Study of the Effect of Reduced Iron Temperature Rising on Total Carbon Formation in Iron Reactor Isobaric and Cooling Zone

Abstract

We presented the mathematical model in the iron reactor. The model was limited to Isobaric Zone and Cooling Zone termed as IZ and CZ, respectively. The simulation was done by adapting the heat and mass transfer equations. The main purpose of this paper is to estimate the temperature increasing effect of reduced-iron on sponge-iron quality. The calculations are solved using Finite Element Method (FEM). The results showed that the temperature and concentration values from the simulation have high similarity to the reference data with Root-Mean-Square Error (RMSE) about 0.7. The formation of total-carbon in the both zones decreased metallization degree until 1.72%. The increase in reduced-iron temperature higher than 1200 K produces total-carbon higher than 3%. Thus the increase in reduced-iron temperature more than 1200 K is not recommended because it can decrease metallization degree.

Optimization of the Iron Ore Direct Reduction Process through Multiscale Process Modeling

“…Reflecting the great effort put in the simulation and development of the DR processes, numerous mathematical and numerical models of the shaft furnace were published, differing by the assumptions, the physico-chemical phenomena accounted for, the numerical scheme, the sections of the furnace considered, and the use of the model, etc. The most recent ones [ 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 ] are classified in Table 1 and Table 2 and below. The basic description is that of an axisymmetric, porous moving bed reactor with counter-current flow between an ascending gas and a descending solid.…”

“…The reduction reactions (in one, two or three steps) are always included. Additionally, methane decomposition and steam methane reforming were also taken into account in [ 10 , 12 , 13 , 14 ], together with the water gas shift and Boudouard reactions in [ 14 ]. The type of heat transfer.…”

Carbon Impact Mitigation of the Iron Ore Direct Reduction Process through Computer-Aided Optimization and Design Changes

“…Alamsari et al studied the impact of higher input gas temperature. It was concluded that this condition led to higher cooling gas requirements and ultimately to higher carbon contents in exiting DRI [13]. Nouri et al [14] found that a higher gas flow rate led to higher solid conversion, and linked it to higher reducing gas concentration near the solid inlet.…”