Minimization of Blast Furnace Fuel Rate
The blast furnace (BF) process is a counter-current moving-bed chemical reactor to reduce iron oxides to iron, which involves complex transport phenomena and chemical reactions. The fuel economy of the blast furnace process is directly coupled to the gas and burden distributions. The knowledge of gas distributions and its influential factors in a blast furnace is essential for the process optimization. Due to the difficulties in measurements, such knowledge can be most readily obtained through the development of high fidelity computational fluid dynamics (CFD) numerical simulations.
The comprehensive CFD model consists of burden distribution, gas distribution, heat transfer and chemical reactions. The multiphase reacting CFD code has been developed to simulate the BF shaft process and predicted the cohesive zone shape under different conditions. The simulation results are validated with industry measurement. The effects of burden distribution, tuyere operation and production rate are investigated.
The CFD results showed the influence of different operating parameters and burden distributions on the shape and position of the cohesive zone. So this model is used as a tool to predict the furnace internal conditions. Research work is going on to optimize the burden and gas distribution for maximum efficiency of the furnace operations.
Sponsor: Department of Energy (DOE)
Partners: ArcelorMittal-USA, SeverStal, ArcelorMittal-Dofasco, US Steel-Stelco Inc., Union Gas