The hydrogen-based direct reduction of iron oxide (DRI) provides a sustainable approach to cleaner ironmaking. In this research, for analyzing hydrogen-based DRI in pellet scale, the random pore model (RPM), the most sophisticated non-catalytic gas-solid model, is applied to determine the effects of structural parameters, including pore-size parameter (ψ), Thiele modulus (ϕ), and product layer resistance (β), along with operational parameters such as pressure, temperature, and gas composition. The PDE equations of RPM were solved numerically using the method of lines together with a finite-difference discretization in space. The effects of parameters ψ and ϕ were investigated, revealing that the reaction rate increases with larger pores and decreases with higher values of ϕ over length and time. Kinetics resemble the unreacted shrinking core model (USCM) for small particles, while pore structure dominates for large particles. Parameter determination is influenced by ϕ changes, shifting control from chemical kinetics to diffusion, with operating conditions impacting reaction rate enhancement. Investigations revealed that as ϕ increases from 0.454 to 1.454, a 6 % conversion gradient forms from the pellet center to the surface. Additionally, at 700°C, reducing the temperature by 100°C slows conversion by 15.45 minutes while increasing it accelerates conversion by 4.55 minutes.
Read full abstract