Numerical simulation of iron ore sintering process with coke oven gas injection and oxygen enrichment
-
Wenjie Ni
,
Lili Jiang
Abstract
Oxygen enrichment is believed to improve productivity and reduce fuel consumption, while gas fuel injection is assumed to improve the product yield and quality in iron ore sintering process. It is important to understand the mutual effect of oxygen enrichment and gas fuel injection for combined usage of these two techniques. A mathematical model is developed to simulate the sintering process with coke oven gas (COG) injection and oxygen enrichment, particularly focusing on predicting the quality and yield of sinter production, as well as NO x emission. The model is validated by comparing the model predictions with sintering pot test data, and numerical simulations are carried out to investigate the mutual effect of oxygen enrichment and COG injection. The results show that, compared with the conventional sintering process, with 0.5% COG injection and 30% oxygen enrichment, the mean melt quantity index (MQI) is increased by 4.1% and the mean cooling rate (CR) is decreased by 62.5%, showing that the sinter quality is improved significantly. The sinter yield is increased by 44.5%, whereas the NO x emission is increased by 8.3%. With the increase of oxygen enrichment from 21% to 30%, the sinter yield increases prominently first and then decreases a little, attaining its maximum at 30% of oxygen concentration. In addition, increasing oxygen concentration will increase the conversion rate of coke-N to NO x . Therefore, excessive oxygen enrichment is not only bad for sinter strength and yield, but also increases NO x emission.
Funding source: National Natural Science Foundation of China http://dx.doi.org/10.13039/501100001809
Award Identifier / Grant number: 52064036
Funding source: The Youth Science and Technology Funding of Gansu Province
Award Identifier / Grant number: 21JR7RA267
-
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
-
Research funding: The authors are grateful for the financial support from the Youth Science and Technology Funding of Gansu Province (21JR7RA267), and the National Natural Science Foundation of China (52064036).
-
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
References
Acharyulu, A. V. B., K. Sudhakar, G. Ramarao, A. Gowthaman, G. Thimmappa, L. R. Singh, and S. S. Baral. 2021. “Thermodynamic and Mineralogical Aspects of Injecting LPG, Coke Oven Gas, and Oxygen into Goethitic Iron Ore Sintering Process.” Journal of Sustainable Metallurgy 7 (1): 136–50, https://doi.org/10.1007/s40831-020-00327-x.Suche in Google Scholar
Castro, J. A., N. Nath, A. B. Franca, V. S. Guilherme, and Y. Sasaki. 2013. “Analysis by Multiphase Multicomponent Model of Iron Ore Sintering Based on Alternative Steelworks Gaseous Fuels.” Ironmaking and Steelmaking 39 (8): 605–13, https://doi.org/10.1179/1743281212y.0000000008.Suche in Google Scholar
Cheng, Z. L., S. S. Wei, Z. G. Guo, J. Yang, and Q. W. Wang. 2017. “Improvement of Heat Pattern and Sinter Strength at High Charcoal Proportion by Applying Ultra-Lean Gaseous Fuel Injection in Iron Ore Sintering Process.” Journal of Cleaner Production 161: 1374–84, https://doi.org/10.1016/j.jclepro.2017.07.017.Suche in Google Scholar
Cheng, Z. L., J. Yang, Z. G. Guo, P. Fu, M. Ihme, and Q. W. Wang. 2019. “Numerical Analysis of Heat and Mass Transfer Coupled with Gaseous Fuel Injection in Reactive Porous Media.” Journal of Heat Transfer 141: 112601, https://doi.org/10.1115/1.4044365.Suche in Google Scholar
