Detailed modelling of packed-bed gas clogging due to thermal-softening of iron ore by Eulerian–Lagrangian approach

Natsui, Shungo; Ishihara, Shingo; Kon, Tatsuya; Ohno, Ko Ichiro; Nogami, Hiroshi

doi:10.1016/j.cej.2019.123643

Cited by 19 publications

(12 citation statements)

References 47 publications

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“…Also, this method is still under development towards fully describing the coupled multiphase flows and thermochemical behaviors inside a BF, although some encouraging progress has been recently achieved. [16][17][18][19][20][21][22][23][24] By contrast, the TFM approach is solved by traditional computational fluid dynamics (CFD) over computational cells that are much larger than particles but still very small compared with process equipment. Therefore, it is computationally convenient and efficient and has been mainly used to predict the primary phenomena related to gas, solid, liquid and powder and the global performance of BFs, especially at an industrial scale.…”

Section: Introductionmentioning

confidence: 99%

CFD Modeling and Analysis of Particle Size Reduction and Its Effect on Blast Furnace Ironmaking

Jiao

Kuang

Liu

et al. 2020

Metall Mater Trans B

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Particle size reduction inevitably occurs inside ironmaking blast furnaces (BFs) but is not studied under BF conditions due to the lack of an effective tool. This paper simulates this phenomenon inside a 5000-m 3 commercial BF using a recently developed three-dimensional computational fluid dynamics (CFD) process model. In particular, the sinter reduction degradation and coke gasification are modeled for considering the size reduction. By incorporating this information in the BF model, the in-furnace states and global performance are evaluated with respect to sinter reduction degradation index (RDI) under different conditions, e.g., keeping a constant blast rate or gas pressure drop. The results show that with increasing RDI, the bed permeability deteriorates, and there exists a critical value of RDI beyond which the decreased bed permeability leads to a significant drop in productivity for a given gas pressure drop. However, this problem can be mitigated substantially by charging more coke particles at the furnace periphery under the conditions considered. The proposed approach offers an extended capability to model and control BF operations.

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Section: Introductionmentioning

confidence: 99%

CFD Modeling and Analysis of Particle Size Reduction and Its Effect on Blast Furnace Ironmaking

Jiao

Kuang

Liu

et al. 2020

Metall Mater Trans B

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“…When using a multisphere discrete-element method (MS-DEM) treatment, both the coke particles and the dispersed phase can be directly tracked in packed bed structures with different cokes morphology. [15][16][17] Moreover, the Eulerian-Lagrangian (E-L) coupling scheme, also known as the computational fluid dynamics-DEM (CFD-DEM) approach that enables the investigation of the interactions between gaseous and solid phases, has been used to solve the gas flow field in various coke bed structures. 18) Using the E-L coupling approach, the two-phase fines-gas flow in a coke bed can be directly determined in accordance with the coke degradation behavior, which is used as an input.…”

Section: Methods For Simulating Gas Permeability Of a Coke Bed Including Fines Based On 3d Imaging On The Coke Particle Morphologymentioning

confidence: 99%

“…The CFD cell size was set equal to the element size. 16) The phase boundary shape, namely the void shape, was then obtained from the locations of solid elements. The CFD cells that included the coordinate of the element center were marked as "filled" and treated as being occupied by the solid.…”

Section: Gas Flow Calculationmentioning

confidence: 99%

“…In most transport phenomena analyses, the void space in the packed bed is assumed to have a continuous structure of circular tubes with various diameters in the flow direction. 16,35) The pressure drop, ΔP, per unit length, L, is equivalent to the energy loss due to the shear stress acting on the tube wall surface. The shear stress corresponds to the frictional force per unit surface area applied to the fluid on the tube wall surface.…”

Section: Void Morphology and Gas Permeabilitymentioning

confidence: 99%

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Method for Simulating Gas Permeability of a Coke Bed Including Fines Based on 3D Imaging on the Coke Particle Morphology

Natsui

Hirai

Terui³

et al. 2021

ISIJ Int.

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In ironmaking blast furnaces, the particle size distribution and voids in the coke bed affects the upward flow of gas, and consequently, the efficiency of the combustion reaction. To clarify the influence of coke pulverization on the packing structure of the coke bed, the permeability of the bed was evaluated using detailed dynamics simulation and geometric data analysis. To obtain detailed 3D morphology of the coke, we derived digital geometric data using rotational strength tests. Using the Euler-Lagrange coupling approach with the multisphere discrete-element method, the effect of the volume fraction of fines and distribution in the coke bed on the gas flow was analyzed. The void shape in the 3D coke bed structure was quantified using geometric data and simulated gas flow distributions. Although a continuous void network was observed in the packed bed before pulverization, areas of highly restricted (or no) gas flow were observed after pulverization. The dominant effect of coke degradation on the packed bed structure was the disruption of the gas flow path because of fines clogging the pores and narrowing the gas flow path. The developed simulation method can comprehensively analyze the effects of coke degradation on the gas flow distribution in the coke bed and can be used to analyze and control the instability of industrial blast furnaces.

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“…Molten slag flow in a packed coke bed was investigated by using the three-dimensional combined discrete element method (DEM) and CFD [12][13][14]. A series of two-dimensional [15,16] and three-dimensional [17] high-resolution direct numerical simulations were also conducted with the aim of understanding the pore-scale fluid dynamics. Although the two-liquid flow in packed beds has received attention but usually focused on room temperature media [18,19], there is no guarantee that the information available from the water-oil-rock system can be applied to the slag-iron-coke system in blast furnaces.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study of Binary Trickle Flow of Liquid Iron and Molten Slag in Coke Bed by Smoothed Particle Hydrodynamics

et al. 2020

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In the bottom region of blast furnaces during the ironmaking process, the liquid iron and molten slag drip into the coke bed by the action of gravity. In this study, a practical multi-interfacial smoothed particle hydrodynamics (SPH) simulation is carried out to track the complex liquid transient dripping behavior involving two immiscible phases in the coke bed. Numerical simulations were performed for different conditions corresponding to different values of wettability force between molten slag and cokes. The predicted dripping velocity changes and interfacial shape were investigated. The relaxation of the surface force of liquid iron plays a significant role in the dripping rate; i.e., the molten slag on the cokes acts as a lubricant against liquid iron flow. If the attractive force between the coke and slag is smaller than the gravitational force, the slag then drops together with the liquid iron. When the attractive force between the coke and slag becomes dominant, the iron-slag interface will be preferentially detached. These results indicate that transient interface morphology is formed by the balance between the momentum of the melt and the force acting on each interface.

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Detailed modelling of packed-bed gas clogging due to thermal-softening of iron ore by Eulerian–Lagrangian approach

Cited by 19 publications

References 47 publications

CFD Modeling and Analysis of Particle Size Reduction and Its Effect on Blast Furnace Ironmaking

CFD Modeling and Analysis of Particle Size Reduction and Its Effect on Blast Furnace Ironmaking

Method for Simulating Gas Permeability of a Coke Bed Including Fines Based on 3D Imaging on the Coke Particle Morphology

Numerical Study of Binary Trickle Flow of Liquid Iron and Molten Slag in Coke Bed by Smoothed Particle Hydrodynamics

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