Energy and emission analysis of flash ironmaking-powder generation coupling processes with various fuels

Yang, Yiru; Shen, Zhongjie; Wen, Xiaochun; Liu, Haifeng

doi:10.1016/j.applthermaleng.2022.119280

Cited by 3 publications

(2 citation statements)

References 43 publications

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“…where Q H Exergy does not satisfy the law of conservation, because entropy always increases in an irreversible process. After heat and mass balances in each operation unit are checked, based on the second law of thermodynamics, the exergy balance for component k in the H-FBDR system can be expressed as the following [31]:…”

Section: Exergy Analysismentioning

confidence: 99%

Energy and Exergy Analysis of Hydrogen-Based Fluidized Bed Direct Reduction towards Efficient Fossil-Free Ironmaking

Du,

Liu,

Pan

et al. 2023

Processes

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Hydrogen-based fluidized bed direct reduction (H-FBDR) is an important and promising route for fossil-free ironmaking. In this study, to achieve the optimal operation state of energy use and exergy efficiency, the influences of the metallization process and the ratios of H2 injected on the energy and exergy flows in the H-FBDR process are studied. The results show that the thermodynamically designed two-stage reduction process (first: Fe2O3→FeO; second: FeO→Fe) requires a smaller H2 quantity than other metallization processes. According to the mass, energy, and exergy balance analyses, variations in the H2 consumption, exergy destruction, and energy/exergy losses of the overall system, iron ore preheater (F1), fluidized bed reactor system (R), heat exchanger (E), and gas preheater (F2) with different ratios of H2 injected (η) are derived. The total H2 consumption, total exergy destruction, and energy/exergy losses rise with increasing η, and sharp increases are observed from η = 1.3 to η = 1.8. The exergy efficiencies (φ) can be ranked as φR > φE > φF1 ≈ φF2, and the exergy destruction in components F1 and F2 is mainly caused by the combustion reaction, whereas physical exergy destruction dominates for components R and E. The performances of components F1, E, and F2 degrade from η = 1.0 to η = 1.8, and significant degradation arises when η exceeds 1.3. Thus, considering the H2 consumption, thermodynamic efficiency, and energy/exergy losses, the ratio of H2 injected should be set below 1.3. Notably, although the energy loss in the H-FBDR system is 2 GJ/h at η = 1.3, the exergy loss is only 360 MJ/h, in which the recycled gases from component E occupy 320 MJ/h, whereas the total exergy destruction is 900 MJ/h. Therefore, improving the performance of operation units, particularly the components F1 and F2, is as important as recovering the heat loss from component E for optimizing the H-FBDR process.

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Section: Exergy Analysismentioning

confidence: 99%

Energy and Exergy Analysis of Hydrogen-Based Fluidized Bed Direct Reduction towards Efficient Fossil-Free Ironmaking

Du,

Liu,

Pan

et al. 2023

Processes

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“…[29] Given the low carbon emission and high efficiency of flash ironmaking, scholars have analyzed the reductants used in flash ironmaking using the energy-mass balance analysis method and found that hydrogen is the optimal reductant for the flash ironmaking process. [30] Compared with CO, H 2 has a higher utilization at high temperatures and a higher reduction rate in ore powder reduction. [31] Hydrogen, as a green energy source, is the best reductant for ironmaking, which can significantly promote the iron and steel industry's carbon and emission reduction tasks.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of the Effect of Feeding Mode on the Reduction of Ore Powder in Hydrogen‐Based Flash Ironmaking Process

Tan,

Guo,

Yang

et al. 2024

steel research int.

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The efficiency and heat utilization of modern large‐scale blast furnace in China are close to limits. The potential for energy saving and consumption reduction by continuing to improve blast furnace operation is limited, so there is a need to develop nonblast furnace ironmaking technologies to solve the problems of high energy consumption and pollution. The emerging flash ironmaking technology, which is highly efficient and has low pollutant emissions, has become an option. This article uses CFD software to simulate the 3D steady‐state hydrogen‐based flash ironmaking process at a pilot scale. It is a complex system involving gas‐particle two‐phase flow, heat transfer, and chemical reactions. The article mainly studies the effects of the feeding mode and hydrogen concentration in the reducing gas on the reduction of ore particles. The results show that the residence time of the particles in the furnace is very sensitive to the feeding method, and the maximum residence time of the particles reaches about 2.8 s under the optimal feeding method. In addition, increasing the hydrogen concentration in the reducing gas decreases the particles’ residence time. However, the minimum residence time is more than 2.2 s, and the ore powder can still obtain a high reduction degree.

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Numerical Investigation on H2 Reduction Characteristics of Fe3O4 in Drop Tube Furnace

Zhou,

Wan,

Wang

2024

The Minerals, Metals &Amp; Materials Series

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Energy and emission analysis of flash ironmaking-powder generation coupling processes with various fuels

Cited by 3 publications

References 43 publications

Energy and Exergy Analysis of Hydrogen-Based Fluidized Bed Direct Reduction towards Efficient Fossil-Free Ironmaking

Energy and Exergy Analysis of Hydrogen-Based Fluidized Bed Direct Reduction towards Efficient Fossil-Free Ironmaking

Numerical Simulation of the Effect of Feeding Mode on the Reduction of Ore Powder in Hydrogen‐Based Flash Ironmaking Process

Numerical Investigation on H2 Reduction Characteristics of Fe3O4 in Drop Tube Furnace

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