Mathematical Modeling for the Process of Smelting Reduction Ironmaking Integrated with Hydrogen-Rich Coal Gasification

Abstract

To reduce pollution and improve the efficiency of coal resource utilization, this study proposed an integrated process for smelting reduction ironmaking and coal gasification. A multi-zone constrained mathematical model, based on heat and mass balance calculations, was developed to predict the energy and material flows required to produce 1 ton of hot metal. Two scenarios were examined: one using pure O2 as the gasification agent (referred to as the non-hydrogen-rich process) and the other using a combination of pure O2 and pure steam (referred to as the hydrogen-rich process). In the non-hydrogen rich process, as the PCR (Post Combustion Ratio) varies from 0% to 8%, the total coal consumption, O2 consumption, and volume of exported gas decrease by 57%, 57% and 53%, respectively. In the hydrogen-rich process, as the H2 content increases from 30% to 50%, the exported gas volume increases by 38%. The upper limit of H2 content in the SRV (Smelting Reduction Vessel) off-gas is mainly determined by the PCR, which decreases from 52.7% to 45.2% as the PCR varies from 0% to 8%. The findings of this work can serve as a theoretical basis for further investigation of the new process.