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60 I and S Coke
60 I and S Coke
furnace operation
A. Babich*, D. Senk and H. W. Gudenau
Two measures for coke saving and increase in blast furnace efficiency related to coke
characteristics reactivity and size are discussed in this paper. Modern blast furnace operation
with low coke rate and high injection rate causes a change in coke quality requirements. A
discussion has arisen recently about highly reactive coke. Here, a theoretical analysis of influence
of coke reactivity on the thermal reserve zone, direct reduction and carbon consumption in the
blast furnace has been undertaken. Experiments have been performed using non-standard test
scenarios that simulate coke behaviour under real blast furnace operating conditions. Coke
reactivity and microstructure have also been investigated under the impact of alkali and
pulverised coal ash and char. Operation of many blast furnaces has proved the possibility of coke
saving and increase in productivity when using small-sized coke (so-called nut coke) mixed with
the burden, but the reasons for this phenomenon, and consequently the limit for nut coke
consumption, are still not very clear. An analytical method and cold model simulations have been
used to quantify the change in shaft permeability and furnace productivity when using nut coke.
Keywords: Blast furnace, Coke reactivity, Shaft permeability, Nut coke, Simulation conditions
Introduction
Coke constitutes a great portion of the production costs
of hot metal and its consumption is strongly related to
CO2 emissions. Its properties affect coke rate, furnace
productivity and metal quality.1,2
The significance of coke reactivity and the complexity
are explained by the fact that this characteristic may
correlate with other chemical, physical and mechanical
properties of coke. Coke reactivity towards CO2 is
determined by its physical and chemical properties, in
particular its texture, structure and composition of
mineral matter.3 The effect of additives such as alkali,
lime, iron oxides and flue dust on coke reactivity was
studied in the 1930s.4 Now it is commonly recognised
that the CRI (coke reactivity index5), which correlates
with the CSR (coke strength after reaction5) index,
should be kept at a low level to shift the solution loss
reaction to higher temperatures.6 This is particularly
important at high pulverised coal (PC) injection rate
because the time of solution loss reaction of coke under
catalytic impact of alkali metals increases.
Blast furnace (BF) operation with high injection rate
requires special coke quality, as particularly its reactivity
may be affected by injected PC or other solid carbonaceous materials. A study conducted by RWTH Aachen
University in cooperation with JFE Steel, Japan,
testified that char and ash, generated from PC or waste
RWTH Aachen University, Department of Ferrous Metallurgy, Intzestrasse
1, 52072 Aachen, Germany
Corresponding author, email babich@iehk.rwth-aachen.de
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(2)
This means that the systems (1) and (2) will reach
thermodynamic equilibrium only at partial conversion
of CO into CO2 according to the equilibrium constants
(KP). For wustite reduction, this can be written as:17
FeOz(1=KP z1)CO~FezCO2 z1=KP CO
(3)
(4)
or
Kp
CO2
~Q(T)
~
CO zCO2 Kp z1
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3 Effect of alkalis (A) on coke weight loss when simulating wall (w) and centre (c) regions of BF
Time, min
CO2, %
CO, %
N2, %
900
900R1100
1100
1100R1300
1300
1300R1500
1500
30
40
30
40
30
40
30
20
0
10
0
0
0
0
20
0
30
0
40
0
40
60
100
60
100
60
100
60
Wall
300R600
600R800
800R1000
Centre 650R1000
1000R1200
3
2
5
3.5
2
20
15
5
10
5
20
25
35
30
35
Experimental
Facilities and test scenarios
60
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Temperature range, uC
K min1
Time, min
0900
9001100
11001500
10.0
2.0
5.0
90
100
80
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CO2, %
CO, %
N2, %
270
20
10
0
20
30
40
60
60
60
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(5)
where ym, yb are the friction factors for mix and burden
respectively; y5f(Re); Re is the Reynolds number; Hm
and Hb are packed bed heights for mix and burden
respectively, m; eem, eeb are the effective voidage of mix
and burden respectively, m3 m3.
Effective voidage was introduced by Professor
Yaroshevskiy and his team at TU Donetsk, Ukraine,
to consider porosity of the materials:22
ee ~ezn:Vg :(1{e)
(6)
3
10 Decrease in pressure drop in BF dry zone when using nut coke of various size
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(7)
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p
at 20% nut coke rate(5{15 mm) : Q2 ~ 0:915:Q1
~0:957:Q1 i:e: by 4:3%
For larger nut coke size (2040 mm), the reserve for
increase in blast volume and productivity makes up
5?1% and 6?2% for 10% and 20% of nut coke rate
respectively.
Assuming that solid materials occupy about 50% of
the furnace height, BF productivity can be increased by
1?83?1%. These figures reflect operation using sinter
with ees529?3%.
Experimental
Facilities, materials and test performance
Streaming conditions in the BF shaft have been
simulated using a cold model (Fig. 11). Air is blown
via six tuyeres and streams through the packed bed.
Characteristics of examined materials are shown in
Table 4 and their photos in Fig. 12. Used grain sizes of
materials simulate size ratios of sinter, nut coke and bell
coke typical of a BF.
Two test series were conducted at the ratio of layer
thickness of coke and burden (sinter and sinternut coke
mixture) 1:1 (50 and 100 mm of each layer). This ratio
corresponds roughly to coke-only operation. For the
third test series, the ratio of coke and burden layer
thickness was set at 1:2 (50 and 100 mm respectively).
This ratio represents the modern BF operation, e.g. at
coke rate of 320 kg tHM1, PC of 170 kg tHM1, iron
Coke
Nut coke
3540 mm
1520 mm
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Conclusions
A reduction in reduction temperature of the FeOFe
reaction does not automatically decrease carbon consumption in a BF. Extension of direct reduction, kinetic
factors and reduction behaviour of Fe2O3 and Fe3O4 can
hinder it.
The higher the porosity of feed coke, the higher the
CRI value. This dependence becomes flatter after the
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Acknowledgements
Part of this research work has been carried out with a
financial grant from the European Coal and Steel
Community (contract no. 7210-PR-324). The authors
wish to express thanks to Professor Yaroshevskiy and
his team at TU Donetsk, Ukraine, for initiating the
theoretical study on nut coke.
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