes the full-chain, multiscale advances in the HyDR of iron oxides. At the atomic/electronic scale, density functional theory (DFT) reveals the facet-dependent dissociative adsorption and interfacial reaction of H2 and CO on iron-oxide surfaces and the corresponding rate-determining steps, while large-scale molecular dynamics driven by deep-learning potentials reproduce at DFT-level accuracy the defect evolution of wüstite and the nucleation-crystallization pathway from an "amorphous iron intermediate" to crystalline iron. At the micro/meso scale, X-ray computed tomography and environmental transmission electron microscopy combined with deep learning quantitatively decouple the dynamic evolution of the pore-crack network and confirm a vacancy-mediated,fluid-like aggregation mechanism of amorphous iron, on which basis the applicability limits of the unreacted shrinking-core, grain and random-pore models are clarified. At the macro scale, three numerical frameworks for the shaft furnace, namely the porous-media continuum model, the Eulerian two-fluid model, and computational fluid dynamics-discrete element method (CFD-DEM) coupled approach, are systematically analyzed. In view of the strongly endothermic nature of pure hydrogen reduction, thermal-management and process-optimization strategies based on coordinated thermal parameters are proposed. Finally, future directions are outlined for cross-scale coupling, general-purpose machine-learning potentials, in situ quantitative characterization, and industrial data validation to refine the theoretical framework of hydrogen metallurgy and provide theoretical support for advancing HyDR from mechanistic understanding to engineering practice.

     

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