Professional Documents
Culture Documents
Mathematical Modelling of Blast Furnace Process at Smelting of Non-Traditional Raw Materials
Mathematical Modelling of Blast Furnace Process at Smelting of Non-Traditional Raw Materials
1. INTRODUCTION
For calculation of the iron oxides reduction processes in the dry part of a blast
furnace is offered to use the following modified equation [1]
1-111
where CO ,H 2 – increment of degree of reduction of hematite (g), magnetite (m) and
g ,m ,w
wustite (w) at the expense of CO или H2 agreeably. Other designations are resulted
in Section 6.
Balance constants (СО2/СО) of reactions
3Fe2O3 CO 2Fe3O4 CO2 , (2)
Fe3O4 CO 3FeO CO2 , (3)
FeO CO Fe CO2 (4)
are described by the equations [2]
lg KgCO 2726/ T 2.144, (5)
lg KmCO 1850/ T 2.1, (6)
lg KwCO 688/ T 0.9 . (7)
Balance constants of iron oxides reduction reactions by hydrogen ( H2O / H2 )
рассчитываются по уравнениям are calculated on the equations
KgH, m2 , w KgCO
, m, w Kwg , (8)
g , m, w
g , m, w
i 1
CO
g , m, w
Hg ,2m,w , (10)
H2 H 2 i 1
0.11Hg 0.166Hm 0.724Hw .
2 2 2
(12)
For check of adequacy of the accepted scheme of reduction of iron oxides
experiments on reduction of agglomerate and pellets by hydrogen in an interval 900-
1100 оС have been made.
In Fig.1 the experimental and settlement kinetic curves constructed with use of
the equations (1), (10-12) are resulted.
The basic equations for heat exchange calculation in the differential form look
like
wg dtg wmdtm ( i p ig )d , (13)
wg dtg wm dtm , (14)
wmdtm ih d V vm (tg tm )d , (15)
dtm V vm (tg t m ) ih V vm (tg t m )
, (16)
d wm wm
1-112
Fig. 1. The experimental (continuous) and calculating (stroke-dotted) kinetic
curves of pellets reduction (а) and agglomerate (b) of Kachkanarsky GOK
ih
wm wm 1 , (18)
dtm
wm
d
wg – water equivalent of gas,
1-113
i
wg wg 1 p . (19)
dtg
wg
d
Solving in common the equations (14) and (16), at an assumption
w
m M = const we receive the equations
wg
t g t gK
аm
wg
в
t m t mH m t m2 t mH
2wg
J
2 p JK
wg
, (24)
As the primary information allowing to analyze the work of gas in the furnace
use usually practical data about distributions CO2 and temperatures of gas on radius of
top. Distinguish two basic types of the distribution influencing on parameters of work
of the furnace – a peripheral and axial course. In the mathematical model the
opportunity of the task of any types of distributions as on practical data, and by expert
is stipulated. The curve СО2 f ( r ) will be transformed to non-uniformity of
distribution of streams of burden and gas, thus the blast furnace is broken into ten
equal rings. Also following assumptions are accepted: ore ( O ) and flux ( F ) are
distributed on section of the furnace in regular intervals unlike coke Кr f r and
gas.
1-114
Thus these values should be distributed on top radius so that to compensate the
accepted assumptions and to reflect such phenomena, as pinching-out of layers of
components of burden, an advancing, segregation, etc.
As a result by means of calculation heat- and mass exchange on model the set
curve is reproduced СО2 f r . For this purpose used the equations with help which
the ore loading ( OB ) and the coke consumption (K) are put accordingly in direct and
inversely proportional dependence on ( CO2 ) and quantity of gas in dependence on
the coke consumption
where OB and K – the average ore loading and the average coke consumption; ρi ,
Ai , Bi , ni – factors which steal up on a condition of maintenance of the greatest
possible coincidence set curve and СО2 f r received as a result of calculations of
heat- and mass exchange in 10 rings.
