energies

Article
Analysis of Energy Consumption of the Reduction of
Fe2O3 by Hydrogen and Carbon Monoxide Mixtures
Guanyong Sun 1,2 , Bin Li 1,2 , Wensheng Yang 1,2 , Jing Guo 1,2 and Hanjie Guo 1,2, *
1 School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing,
Beijing 100083, China; sunguanyong@xs.ustb.edu.cn (G.S.); libin4962337@163.com (B.L.);
yws3179608@163.com (W.Y.); guojing@ustb.edu.cn (J.G.)
2 Beijing Key Laboratory of Special Melting and Preparation of High-End Metal Materials, University of
Science and Technology Beijing, Beijing 100083, China
* Correspondence: guohanjie@ustb.edu.cn; Tel.: +86-010-62334964




Received: 5 March 2020; Accepted: 16 April 2020; Published: 17 April 2020


Abstract: Energy consumption is directly related to the energy supply and production costs of
gas-based direct reduction ironmaking, which is an effective choice to reduce the energy consumption
of iron making. In this paper, the minimum Gibbs free energy principle was used to calculate
the equilibrium composition under the conditions of reduction gas consisting of hydrogen and
carbon monoxide (hydrogen concentration of 0–100%, reduction gas amount of 0–6.0 mol, reduction
temperature of 790–1100 ◦ C, and 0.5 mol Fe2 O3 ). According to the enthalpy change, a simplified energy
consumption model of a gas-based direct reduction ironmaking process was established, and the
energy consumption per mole of metallic iron produced was calculated in detail. The following
conclusions were drawn: at the stage when the reduction reaction occurred, the utilization rate of
hydrogen or carbon monoxide remained unchanged with the increase in the amount of reduction
gas or the increase in the hydrogen concentration of initial gas. The direct energy consumption
increased with the increase in the hydrogen concentration at 790–980 ◦ C and the opposite was true at
980–1100 ◦ C. At 790–980 ◦ C, the total energy consumption per ton of iron was greater than 0 and
increased with the increase in initial hydrogen concentration from 40% to 100%, and it was less than 0
and increased with the increase in initial hydrogen concentration from 0% to 30%. It was possible to
achieve zero total energy consumption with a hydrogen concentration of 30% and a 973 ◦ C reduction.

Keywords: gas-based direct reduction ironmaking; gas utilization rate; energy consumption; energy
utilization; recoverable heat; minimized Gibbs free energy principle; equilibrium state

1. Introduction
The iron and steel industry were regarded as the largest energy consumption manufacturing
sector [1]. The conventional coke-based blast furnace consumes a large amount of energy [2,3], such as
coke, oxygen, pulverized coal, etc., so non-blast furnace technologies are expected to reduce energy
consumption and carbon emission [4].
Due to technological progress, the consumption of natural resources for ironmaking continuously
decreases, but still, there is a lot of potential for further savings [5]. The energy savings can be obtained
by reducing energy consumption and improving energy recovery [6,7]. Any modification leading to
improvement of energy utilization needs to be emphatic. Gas utilization rate is an important indicator
reflecting the operating state and energy consumption of blast furnaces [8] and non-blast furnaces [9].
Energy consumption could be reduced, with sufficient recovery of gas, heat and surplus energy during
the iron and steel manufacturing process [10].

Energies 2020, 13, 1986; doi:10.3390/en13081986 www.mdpi.com/journal/energies

Energies 2020, 13, 1986 2 of 13

However, little progress has been made on decreasing energy consumption through the
modification of conventional gas-based ironmaking processes. So, it is an urgent need for researchers
and workers to recognize the necessity and feasibility to further lower the energy consumption for
gas-based ironmaking.
In the present paper, a simple ironmaking system, just composed only of reduction gas and
hematite, is proposed for consideration. The composition and amount of reduction gas and reduction
temperature are selected as key factors affecting the energy consumption of ironmaking. Additionally,
the temperature change of the system is taken into account, because of the large percentage in all energy
demand. The purpose of this paper is to investigate the possibility of minimum energy consumption
for gas-based direct reduction iron.

