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Simulation of In-Flight Reduction of the Fine Iron Ore Concentrate by Hydrogen

  • Bahador Abolpour , M. Mehdi Afsahi EMAIL logo , Ataallah Soltani Goharrizi and Mehdi Azizkarimi
Published/Copyright: November 11, 2016
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Abstract

A mathematical model has been proposed to simulate a novel method for direct reduction of iron concentrate by hydrogen. Flight of fine particles in a vertical reactor containing a gaseous mixture of H2-N2-H2O has been studied. Effect of generating gaseous jet on the residence time of the particles has been also investigated. Coupled turbulent Navier-Stokes equations with eddy kinetic energy equation have been solved using a developed homemade code. Kinetics of this reaction has been studied using the unreacted core model. Accuracy of the model predictions has been approved by the experimental data. Finally, effects of vital variables (i. e. temperature, particle size, hydrogen concentration and particle feed rate) on the particle residence time and also fractional conversion have been studied.

Funding statement: The authors acknowledge the financial support from the Golgohar iron ore and steel research institute, Sirjan, Iran, under award number 92.2501.

List of Symbols

A

Annular cross section area between reactor tube and particles feeder tube (m2)

a

Cross section area of solid particles feeder tube (m2)

Cc

Cunningham correction factor, which defined in reference [23]

Cµ, C, C

Constant (0.09, 1.44 and 1.92, respectively)

D

Inner diameter of reactor tube (m)

De

Effective diffusivity in the solid particles (m2.s–1)

D

Outer diameter of solid feeder tube (m)

dp

Particle diameter (m)

eH2

Percent of excess hydrogen gas (%)

FD

Drag force factor, which was calculated as follow [23]: (s–1)FD=18μgCcρFe3O4dp2

g

Gravity acceleration (m.s–2)

H

Height of the reaction zone (m)

h

Height of the particle feeder tube (m)

K

Equilibrium constant for reaction (11), was calculated by HSC software [20]

k

Turbulent kinetic energy (m2.s–2)

kg

Mass transfer coefficient of reducing gas in the gaseous film around the particles, was calculated from reference [21] (m.s–1)

ks

Intrinsic reaction rate constants for reaction (11), was presented in reference [16] as below: (m3.kmol–1.s–1)ks=9.9×104exp4.63×108RT

L

Height of the reactor tube (m)

MFe,MFe3O4,MH2,MH2O,MN2

Molecular weight of iron, magnetite, hydrogen, water vapor and Nitrogen, respectively (kg.kmol–1)

m.s

Particles feed rate (kg.s–1)

P

System total pressure (pa)

PH20,PN20

Initial partial pressures of hydrogen and nitrogen, respectively (pa)

Q0

Initial flow rate of entering gas mixture to the annulus space at top of the reactor (m3.s–1)

QH20,QN20

Initial flow rate of entering hydrogen and nitrogen to the annulus space at top of the reactor tube, respectively (m3.s–1)

QH2req.

Required hydrogen flow rate to achieve mentioned excess hydrogen for reaction (11), can be calculated by following equation [16]: (m3.s–1)QH2req.=4MH2m.1+1KρH2MFe3O4×1+eH2100

q

Flow rate of solid particles carrier gas (m3.s–1)

Rˉ

Universal Gas Constant (pa. m3.kmol–1.K–1)

T

Temperature (K)

t

Time (s)

tend

Residence time of the particles in the reaction zone (s)

u

Velocity of gas phase in the x direction (m.s–1)

V

Velocity vector of gas phase (m.s–1)

V0

Initial velocity vector of entering gas mixture to the annulus space at top of the reactor tube (m.s–1)

Vp

Velocity vector of the particles (m.s–1)

v

Velocity of gas phase in the y direction (m.s–1)

v0

Initial velocity vector of the particles in the injected gas (m.s–1)

W

Weight of the particles (N)

w

Velocity of gas phase in the z direction (m.s–1)

X

Conversion of the particles

x

x position in the reactor (m)

xp

Position of the particle (m)

yH20,yN20

Initial molar fractions of hydrogen and nitrogen at the top of reaction zone, respectively

yH2,yH2O,yN2

Molar fractions of hydrogen, water vapor and nitrogen at each height of the reaction zone, respectively

y

y position in the reactor (m)

yp

y position of the particles (m)

z

z position in the reactor (m)

zp

z position of the particles (m)

Greek symbols
δij

Kronecker delta: δij=1i=j0ij

σk, σε

Turbulent Prandtl numbers (1 and 1.3, respectively)

Ε

Turbulent dissipation (m2.s–3)

θ

Dimensionless temperature: θ=T1.6×103T+1.6×103

ε

Turbulent kinetic energy dissipation rate (J. kg–1)

εp

Porosity of reduced ash layer in the particle, which was calculated by the following equation:εp=1ρFe3O4MFe3ρFeMFe3O4

ρg

Density of the gas mixture, which was calculated using ideal gas mixture assumption (kg. m–3)

ρp (ρFe,ρFe3O4)

Densities of iron and magnetite particles, respectively (kg. m–3)

ρH2,ρH2O,ρN2

Densities of gases hydrogen, water vapor and nitrogen, respectively, which were calculated using ideal gas assumption (kg. m–3)

μg

Viscosity of the gas mixture, which was calculated by Wilke method (pa.s)

μH2,μH2O,μN2

Viscosities of gases hydrogen, water vapor and nitrogen, respectively, which were calculated using the Sutherland equations [17] (pa.s)

µt

Turbulent viscosity of the flow based on the k-ε model (Pa.s):μt=ρgCμk2ε

τreact, τash, τfilm

Time constants of chemical reaction, diffusion in the ash layer and diffusion in the gaseous film, respectively, which were calculated using the following equations [19, 21]: (s)

τash=ρFe3O4MH2dp26ρH2MFe3O4De,τfilm=2ρFe3O4MH2dp3ρH2MFe3O4kg,τreact=2ρFe3O4MH2dpρH2MFe3O4ks11K

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Received: 2016-4-8
Revised: 2016-7-6
Accepted: 2016-7-26
Published Online: 2016-11-11
Published in Print: 2017-3-1

©2017 by De Gruyter

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