Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

Abdelghany, Amr; Fan, De-Qiu; Elzohiery, Mohamed; Sohn, Hong Yong

doi:10.1002/srin.201900126

Title: Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

Journal Article · Sun Jul 28 00:00:00 EDT 2019 · Steel Research International

DOI:https://doi.org/10.1002/srin.201900126· OSTI ID:1545393

^[1]; Fan, De-Qiu ^[1]; Elzohiery, Mohamed ^[1]; Sohn, Hong Yong ^[1]

Department of Metallurgical Engineering University of Utah 135 S 1460 E, RM 412 Salt Lake City, Utah 84112 USA

A large‐scale bench reactor (LSBR) is operated at the University of Utah to develop a novel flash ironmaking process. The reactor vessel is a refractory‐lined furnace with 0.8 m in diameter and 2.1 m in length, with a capacity of processing 1–7 kg h ⁻¹ of magnetite concentrate. Natural gas is partially oxidized with oxygen in a uniquely designed burner, producing a short flame that provides heat (1423–1873 K) and a reducing gas mixture (hydrogen and carbon monoxide). The reducing gas reacts with magnetite (Fe ₃ O ₄ ) concentrate particles to produce metallic iron. A computational fluid dynamics (CFD) model is developed to simulate the LSBR runs, in which the kinetics of magnetite concentrate reduction, separately determined in a drop‐tube reactor, is incorporated. The reduction degrees and composition of the off‐gas obtained from the CFD model show reasonable agreements with the experimental results.

View Accepted Manuscript (Publisher)

Cite

Export

Save

Sponsoring Organization:: USDOE

Grant/Contract Number:: EE0005751

OSTI ID:: 1545393

Journal Information:: Steel Research International, Journal Name: Steel Research International Vol. 90 Journal Issue: 9; ISSN 1611-3683

Publisher:: Wiley Blackwell (John Wiley & Sons)Copyright Statement

Country of Publication:: Germany

Language:: English

Citation Metrics:

Cited by: 11 works

Citation information provided by
Web of Science

References (19)

