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

Abstract

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 (Fe3O4) 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.