Comparison of Energy Consumption and CO2 Emission for Three Steel Production Routes—Integrated Steel Plant Equipped with Blast Furnace, Oxygen Blast Furnace or COREX

Song, Jiayuan; Jiang, Zeyi; Bao, Cheng; Xu, Anjun

doi:10.3390/met9030364

Cited by 25 publications

(24 citation statements)

References 24 publications

(36 reference statements)

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“…In simulating the CCB reaction behavior under each scenario, the environment variables were determined by the experimental conditions. Owing to the sintering of the iron-oxide particles, it was difficult to determine a gs in the reaction rates of reactions (1)(2)(3). A trial-and-error method was used, and it was found that an effective a gs of 1500 m 2 •m −3 was adequate.…”

Section: Ccb Model Validation Under Simulated Bf Conditionsmentioning

confidence: 99%

“…Although these processes are well-established and highly efficient, they face challenges related to lowering energy consumption and minimizing CO 2 emissions that are needed to create a more efficient and sustainable iron and steel industry. As the BF sector accounts for 75%-80% of the total energy consumption and it generates the largest amount of CO 2 emissions [2,3] finding ways for the BF industry to conform to these environmentally standards is crucial.…”

Section: Introductionmentioning

confidence: 99%

“…In general, CCB comprises iron-bearing oxide and carbonaceous materials in general. Using CCB as a partial charge in a BF offers the benefits of (1) less sintering and coking processes [5,6], (2) the effective use of non-coking coal and iron-bearing dust and sludge [7], (3) faster reduction of iron oxide [8,9], and (4) the decrease of BF energy consumption [10]. Several methods have been proposed to prepare CCB with sufficient high-temperature strength in a BF.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Experimental and Numerical Investigation of Reaction Behavior of Carbon Composite Briquette in Blast Furnace

Tang

Sun

2019

Metals

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The application of carbon composite briquette (CCB) is considered to be an efficient method for achieving low-energy and low-CO2-emission blast furnace (BF) operations. In this research, a combined experimental and numerical study was conducted on the CCB reaction behavior in BF. The CCB used in this study had a composition of 20.10 wt.% carbon, 29.70 wt.% magnetite, 39.70 wt.% wüstite, and 1.57 wt.% metallic iron. Using the prepared CCB samples, isotherm reduction tests under a simulated BF atmosphere (CO-CO2-N2) were conducted and a reaction model was developed. Subsequently, the reaction behavior of CCB along the mid-radial solid descending path in an actual BF of 2500 m3 was analyzed by numerical simulations based on the experimental findings and the previous results of comprehensive BF modeling. The results of the experiments showed that the CCB model predictions agreed well with the experimental measurements. With respect to the BF, the results of the numerical simulations indicated that, along the path, before the CCB temperature reached 1000 K, the CCB was reduced by CO in the BF gas; when its temperature was in the range from 1000 to 1130 K, it underwent self-reduction and contributed both CO and CO2 to the BF gas; when its temperature was above 1130 K, it only presented carbon gasification. Moreover, these results also revealed that the reduction of iron oxide and the gasification of carbon inside the CCB proceeded under an uneven mode. The uneven radial distribution of the local reduction fraction and local carbon conversion were evident in the self-reducing stage of the CCB.

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Section: Ccb Model Validation Under Simulated Bf Conditionsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Experimental and Numerical Investigation of Reaction Behavior of Carbon Composite Briquette in Blast Furnace

Tang

Sun

2019

Metals

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“…The use of lump ore or pellets also dispenses with the need of sinter plants. Since coking and sintering plants are not required for the COREX process, substantial cost savings of up to 20% can be achieved in the production of hot metal, of a grade similar to that of the blast furnace [3]. Since the distribution of charged burden plays a crucial role in determining the gas flow and thus in achieving a stable operation in BF and SF, it is of considerable importance to investigate the burden distribution influenced by the complicated charging system of COREX MG.…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Model Study on Burden Distribution in COREX Melter Gasifier