Fan, X. H., Y. J. Zhao, Z. Y. Ji, H. R. Li, M. Gan, H. Y. Zhou, X. L. Chen, and X. X. Huang. 2021. “New Understanding about the Relationship between Surface Ignition and Low-Carbon Iron Ore Sintering Performance.” Process Safety and Environmental Protection 146: 267–75, https://doi.org/10.1016/j.psep.2020.09.004.Suche in Google Scholar
Guilherme, V. S., and J. A. D. Castro. 2012. “Use of Coke Oven Gas in Iron Ore Sintering.” Metallurgy and Materials 65 (3): 357–62, https://doi.org/10.1590/s0370-44672012000300012.Suche in Google Scholar
Han, F. G., L. X. Xu, X. F. Wu, H. P. Li, C. G. Bi, H. M. Long, H. Y. Nie, and P. Q. Liu. 2016. “Technical Research on Sintering Intensification with Coke Oven Gas Injection.” Sintering and Pelletizing 41 (2): 12–6.Suche in Google Scholar
Hobbs, M. L., P. T. Radulovic, and L. D. Smoot. 1992. “Modeling Fixed-Bed Coal Gasifiers.” AIChE Journal 38 (5): 681–701, https://doi.org/10.1002/aic.690380506.Suche in Google Scholar
Huang, X. X., X. H. Fan, Z. Y. Ji, M. Gan, X. L. Chen, Y. J. Zhao, and T. Jiang. 2019. “Investigation into the Characteristics of H2-Rich Gas Injection over Iron Ore Sintering Process: Experiment and Modelling.” Applied Thermal Engineering 157: 113709, https://doi.org/10.1016/j.applthermaleng.2019.04.119.Suche in Google Scholar
Huang, X. X., X. X. Fan, X. L. Chen, X. Z. Zhao, and M. Gan. 2018. “Optimisation Model of Fuel Distribution in Materials Bed of Iron Ore Sintering Process.” Ironmaking and Steelmaking 46 (7): 649–55, https://doi.org/10.1080/03019233.2018.1440160.Suche in Google Scholar
Iwami, Y., T. Yamamoto, T. Higuchi, K. Nushiro, M. Sato, and N. Oyama. 2013. “Effect of Oxygen Enrichment on Sintering with Combined Usage of Coke Breeze and Gaseous Fuel.” ISIJ International 53 (9): 1633–41, https://doi.org/10.2355/isijinternational.53.1633.Suche in Google Scholar
Iwami, Y., T. Yamamoto, T. Higuchi, K. Nushiro, M. Sato, and N. Oyama. 2014. “Effect of Oxygen Enrichment on Sintering with Combined Usage of Coke Breeze and Gaseous Fuel.” Tetsu-To-Hagane 100 (2): 189–97, https://doi.org/10.2355/tetsutohagane.100.189.Suche in Google Scholar
Kagn, H., S. Choi, W. Yang, and B. Cho. 2011. “Influence of Oxygen Supply in an Iron Ore Sintering Process.” ISIJ International 51 (7): 1065–71.10.2355/isijinternational.51.1065Suche in Google Scholar
Liu, B., Y. H. Feng, Z. Y. Jiang, and X. X. Zhang. 2012. “Heat and Mass Transfer in Sintering Process.” CIE Journal 63 (5): 1344–53.Suche in Google Scholar
Loo, C. E., N. Tame, and G. C. Penny. 2012. “Effect of Iron Ores and Sintering Conditions on Flame Front Properties.” ISIJ International 52 (6): 967–76, https://doi.org/10.2355/isijinternational.52.967.Suche in Google Scholar
Nakano, M., and J. Okazaki. 2011. “Ideal Behavior of Sinter Block Densification and Relation Thereof to Yield and Strength in Iron Ore Sintering.” ISIJ International 51 (9): 1418–24, https://doi.org/10.2355/isijinternational.51.1418.Suche in Google Scholar
Nath, N. K., A. J. D. Silva, and N. Chakraborti. 1997. “Dynamic Process Modelling of Iron Ore Sintering.” Process Metallurgy 68 (9): 285–92, https://doi.org/10.1002/srin.199701791.Suche in Google Scholar
Nath, N. K., and K. Mitra. 2004. “Optimisation of Suction Pressure for Iron Ore Sintering by Genetic Algorithm.” Ironmaking and Steelmaking 31 (3): 199–206, https://doi.org/10.1179/030192304225018118.Suche in Google Scholar
