Journal
METALS
Volume 11, Issue 2, Pages -Publisher
MDPI
DOI: 10.3390/met11020332
Keywords
concentrate; flash ironmaking technology (FIT); hydrogen; kinetics; magnetite; natural gas; CFD simulation; reactor design; partial combustion
Funding
- U.S. Department of Energy [DE-EE0005751]
- American Iron and Steel Institute (AISI)
- University of Utah
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The simulation work on the novel flash ironmaking technology demonstrated the feasibility of using a reasonably sized reactor, with possibilities for improving production rates. Design considerations include minimizing particle-wall collisions and utilizing a large diameter-to-height ratio to reduce heat loss.
The development of a novel ironmaking technology based on fine iron ore concentrate in a flash reactor is summarized. The design of potential industrial reactors for flash ironmaking based on the computational fluid dynamics technique is described. Overall, this simulation work has shown that the size of the reactor used in the novel flash ironmaking technology (FIT) can be quite reasonable vis-a-vis the blast furnaces. A flash reactor of 12 m diameter and 35 m height with a single burner operating at atmospheric pressure would produce 1.0 million tons of iron per year. The height can be further reduced by either using multiple burners, preheating the feed gas, or both. The computational fluid dynamics (CFD)-based design of potential industrial reactors for flash ironmaking pointed to a number of features that should be incorporated. The flow field should be designed in such a way that a larger portion of the reactor is used for the reduction reaction but at the same time excessive collision of particles with the wall must be avoided. Further, a large diameter-to-height ratio that still allows a high reduction degree should be used from the viewpoint of decreased heat loss. This may require the incorporation of multiple burners and solid feeding ports.
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