Methods for Calculating Energy Requirements for Processes in Which a Reactant Is Also a Fuel: Need for Standardization

Sohn, Hong Yong; Olivas-Martinez, Miguel

doi:10.1007/s11837-014-1120-y

Cited by 24 publications

(19 citation statements)

References 5 publications

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“…A novel flash ironmaking process under development at the University of Utah aims at producing iron directly from iron ore concentrates (particle size less than 100 μm) by a gas‐solid flash reaction utilizing hydrogen or natural gas as the reductant and fuel in the temperature range 1300–1550 °C. This process requires significantly less energy and generates much lower CO 2 emissions compared with most of the current ironmaking processes . The blast furnace (BF) produces over 90% of the iron world‐wide.…”

Section: Introductionmentioning

confidence: 99%

Kinetics of Hydrogen Reduction of Magnetite Concentrate Particles in Solid State Relevant to Flash Ironmaking

Elzohiery

Sohn

Mohassab

2016

steel research int.

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The kinetics of hydrogen reduction of solid magnetite concentrate particles is determined in the temperature range 1150–1350 °C as part of the development of a novel ironmaking process on‐going at University of Utah. A laminar‐flow reactor is used to provide the most uniform conditions to measure as accurately as possible the very rapid kinetics of the reduction reaction. Reduction degrees greater than 90% are achieved in a few seconds of residence time, depending on experimental conditions, which are the typical lengths of time available in a flash reaction process. Different particle size fractions are used in the experiments under various hydrogen partial pressures and residence times. The nucleation and growth model with Avrami parameter n = 1 and first‐order dependence on hydrogen partial pressure describes the reduction kinetics. The kinetics have no particle size effect within the size range and reaction conditions tested. The rate equation obtained from this work is being applied to the analysis of the data obtained from a laboratory flash reactor as well as to the design of industrial‐size flash ironmaking reactor in which hydrogen generated from the partial oxidation of natural gas is the main reducing agent.

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Section: Introductionmentioning

confidence: 99%

Kinetics of Hydrogen Reduction of Magnetite Concentrate Particles in Solid State Relevant to Flash Ironmaking

Elzohiery

Sohn

Mohassab

2016

steel research int.

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“…It is noted here that a caution must be exercised when comparing the presented energy intensity values or energy requirements to clearly understand the energy items included in these values [16]. There are currently different approaches for selecting energy items to include in the overall "energy requirements" when an input fuel also serves as a reactant.…”

Section: Note Of Caution Regarding 'Energy Requirement'mentioning

confidence: 99%

Energy Consumption and CO2 Emissions in Ironmaking and Development of a Novel Flash Technology

Sohn

2019

Metals

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The issues of energy consumption and CO2 emissions of major ironmaking processes, including several new technologies, are assessed. These two issues are interconnected in that the production and use of fuels to generate energy add to the total amount of CO2 emissions and the efforts to sequester or convert CO2 require energy. The amounts of emissions and energy consumption in alternate ironmaking processes are compared with those for the blast furnace, currently the dominant ironmaking process. Although more than 90% of iron production is currently through the blast furnace, intense efforts are devoted to developing alternative technologies. Recent developments in alternate ironmaking processes, which are largely driven by the needs to decrease CO2 emissions and energy consumption, are discussed in this article. This discussion will include the description of the recently developed novel flash ironmaking technology. This technology bypasses the cokemaking and pelletization/sintering steps, which are pollution prone and energy intensive, by using iron ore concentrate. This transformational technology renders large energy saving and decreased CO2 emissions compared with the blast furnace process. Economic analysis indicated that this new technology, when operated using natural gas, would be economically feasible. As a related topic, we will also discuss different methods for computing process energy and total energy requirements in ironmaking.

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“…The novel flash ironmaking technology conceived by Sohn is based on the gaseous reduction of iron oxide concentrate in suspension in the temperature range of 1423–1873 K (1150–1600 °C). Sohn and co‐workers have performed many experimental and bench‐scale investigations, kinetics determination, flowsheet development, and economic analyses to prove the technical and economic feasibilities of the novel technology. A set of experiments were performed by Elzohiery and co‐workers where a mixture of hydrogen and carbon monoxide was used to reduce the magnetite concentrate in different operating temperature ranges.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

Abdelghany

Fan

Elzohiery

et al. 2019

steel research int.

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A large‐scale bench reactor (LSBR) is operated at the University of Utah to develop a novel flash ironmaking process. The reactor vessel is a refractory‐lined furnace with 0.8 m in diameter and 2.1 m in length, with a capacity of processing 1–7 kg h−1 of magnetite concentrate. Natural gas is partially oxidized with oxygen in a uniquely designed burner, producing a short flame that provides heat (1423–1873 K) and a reducing gas mixture (hydrogen and carbon monoxide). The reducing gas reacts with magnetite (Fe3O4) concentrate particles to produce metallic iron. A computational fluid dynamics (CFD) model is developed to simulate the LSBR runs, in which the kinetics of magnetite concentrate reduction, separately determined in a drop‐tube reactor, is incorporated. The reduction degrees and composition of the off‐gas obtained from the CFD model show reasonable agreements with the experimental results.

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Methods for Calculating Energy Requirements for Processes in Which a Reactant Is Also a Fuel: Need for Standardization

Cited by 24 publications

References 5 publications

Kinetics of Hydrogen Reduction of Magnetite Concentrate Particles in Solid State Relevant to Flash Ironmaking

Kinetics of Hydrogen Reduction of Magnetite Concentrate Particles in Solid State Relevant to Flash Ironmaking

Energy Consumption and CO2 Emissions in Ironmaking and Development of a Novel Flash Technology

Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

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