Predictive Modeling and Optimization of the Variant Combinations of Material Ratios in the Gasification–Reduction Coupling Process

Abstract

The combined coal gasification and flash ironmaking process (CG-FI) was the latest technology practice of the alternative ironmaking process, and it can also be recognized as a multi-generation system for high-quality syngas and reduced iron. The computational fluid dynamics (CFD) model was established to explore the process conditions based on the pilot-scale equipment. The turbulent flow, gas–particle coupling, and kinetic reaction model were considered in the model, which was already validated in the prior researches. In this study, the different material ratio combinations, including oxygen/coal ratio (0.6–0.8) and ore/coal ratio (0.2–1.6), were investigated to illuminate the interrelationship during the gasification–reduction coupling process. The results demonstrated that the qualified reduced iron (Reduction Degree = 52.47%) could be obtained even in the worst case (oxygen/coal ratio = 0.6, ore/coal ratio = 1.6). Moreover, the dispersed hematite particles replaced the role of H2O as the coolant and partial oxidant in the traditional coal gasification process to improve the gasification performance.