Three-Dimensional Modeling of Flow and Thermochemical Behavior in a Blast Furnace

An ironmaking blast furnace (BF) is a complex high-temperature moving bed reactor involving counter-, co- and cross-current flows of gas, liquid and solid, coupled with heat and mass exchange and chemical reactions. Two-dimensional (2D) models were widely used for understanding its internal state in the past. In this paper, a three-dimensional (3D) CFX-based mathematical model is developed for describing the internal state of a BF in terms of multiphase flow and the related thermochemical behavior, as well as process indicators. This model considers the intense interactions between gas, solid and liquid phases, and also their competition for the space. The model is applied to a BF covering from the burden surface at the top to the liquid surface in the hearth, where the raceway cavity is considered explicitly. The results show that the key in-furnace phenomena such as flow/temperature patterns and component distributions of solid, gas and liquid phases can be described and characterized in different regions inside the BF, including the gas and liquids flow circumferentially over the 3D raceway surface. The in-furnace distributions of key performance indicators such as reduction degree and gas utilization can also be predicted. This model offers a cost-effective tool to understand and control the complex BF flow and performance.

[1]  Jun-ichiro Yagi,et al.  Mathematical Modeling of the Flow of Four Fluids in a Packed Bed. , 1993 .

[2]  Paul Zulli,et al.  A three-dimensional numerical study of the combustion of coal blends in blast furnace , 2009 .

[3]  X. F. Dong,et al.  Modelling of Multiphase Flow in a Blast Furnace: Recent Developments and Future Work , 2007 .

[4]  Shinroku Matsuzaki,et al.  Development of mathematical model of blast furnace , 2006 .

[5]  Hiroshi Nogami,et al.  Numerical Analysis on Blast Furnace Performance under Operation with Top Gas Recycling and Carbon Composite Agglomerates Charging , 2004 .

[6]  Paul Zulli,et al.  Modelling of the Solids Flow in a Blast Furnace , 1998 .

[7]  Hiroshi Nogami,et al.  A Mathematical Model of Four Phase Motion and Heat Transfer in the Blast Furnace , 1997 .

[8]  W. Marsden.  I and J , 2012 .

[9]  G. G. Stokes.  "J." , 1890, The New Yale Book of Quotations.

[10]  Paul Zulli,et al.  Modelling of liquid flow in the blast furnace. Theoretical analysis of the effects of gas, liquid and packing properties , 2001 .

[11]  Nikola Anastasijevic,et al.  Low CO2 emission technologies for iron and steelmaking as well as titania slag production , 2007 .

[12]  Shin-ichi Kondo,et al.  Dissection of Blast Furnaces and Their Internal State , 1977 .

[13]  Gang Du,et al.  A Blast Furnace Prediction Model Combining Neural Network with Partial Least Square Regression , 2005 .

[14]  Margaret Nichols.  Trans , 2015, De-centering queer theory.

[15]  Koichi Kurita,et al.  A Mathematical Model of Blast Furnace with Radial Distribution of Gas Flow, Heat Transfer and Reactions Considered , 1982 .

[16]  Julian Szekely,et al.  A Mathematical Representation of Spatially Non-uniform, Countercurrent Flow of Gases and Liquids in Packed Beds- of Relevance to Flow Phenomena in the Bosh of Iron Blast Furnaces , 1979 .

[17]  Paul Zulli,et al.  Modelling in-furnace phenomena of pulverized coal injection in ironmaking blast furnace: Effect of coke bed porosities , 2012 .

[18]  Hiroshi Nogami,et al.  A mathematical model for blast furnace reaction analysis based on the four fluid model , 1997 .

[19]  Paul Zulli,et al.  CFD study of in-furnace phenomena of pulverised coal injection in blast furnace: Effects of operating conditions , 2012 .

[20]  Paul Zulli,et al.  Three-dimensional modelling of in-furnace coal/coke combustion in a blast furnace , 2011 .

[21]  Tatsuro Ariyama,et al.  Recent Progress and Future Perspective on Mathematical Modeling of Blast Furnace , 2010 .

[22]  Sangmin Choi,et al.  Numerical Modeling of Reaction and Flow Characteristics in a Blast Furnace with Consideration of Layered Burden , 2010 .

[23]  Paul Zulli,et al.  A simplified mathematical model for gas–solid flow in a blast furnace , 2004 .

[24]  Jun-ichiro Yagi,et al.  Simulation Model of the Gas-Liquid Flows in the Packed Bed , 1991 .

[25]  Hiroshi Nogami,et al.  Transient Mathematical Model of Blast Furnace Based on Multi-fluid Concept, with Application to High PCI Operation , 2000 .

[26]  Jun-ichiro Yagi,et al.  A Six-phases 3-D Model to Study Simultaneous Injection of High Rates of Pulverized Coal and Charcoal into the Blast Furnace with Oxygen Enrichment , 2011 .

[27]  Takanobu Inada,et al.  Three-dimensional Dynamic Simulator for Blast Furnace , 1999 .

[28]  Bo Björkman,et al.  Some applications of neural networks for prediction of blast furnace irregularities , 1998 .

[29]  T. Thompson.  Miner , 2014 .

[30]  鉄鋼基礎共同研究会.  Blast furnace phenomena and modelling , 1987 .

[31]  Yansong Shen,et al.  Proper MgO Addition in Blast Furnace Operation , 2006 .

[32]  Hiroshi Nogami,et al.  Three-dimensional Multiphase Mathematical Modeling of the Blast Furnace Based on the Multifluid Model , 2002 .

[33]  Andrew G. Glen,et al.  APPL , 2001 .

[34]  Paul Zulli,et al.  Model study of the effects of coal properties and blast conditions on pulverized coal combustion , 2009 .

[35]  Paul Zulli,et al.  Computational Fluid Dynamics Study of Pulverized Coal Combustion in Blast Furnace Raceway , 2009 .

[36]  Hiroshi Nogami,et al.  Multi-dimensional transient mathematical simulator of blast furnace process based on multi-fluid and kinetic theories , 2005, Comput. Chem. Eng..

[37]  Dong Fu,et al.  CFD modeling of multiphase reacting flow in blast furnace shaft with layered burden , 2014 .

[38]  Paul Zulli,et al.  CFD Modelling and Analysis of Pulverized Coal Injection in Blast Furnace: An Overview , 2011 .

[39]  R. R. Willmers.  Coke properties in the bosh and raceway regions of the blast furnace , 1992 .

[40]  Aibing Yu,et al.  Experimental and numerical investigations of gouge formation related to blast furnace burden distribution , 2009 .

[41]  T. Miyazaki,et al.  Mathematical Model for Blast Furnace Operation Considering the Degradation of Coke by Gasification , 1980 .

[42]  Paul Zulli,et al.  Modelling of Liquid Flow in the Blast Furnace. Application in a Comprehensive Blast Furnace Model , 2001 .

[43]  Aaas News,et al.  Book Reviews , 1893, Buffalo Medical and Surgical Journal.

[44]  Takanobu Inada,et al.  Effect of Blast Furnace Profile on Inner Furnace States , 2003 .

[45]  Paul Zulli,et al.  Modeling the discontinuous liquid flow in a blast furnace , 1997 .

[46]  Paul Zulli,et al.  Numerical simulation of solids flow in a blast furnace , 2002 .

[47]  Paul Zulli,et al.  Modeling of Blast Furnace with Layered Cohesive Zone , 2010 .