2. Methods

2.1. Energy Consumption Model

To formulate the thermodynamic model of energy consumption of the reduction of Fe2 O3 by
hydrogen and carbon monoxide mixtures with counter-current gas and solid, the following assumptions
are made:
(a) The heat of the reactions is released to the external environment, so the temperature of
substances before and after the reduction reaction is unchanged.
(b) The kinetic of reaction and heat transfer is neglected.
(c) Some specific aspects, like gangue in iron ore, inert gas in reduction gas, the heat loss of the
furnace, etc., have not been considered.
The energy consumption model can show the processes from iron ore and reduction gas at initial
temperature to metalized iron and exhaust gas at given temperatures, as is presented in Figure 1.
The processes are set as:
(1) Fe2 O3 and reduction gas are heated by the respective preheat process from 25 ◦ C to the given
reduction temperature, and the sensible heat input of solid Fe2 O3 and reduction gas are calculated by
Formula (1).
(2) Fe2 O3 and reduction gas reach thermodynamic equilibrium in the reduction process.
The temperature before and after the reactions does not change, and the reaction heat of the system is
calculated by Formula (1), which is also contained in the heat input.
(3) The product metalized iron and exhaust gas are respectively cooled to 50 ◦ C and 150 ◦ C by
heat exchange process, and the possible released heat is calculated by Formula (1). These released
heats can be recycled, and contained in the heat output.
In a closed system under an equal pressure condition, the energy change equals enthalpy change,
so the energy consumption is studied by the enthalpy change between the one state and another state.
The enthalpy change is shown in Formula (1).

N
X M
X
O
∆H = ni Hi,T − n j H j,T j (1)
i
i=1 j=1

where ∆H, represents the enthalpy change and also energy change, J, and negative value is exothermic,
positive value is endothermic; i, j, signify the components after and before the state change, respectively;
N, M, represent the number of components after and before the state change, respectively; ni , nj ,
represent the amount of components after and before the state change, respectively, mol; Ti , Tj , represent
the thermodynamic temperature of components after and before the state change, respectively, K; Hi,T O ,
i
HO
j,T
, represent the standard molar enthalpy of the component i at the thermodynamic temperature Ti
j
and the component j at the thermodynamic temperature Tj , respectively, J·mol−1 , are derived from the
specific heat capacity data [11] measured by the predecessors.
Energies 2020, 13, 1986 3 of 13

The temperature increasing or decreasing and chemical reactions, all indicate the changes of
the
Energies 2020, state,
system so PEER
13, x FOR the sensible
REVIEW heat and chemical reaction heat, heat input and heat output can 3 ofbe
13
calculated by Formula (1).
The heat
The heat input
input is
is defined
defined toto express
express the
the heat
heat from
from outside,
outside, such
such asas heating
heating system,
system, and
and contains
contains
the sensible
the sensibleheatheatinput
input and
and reaction
reaction heat,
heat, and and indicates
indicates the direct
the direct energyenergy consumption.
consumption. The
The heat heat
output
output expresses
expresses the releasedthe released
heat intoheat into thewhich
the outside, outside,
canwhich
be usedcaninbe used
total in total
product product According
processes. processes.
According
to to energy
energy balance balanceand
principles principles
overall and overall considerations,
considerations, the total
the total energy energy consumption
consumption is the sum of is
the sum of heat input and heat output. The calculation formulas of sensible heat
heat input and heat output. The calculation formulas of sensible heat input, heat input, heat outputinput, heat input,
heattotal
and outputheatandaretotal heat
shown inare shown (2)–(5).
Formulas in Formulas (2)–(5).
ΔH sensible heat input =ΔH sensible heat input of Fe2O3 + ΔH sensible heat input of reduction gas (2)
∆Hsensible heat input = ∆Hsensible heat input of Fe2 O3 + ∆Hsensible heat input of reduction gas (2)
ΔH heat input =ΔH sensible heat input + ΔH reaction heat
∆Hheat input = ∆Hsensible heat input + ∆Hreaction heat (3)
=ΔH heat input of Fe O + ΔH sensible heat input of reduction gas + ΔH reaction heat
(3)
= ∆Hsensible heatsensible
input of Fe2 O3 2+3 ∆Hsensible heat input of reduction gas + ∆Hreaction heat

∆Hheat outputΔ H ∆H
=heat output =ΔH
sensible sensible Fe +
heat outputofof Fe
heat output +Δ∆H
H sensible heat output of eahaust gas
sensible heat output of eahaust gas (4)
(4)
ΔHheat
∆Htotal heat = ∆H =ΔH ∆H
input +heat
total heat input + ΔH heat output
heat output
= ∆Hsensible=heatΔH sensible
inputheat of input
Fe2 O + ∆H H sensible heat
of 3Fe2 O3 + Δsensible heatinput
input gas + ΔH
of reduction
of reduction gas + ∆H
reaction heat reaction heat
(5)
(5)
+∆Hsensible heat + ΔH
output of Fe + ∆H + ΔH
sensible heat output of eahaust gas
sensible heat output of Fe sensible heat output of eahaust gas