Zou

Luo

et al. 2019

Processes

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COREX is one of the commercialized smelting reduction ironmaking processes. It mainly includes two reactors, i.e., a (reduction) shaft furnace (SF) and a melter gasifier (MG). In comparison with the conventional blast furnace (BF), the COREX MG is not only equipped with a more complicated top charging system consisting of one gimbal distributor for coal and eight flap distributors for direct reduction iron (DRI), but also the growth mechanism of its burden pile is in a developing phase, rather than that in a fully-developed phase in a BF. Since the distribution of charged burden plays a crucial role in determining the gas flow and thus in achieving a stable operation, it is of considerable importance to investigate the burden distribution influenced by the charging system of COREX MG. In the present work, a mathematical model is developed for predicting the burden distribution in terms of burden layer structure and radial ore/coal ratio within the COREX MG. Based on the burden pile width measured in the previous physical experiments at different ring radii on a horizontal flat surface, a new growth mechanism of burden pile is proposed. The validity of the model is demonstrated by comparing the simulated burden layer structure with the corresponding results obtained by physical experiments. Furthermore, the usefulness of the mathematical model is illustrated by performing a set of simulation cases under various charging matrixes. It is hoped that the model can be used as a what-if tool in practice for the COREX operator to gain a better understanding of burden distribution in the COREX MG. Processes 2019, 7, 892 2 of 15In the COREX process [2], all the metallurgical reactions take place in two separate process reactors, the upper shaft furnace (SF) for the iron ore pre-reduction and the lower melter gasifier (MG) for final reduction and smelting. A schematic process flow sheet is shown in Figure 1. Iron ore (lump ore, pellets, or a mixture thereof) is charged into the upper SF where the burden is reduced to direct reduced iron (DRI) by the reduction gas arising from the lower MG. Discharge screws convey the DRI from the SF into the MG where final reduction and melting take place in addition to all other metallurgical reactions. In comparison with a conventional BF, COREX MG is equipped with a more complicated top charging system consisting of one gimbal distributor for coal and eight flap distributors for DRI.Processes 2019, 7, x FOR PEER REVIEW 2 of 14In the COREX process [2], all the metallurgical reactions take place in two separate process reactors, the upper shaft furnace (SF) for the iron ore pre-reduction and the lower melter gasifier (MG) for final reduction and smelting. A schematic process flow sheet is shown in Figure 1. Iron ore (lump ore, pellets, or a mixture thereof) is charged into the upper SF where the burden is reduced to direct reduced iron (DRI) by the reduction gas arising from the lower MG. Discharge screws convey the DRI from the SF into the MG where final reduction and melting take place i...

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A Review on Explorations of the Oxygen Blast Furnace Process

Zhang

Dai

et al. 2020

steel research int.

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The oxygen blast furnace (OBF) process has been extensively studied theoretically because of the potentials of promising energy conservation and CO2 emission reduction. Herein, investigations of the OBF process are reviewed and some suggestions for its future development are presented. The main findings can be condensed into the following: static and dynamic models of the OBF should be revised to considering the newest theoretical findings in the thermodynamics and kinetics involved as well as the particular limitations of the technology. Models focusing on energy demand and emissions should be further developed and applied to enhance the design for increased efficiency and sustainability of the complicated OBF system. It will be challenging to operate the full OBF process with top gas recycling (TGR). The development of mathematical models focusing on the practical operation is therefore warranted and would provide useful tools for tackling control problems and difficulties that will arise in forthcoming industrial trials. Considering these potential challenges, a medium oxygen‐enriched blast furnace with TGR as a forerunner is suggested because its operation conditions show greater resemblance with those of the traditional blast furnace. This furthermore provides a path of transition to the use of the full OBF in industrial scale.

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Comparison of Energy Consumption and CO2 Emission for Three Steel Production Routes—Integrated Steel Plant Equipped with Blast Furnace, Oxygen Blast Furnace or COREX

Cited by 25 publications

References 24 publications

Experimental and Numerical Investigation of Reaction Behavior of Carbon Composite Briquette in Blast Furnace

Experimental and Numerical Investigation of Reaction Behavior of Carbon Composite Briquette in Blast Furnace

Model Study on Burden Distribution in COREX Melter Gasifier

A Review on Explorations of the Oxygen Blast Furnace Process

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