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Reduction Furnace Modeling

1. The direct reduction shaft furnace process at the Midrex plant was simulated. This furnace is a counter-current solid-gas reactor that converts iron ore lumps into sponge iron. 2. Mass and energy balances for this reactor yield a system of ordinary differential equations with two boundary conditions. The kinetics used in the model is the unreacted shrinking core model. 3. Solving the system provides temperature and concentration profiles for all components along the reactor length. Orthogonal collocation was used to solve the system of equations, which has a shorter solution time than the shooting method.

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0% found this document useful (0 votes)
68 views

Reduction Furnace Modeling

1. The direct reduction shaft furnace process at the Midrex plant was simulated. This furnace is a counter-current solid-gas reactor that converts iron ore lumps into sponge iron. 2. Mass and energy balances for this reactor yield a system of ordinary differential equations with two boundary conditions. The kinetics used in the model is the unreacted shrinking core model. 3. Solving the system provides temperature and concentration profiles for all components along the reactor length. Orthogonal collocation was used to solve the system of equations, which has a shorter solution time than the shooting method.

Uploaded by

mrrazavi
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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.
.
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Shooting .
:

Unreacted shrinking core


Orthogonal Collocation


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)Fe(s) + HO (g
)(
)FeO (s) + H (g
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)Fe(s) + CO (g
)(

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CCO

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)(8

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)(10

=0

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) Gmsol ( X 3 )Cpsol ( X 3 , Tsol

u sol

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dz
dX 2
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dz
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=0
) dz Gmg Cp g ( X 1 , X 2 , Tg
u

Ap h(Tsol Tg )

:
X 2 ( z = L) = 0

X 1 ( z = L) = 0

Tg ( z = L) = Tgin

X 3 ( z = 0) = 0
Ts ( z = 0) = Tatm

)(11

X X Tg ) z= ( )(
) ( z=L .
:
)(12

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= R

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)(14

+ (r03 rc3 ) ps / M wps

/ M wps

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)(15

wrs

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[r / M

3
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Pr 2 / 3
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R [] E a1 / R g = 179.14 R
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MATLAB .



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Gas
Gas
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rate

flow

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HO
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CH+N
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,
,
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,

length

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Production
t/h
Mineral pellet density
g/cm
Sponge iron density
g/cm
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cm
np
pellets/cm

zone

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Reaction
cm
Diameter
cm

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data
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base) %

orthogonal collocation
Shooting
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CO
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HO
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CO
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metallization
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)CPU Time(min
---

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Gas flow rate
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H
,%
CO
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HO
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CO
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pressure
atm
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Production
t/h
Mineral pellet density
g/cm
Sponge iron density
g/cm
Pellet ratio
cm
np
pellets/cm
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Reaction zone length
cm
Diameter
cm

,
,
,
,
,

:
) ( ].[
) :(
(,exp
(,exp
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, T, cm/s
cal/cm/K

K
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K
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D
D
h

) ( .
) :(
model
)(Dry base

gilmore data
model data
(Dry base) %
(Dry base) %

data
%

Orthogonal

,
,
,
,
,
,

collocation
Shooting
)outlet gas composition(z=
H
,
,
CO
,
,
,
HO
,
CO
,
,
,
CH+N
,
metallization

,
)CPU Time(min
--



.
.

[] W.D Munro, N.R. Amundson, Solid-fluid heat exchange in moving beds, Ind. Eng. Chem, ()
.
[] N.R. Amundson, Solid-fluid interaction in fixed and moving beds, Ind. Eng. Chem, () .
[] C.W. Siegmund, W.D. Munro, N.R. Amundson, Solid-fluid interaction in fixed and moving beds. Two
problems on moving beds. Ind. Eng. Chem, () .
[] R.J. Schaefer, D. Vortmeyer, C.C. Watson, Steady state behavior of moving bed reactors, Chem. Eng.
Sci. () .
[] H. Yoon, J. Wei, M.M. Denn, A model for moving bed coal gasification reactors. AIChE J. ()
.
[] N.R. Amundson, L.E. Arri, Char gasification in counter current reactor, AIChE J. () .
[] Takenaka Y., Kimura Y., Narita K. and Kaneko D., Mathematical model of direct reduction shaft
furnace and its application to actual operation of a model plant, Comp. and Chem. Engng. (),.
[] Towhidi N. , Direct Reduction, V., Tehran University press,
[] Patisson F. and Ablitzer, Physicochemical and thermal modeling of the reaction between a porous
pellet and a gas, Powder Technology () .

[]

Daniel R. Parisi, Miguel A. Laborde , Modeling of counter current moving bed gas-solid reactor
used in direct reduction of iron ore, Chemical Engineering journal () .

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