Abstract
COREX is one of the commercialized smelting reduction ironmaking processes. It mainly includes two reactors, i.e., a (reduction) shaft furnace (SF) and a melter gasifier (MG). In comparison with the conventional blast furnace (BF), the COREX MG is not only equipped with a more complicated top charging system consisting of one gimbal distributor for coal and eight flap distributors for direct reduction iron (DRI), but also the growth mechanism of its burden pile is in a developing phase, rather than that in a fully-developed phase in a BF. Since the distribution of charged burden plays a crucial role in determining the gas flow and thus in achieving a stable operation, it is of considerable importance to investigate the burden distribution influenced by the charging system of COREX MG. In the present work, a mathematical model is developed for predicting the burden distribution in terms of burden layer structure and radial ore/coal ratio within the COREX MG. Based on the burden pile width measured in the previous physical experiments at different ring radii on a horizontal flat surface, a new growth mechanism of burden pile is proposed. The validity of the model is demonstrated by comparing the simulated burden layer structure with the corresponding results obtained by physical experiments. Furthermore, the usefulness of the mathematical model is illustrated by performing a set of simulation cases under various charging matrixes. It is hoped that the model can be used as a what-if tool in practice for the COREX operator to gain a better understanding of burden distribution in the COREX MG.
Highlights
Steel is the world’s most popular construction material due to its durability, processability, and cost cheapness
Since the burden distribution is determined according to its flow width, and do not consider the rolling of the particles at a horizontal level in the mathematical model, no material reaches the central area of the furnace
Based on the previous physical experiment, a new wasarriving proposed to characterize the growing mechanism of burden surface with the width of approach burden flow at the burden surface growing mechanism of burden surface with the width of burden flow arriving at the burden surface in the COREX melter gasifier (MG)
Summary
Steel is the world’s most popular construction material due to its durability, processability, and cost cheapness. COREXprocess, process,which whicheliminates eliminatesthe theneed needfor forcoke coke directly used for ore reduction and smelting in process, which eliminates the need for coke making makingunits. Sintering plants are not required process, substantial savings of up to be achieved in the of hot of a grade similar to that theof furnace [3]. The experimental measurement showed that the pile width was practically the same as the width of burden flow arriving at the burden surface This makes the formation of burden pile in COREX MG being different from that in a BF. This work will focus on the formation process of burden pile when certain material reaches the burden surface, and thereby a thorough understanding of the charging process as well as burden pile evolution can be expected, especially for the mechanism of developing growing with developing pile angles
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