Nath, N. K., and K. Mitra. 2005. “Mathematical Modeling and Optimization of Two-Layer Sintering Process for Sinter Quality and Fuel Efficiency Using Genetic Algorithm.” Materials and Manufacturing Processes 20: 335–49, https://doi.org/10.1081/amp-200053418.Suche in Google Scholar
Ni, W. J., H. F. Li, L. Shao, and Z. S. Zou. 2020. “Numerical Simulation on Influence of Coke Oven Gas Injection on Iron Ore Sintering.” ISIJ International 60 (4): 662–73, https://doi.org/10.2355/isijinternational.isijint-2019-486.Suche in Google Scholar
Ni, W. J., H. F. Li, Y. Y. Zhang, and Z. S. Zou. 2019. “Effects of Fuel Type and Operation Parameters on Combustion and NOx Emission of the Iron Ore Sintering Process.” Energies 12: 213, https://doi.org/10.3390/en12020213.Suche in Google Scholar
Ni, W. J., Z. S. Zou, H. F. Li, and Y. Y. Zhang. 2018. “Static Model and Process Optimization of Iron Ore Sintering with Coke Oven Gas Injection.” Journal of Materials and Metallurgy 17 (3): 159–65.Suche in Google Scholar
Oyama, N., Y. Iwami, T. Yamamoto, S. Machida, T. Higuchi, H. Sato, M. Sato, K. Takeda, Y. Watanabe, M. Shimizu, and K. Nishioka. 2011. “Development of Secondary-Fuel Injection Technology for Energy Reduction in the Iron Ore Sintering Process.” ISIJ International 51 (6): 913–21, https://doi.org/10.2355/isijinternational.51.913.Suche in Google Scholar
Pahlevaninezhad, M., M. D. Emami, and M. Panjepour. 2016. “Identifying Major Zones of an Iron Ore Sintering Bed.” Applied Mathematical Modelling 40: 8475–92, https://doi.org/10.1016/j.apm.2016.05.005.Suche in Google Scholar
Seenivasan, R., A. V. B. Acharyulu, V. Sabariraj, J. Arvind, S. Rameshwar, and G. Balachandran. 2021. “Modelling the Effect of Sinter Machine Speed on Bed Temperature and Coke Combustion Characteristics in Iron Ore Sintering Process.” Ironmaking and Steelmaking 48 (6): 637–48, https://doi.org/10.1080/03019233.2021.1889893.Suche in Google Scholar
Shrestha, S., J. Xu, A. B. Yu, and Z. Y. Zhou. 2021. “Numerical Simulation of Fuel Layered Distribution Iron Ore Sintering Technology.” Ironmaking and Steelmaking 2021: 1–18, https://doi.org/10.1080/03019233.2021.1968259.Suche in Google Scholar
Taira, K. 2019. “NOx Emission Profile Determined by In-Situ Gas Monitoring of Iron Ore Sintering during Packed-Bed Coke Combustion.” Fuel 236: 244–50, https://doi.org/10.1016/j.fuel.2018.09.008.Suche in Google Scholar
Wang, G., Z. Wen, G. F. Lou, R. F. Dou, X. W. Li, X. L. Liu, and F. Y. Su. 2016. “Mathematical Modeling and Combustion Characteristic Evaluation of a Flue Gas Recirculation Iron Ore Sintering Process.” International Journal of Heat and Mass Transfer 97: 964–74, https://doi.org/10.1016/j.ijheatmasstransfer.2016.02.087.Suche in Google Scholar
Yang, W., C. Ryu, S. Choi, E. Choi, D. Lee, and W. Huh. 2004. “Modeling of Combustion and Heat Transfer in an Iron Ore Sintering Bed with Considerations of Multiple Solid Phases.” ISIJ International 44 (3): 492–9, https://doi.org/10.2355/isijinternational.44.492.Suche in Google Scholar
Zhang, B., J. M. Zhou, M. Li, and Y. Li. 2018. “Modeling and Simulation of Iron Ore Sintering Process with Consideration of Granule Growth.” ISIJ International 58 (1): 17–24, https://doi.org/10.2355/isijinternational.isijint-2017-342.Suche in Google Scholar