Flowsheet development, process simulation and economic feasibility analysis for novel suspension ironmaking technology based on natural gas: Part 2 – Flowsheet and simulation for ironmaking combined with steam methane reforming Pinegar, H. K.; Moats, M. S.; Sohn, H. Y. Ironmaking & Steelmaking, Vol. 40, Issue 1 https://doi.org/10.1179/030192312X13345671456851	journal	January 2013
Re-oxidation Kinetics of Flash-Reduced Iron Particles in H2-H2O(g) Atmosphere Relevant to a Novel Flash Ironmaking Process Yuan, Zhixue; Sohn, Hong Yong; Olivas-Martinez, Miguel Metallurgical and Materials Transactions B, Vol. 44, Issue 6 https://doi.org/10.1007/s11663-013-9910-0	journal	July 2013
Methods for Calculating Energy Requirements for Processes in Which a Reactant Is Also a Fuel: Need for Standardization Sohn, H. Y.; Olivas-Martinez, Miguel JOM, Vol. 66, Issue 9 https://doi.org/10.1007/s11837-014-1120-y	journal	August 2014
Hydrogen Reduction Kinetics of Magnetite Concentrate Particles Relevant to a Novel Flash Ironmaking Process Wang, Haitao; Sohn, H. Y. Metallurgical and Materials Transactions B, Vol. 44, Issue 1 https://doi.org/10.1007/s11663-012-9754-z	journal	October 2012
Flowsheet development, process simulation and economic feasibility analysis for novel suspension ironmaking technology based on natural gas: Part 1 – Flowsheet and simulation for ironmaking with reformerless natural gas Pinegar, H. K.; Moats, M. S.; Sohn, H. Y. Ironmaking & Steelmaking, Vol. 39, Issue 6 https://doi.org/10.1179/1743281211Y.0000000053	journal	August 2012
Kinetic Analysis of Spherical Wustite Reduction Transported with CH4 Gas Takeuchi, Naoyuki; Nomura, Yohei; Ohno, Ko-ichiro Tetsu-to-Hagane, Vol. 94, Issue 4 https://doi.org/10.2355/tetsutohagane.94.115	journal	January 2009
A new k-ϵ eddy viscosity model for high reynolds number turbulent flows Shih, Tsan-Hsing; Liou, William W.; Shabbir, Aamir Computers & Fluids, Vol. 24, Issue 3 https://doi.org/10.1016/0045-7930(94)00032-T	journal	March 1995
Reduction of Molten Iron Oxide in CO Gas Conveyed System Tsukihashi, Fumitaka; Kato, Kimio; Otsuka, Ken-ichi Transactions of the Iron and Steel Institute of Japan, Vol. 22, Issue 9 https://doi.org/10.2355/isijinternational1966.22.688	journal	January 1982
Global reaction schemes for hydrocarbon combustion Jones, W. P.; Lindstedt, R. P. Combustion and Flame, Vol. 73, Issue 3 https://doi.org/10.1016/0010-2180(88)90021-1	journal	September 1988
Computation of Radiant heat Transfer on a Nonorthogonal mesh Using the Finite-Volume Method Chui, E. H.; Raithby, G. D. Numerical Heat Transfer, Part B: Fundamentals, Vol. 23, Issue 3 https://doi.org/10.1080/10407799308914901	journal	April 1993
Analysis of the Hydrogen Reduction Rate of Magnetite Concentrate Particles in a Drop Tube Reactor Through CFD Modeling Fan, Deqiu; Mohassab, Yousef; Elzohiery, Mohamed Metallurgical and Materials Transactions B, Vol. 47, Issue 3 https://doi.org/10.1007/s11663-016-0603-3	journal	February 2016
Process Simulation and Economic Feasibility Analysis for a Hydrogen-Based Novel Suspension Ironmaking Technology Pinegar, Haruka K.; Moats, Michael S.; Sohn, H. Y. steel research international, Vol. 82, Issue 8 https://doi.org/10.1002/srin.201000288	journal	April 2011
Development of a Novel Flash Ironmaking Technology with Greatly Reduced Energy Consumption and CO2 Emissions Sohn, Hong Yong; Mohassab, Yousef Journal of Sustainable Metallurgy, Vol. 2, Issue 3 https://doi.org/10.1007/s40831-016-0054-8	journal	April 2016
A Numerical Study of a Bluff-Body Stabilized Diffusion Flame. Part 2. Influence of Combustion Modeling And Finite-Rate Chemistry Gran, Inge R.; Magnussen, BjØRn F. Combustion Science and Technology, Vol. 119, Issue 1-6 https://doi.org/10.1080/00102209608951999	journal	October 1996
Mathematical modeling of sulfide flash smelting process: Part II. Quantitative analysis of radiative heat transfer Hahn, Y. B.; Sohn, H. Y. Metallurgical Transactions B, Vol. 21, Issue 6 https://doi.org/10.1007/BF02670266	journal	December 1990
Reduction of Fine Iron Ores in Gas Conveyed Systems [微粉鉄鉱石の水素による輸送層還元] Ozawa, Masaya; Tanaka, Minoru Tetsu-to-Hagane, Vol. 58, Issue 7 https://doi.org/10.2355/tetsutohagane1955.58.7_821	journal	January 1972
Hydrogen Reduction of Liquid Iron Oxide Fines in Gas-conveyed Systems. Hayashi, Shoji; Iguchi, Yoshiaki ISIJ International, Vol. 34, Issue 7 https://doi.org/10.2355/isijinternational.34.555	journal	January 1994
Structural changes and kinetics in the gaseous reduction of hematite Bradshaw, A. V.; Matyas, A. G. Metallurgical and Materials Transactions B, Vol. 7, Issue 1 https://doi.org/10.1007/BF02652822	journal	March 1976
Flowsheet development, process simulation and economic feasibility analysis for novel suspension ironmaking technology based on natural gas: Part 3 – Economic feasibility analysis Pinegar, H. K.; Moats, M. S.; Sohn, H. Y. Ironmaking & Steelmaking, Vol. 40, Issue 1 https://doi.org/10.1179/030192312X13345671456897	journal	January 2013

Similar Records

Design of Novel Flash Ironmaking Reactors for Greatly Reduced Energy Consumption and CO2 Emissions

Journal Article · Sun Feb 14 00:00:00 EST 2021 · Metals · OSTI ID:1545393

Sohn, Hong Yong; Fan, De-Qiu; Abdelghany, Amr

Kinetics of Hydrogen Reduction of Magnetite Concentrate Particles in Solid State Relevant to Flash Ironmaking

Journal Article · Mon Oct 24 00:00:00 EDT 2016 · Steel Research International · OSTI ID:1545393

Elzohiery, Mohamed; Sohn, Hong Yong; Mohassab, Yousef

Interaction of Iron with Alumina Refractory Under Flash Ironmaking Conditions

Journal Article · Thu Aug 15 00:00:00 EDT 2019 · Metallurgical and Materials Transactions. B, Process Metallurgy and Materials Processing Science · OSTI ID:1545393

Sarkar, Rahul; Sohn, H. Y.

Title: Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

Citation Formats

References (19)

Similar Records

Related Subjects