1-115
Table 1. The basic parameters of smelting of ferronickel in a blast furnace
Indices Value
Productivity, t/day 53
The sinter consumption, kg/t pig-iron 6430
General contents Fe in burden, % 13,96
Coke consumption, kg/t pig-iron 1532
Flux, kg/t pig-iron 82
Blast:
natural gas consumption, m3/minute 1558
temperature, оС 1100
oxygen contents, % 21,0
Pig-iron, composition, %:
[Si] 1.50
[Ni] 6.39
[Cr] 1.38
Slag: quantity, kg/t pig-iron 5138
composition, %: (CaO) 28.8
(MgO) 14.9
(Al2O3) 28.8
basic capacity (CaO/SiO2) 0.60
Reduction processes of iron oxides in all cuts are developed actively enough
because of tall reductibility of sinter. The greatest activity of reduction processes of
iron oxides is observed at furnace centre. At the centre of furnace and on the rim the
reduction of iron oxides is terminated completely in the “dry” zone of the board, i.e.
to temperatures 950 oС. In the ridge ore the rereduction processes are developed less
actively and to the emolliating zone the material is enters in which wustite it is
reduced only on 50 %. Therefore early slags in this cut will differ from slags of
central and peripheral cuts both on consumption and on properties.
1-116
Centre of furnace
Ore crest
Periphery of furnace
Fig. 2. Distribution of temperatures of the burden and gas (at the left) and reduction
processes (on the right) in vertical sections (rings 1, 8, 10) of the blast furnace at
ferronickel smelting
1-117
Fig. 3. The analysis of reduction processes and heat interchange for
ferromanganese smelting conditions
6. SYMBOLS
CO
g , m, w
, H 2 – gain of the reduction degree of the hematite, magnetite and wustite at
the expense of CO or H2 accordingly;
K Хg ,m,w – constants of the reduction velocities for the hematite, magnetite and wustite;
CO950 – CO content at 950оС, %;
d Р – diameter of the ore piece, mm;
(DEg ,m,w ) CO2 ,H2O
– the effective diffusivity defining the diffusive resistance of the
reduced layer for hematite, magnetite and wustite accordingly;
Ag ,m,w , Bg ,m,w , Cg ,m,w , Dg ,m,w – auxiliary coefficients;
1-118
t m, g – temperature of materials or gas, accordingly, оС;
V – volume heat-transfer factor;
ih – heat effect of the reaction, kJ/(h ∙ t);
ip – warmth losses, kJ/(h ∙ t);
m – the ration of water equivalents of the burden and gas;
(О), (К), (F) – consumption of ore, coke and limestone, accordingly, kg/t pig-iron;
OB – ore burden;
Vg – top gas amount, kg/t pig-iron;
(CO2) – contents of the carbon dioxide in the top gas, %.
7. CONCLUSION
AKNOWLEDGEMENTS
This work was executed with support from Council under Grants for Leading
Scientific Schools of Russia (School № 4358.2008.3).
REFERENCES:
1. Chentsov A.V., Chesnokov Yu.A. and Shavrin S.V.: The Logic-Statistic Balance
Model of Blast Furnace Smelting. Ural Branch of Russian Academy of Sciences,
Ekaterinburg, 2003.
2. Popel S.I., Sotnikov A.I. and Boronenkov V.N.: The theory of metallurgical
processes. Moscow, Metallurgy, 1986.
3. Chentsov A.V., Chesnokov Yu.A. and Shavrin S.V.: 'Controllable parameters of
system of loading and elements of modelling of domain process'. Izvestia Vuzov,
Chernaya Mettalurgia 2006 7 22-24.
4. Belyaev I.L, Chentsov A.V., Chesnokov Yu.A. and Shavrin S.V.: 'Use of two-
dimensional model of blast furnace process at pig-iron melt about 6 % Ni'.
Izvestia Vuzov, Chernaya Mettalurgia 2006 9 18-20.
5. Kudinov D.Z., Chesnokov Yu.A. and Shavrin S.V.: Features of blast furace process
at melt of manganous alloys in the form of diagrams ω – t – τ. Izvestia Vuzov,
Chernaya Mettalurgia 2002 3 76-77.
1-119