Zhang, J., X. M. Guo, Y. H. Qi, and D. L. Yan. 2015. “Model of Iron Ore Sintering Based on Melt and Mineral Formation.” Journal of Iron and Steel Research International 22 (4): 288–96, https://doi.org/10.1016/s1006-706x(15)30002-9.Suche in Google Scholar
Zhang, X. H., P. Feng, J. R. Xu, L. B. Feng, and S. Qing. 2020. “Numerical Research on Combining Flue Gas Recirculation Sintering and Fuel Layered Distribution Sintering in the Iron Ore Sintering Process.” Energy 192: 1–11, https://doi.org/10.1016/j.energy.2019.116660.Suche in Google Scholar
Zhang, Y. Z., and L. Q. Ai. 1997. Mathematical Analysis and Simulation of Metallurgical Process. Beijing: Metallurgical Industry Press. (in Chinese).Suche in Google Scholar
Zhou, W. T., J. G. Hu, and Y. L. Guo. 2011. “New Sintering Technologies and Analysis on Prospect of Popularization in China.” World Iron & Steel (6): 47–52. (in Chinese). https://doi.org/10.3969 /j.issn.1672-9587.2011.06.007.Suche in Google Scholar
Zhou, H., Z. H. Liu, M. Cheng, M. X. Zhou, and R. P. Liu. 2015. “Influence of Coke Combustion on NOx Emission during Iron Ore Sintering.” Energy & Fuels 29: 974–84, https://doi.org/10.1021/ef502524y.Suche in Google Scholar
Zhou, H., J. P. Zhao, C. E. Loo, B. G. Ellis, and K. F. Cen. 2012. “Numerical Modeling of the Iron Ore Sintering Process.” ISIJ International 52 (9): 1550–8, https://doi.org/10.2355/isijinternational.52.1550.Suche in Google Scholar
© 2022 Walter de Gruyter GmbH, Berlin/Boston
Artikel in diesem Heft
- Frontmatter
- Special Issue Articles
- Preface: Special issue of “Metallurgical Reaction Engineering”
- The relationship between melt structure and viscosity: the effect of different fluxes on CaO–SiO2 slags
- Analysis of nozzle clogging position in a continuous casting mold
- Numerical simulation of iron ore sintering process with coke oven gas injection and oxygen enrichment
- Bubble behavior and evolution characteristics in the RH riser tube-vacuum chamber
- Combined models with tanks in series for characterization of tundish flows in continuous casting of steel
- Numerical simulation of inner characteristics in COREX shaft furnace with center gas distribution: influence of bed structure
- Effects of operation parameters on particle mixing performance in a horizontal high shear mixer
- Numerical study on the distribution of flue gas residence time in the desulfurization and denitrification system by the optimization of the model
- Numerical investigation of scrap melting in high-carbon hot metal
Artikel in diesem Heft
- Frontmatter
- Special Issue Articles
- Preface: Special issue of “Metallurgical Reaction Engineering”
- The relationship between melt structure and viscosity: the effect of different fluxes on CaO–SiO2 slags
- Analysis of nozzle clogging position in a continuous casting mold
- Numerical simulation of iron ore sintering process with coke oven gas injection and oxygen enrichment
- Bubble behavior and evolution characteristics in the RH riser tube-vacuum chamber
- Combined models with tanks in series for characterization of tundish flows in continuous casting of steel
- Numerical simulation of inner characteristics in COREX shaft furnace with center gas distribution: influence of bed structure
- Effects of operation parameters on particle mixing performance in a horizontal high shear mixer
- Numerical study on the distribution of flue gas residence time in the desulfurization and denitrification system by the optimization of the model
- Numerical investigation of scrap melting in high-carbon hot metal