The units of ∆H are J or kece, and the heat of 1 kgce equals the heat of 29,288 kJ, namely 1 GJ
The units of ΔH are J or kece, and the heat of 1 kgce equals the heat of 29,288 kJ, namely 1 GJ
equals 34.144 kgce.
equals 34.144 kgce.
In addition, the heat recovery rate is the ratio of heat output to heat input, as shown in Formula
In addition, the heat recovery rate is the ratio of heat output to heat input, as shown in Formula
(6), and evaluate the energy utilization limit of solid and gas after reduction equilibrium.
(6)Error! Reference source not found., and evaluate the energy utilization limit of solid and gas after
reduction equilibrium. ∆Hheat output
heat recovery rate = × 100% (6)
∆H
ΔHheat input
heat output
heat recovery rate = × 100% (6)
ΔH heat input

Exhaust Gas:
25℃ Solid Fe2O3 150℃
H2+CO+H2O+CO2

Sensible heat input Preheat process Heat exchang process Sensible heat output

Reduction process，
Reaction heat Reaction heat
Reduction temperature 790～1100℃

Sensible heat output Heat exchang process Preheat process Sensible heat input

50℃ Solid Fe Reduction gas: 25℃

H2+CO

Figure Schematic
1.Schematic
Figure 1. diagram
diagram of energy
of energy consumption
consumption model ofmodel of gas-based
gas-based directironmaking
direct reduction reduction
ironmaking
process. process.

2.2. Equilibrium Composition

2.2. Equilibrium Composition
The minimum Gibbs free energy method is used to calculate the equilibrium state composition
The minimum Gibbs free energy method is used to calculate the equilibrium state composition
in the reducer [12]. The initial state conditions (amount, temperature, and pressure) can be used to
in the reducer [12]. The initial state conditions (amount, temperature, and pressure) can be used to
calculate the amount of component in the equilibrium state, ignoring the specific reaction process.
calculate the amount of component in the equilibrium state, ignoring the specific reaction process.
The
The initial
initial conditions
conditions and
and equilibrium
equilibriumcomponents
componentsset
setare
areshown
shownin
inFigure
Figure2.2.
 Energies 2020, 13, 1986 4 of 13
Energies 2020, 13, x FOR PEER REVIEW 4 of 13

Initial state：
Solid：0.5 mol Fe2O3 ；
Gaseous：H2，CO

Tempeature：790～1100℃；
Pressure：ptotal=101325 Pa
ΔH r

Equilibrium state：
Solid：Fe2O3 ，Fe3O4，Fe0.95 O，Fe；
Gaseous：H2，CO，H2 O，CO2

Figure
Figure2.2.The
Theinitial
initialand
andequilibrium
equilibriumstate
stateofofthe
thesystem
systemof
ofthe
thereducer.
reducer.

Basedon
Based onthe
theprinciple
principleofofminimum
minimumfree freeenergy,
energy, that
that is,
is, the
the sum
sum of
of Gibbs
Gibbs free
free energy
energy of
of each
each
componentininthe
component theequilibrium
equilibriumstate
stateisisthe
thesmallest,
smallest, a calculation
a calculation model
model is established,
is established, as shown
as shown in
in Formulas
Formulas (7) and
(7) and (8). (8).
The The non-linear
non-linear equation
equation is solved
is solved usingusing constraints
constraints to obtain
to obtain the mass
the mass of each of
each component of the equilibrium state at different temperatures and different
component of the equilibrium state at different temperatures and different initial amounts of initial amounts of
reductiongas.
reduction gas.
XN XN
N N
min·G = n G =
i i i=  n（ ni(GO + RT ln ai ) (7)(7)
i Gi +i RT ln ai）
allGall =  ni G
min.
i =11
i= i =1i=1

NN
s.t.  αie ni = ne (e = 1, 2,, M ) (8)(8)
X
s.t. i =1αie ni = ne (e = 1, 2, · · · , M)
i=1
In the formula, i, e, represent the components and elements in the equilibrium state, respectively;
In the formula, i, e, represent the components and elements in the equilibrium state, respectively;
N, M, represent the number of components and the number of elements in the equilibrium state,
N, M, represent the number of components and the number of elements in the equilibrium state,
respectively; ni, ne, are the amounts of the components i and elements e in the equilibrium state,
respectively; ni , ne , are the amounts of the components i and elements e in the equilibrium state,
respectively, mol; G , Gi , represent the Gibbs free energy and the standard Gibbs free energy of the
respectively, mol; Gii , GOi
, represent the Gibbs free energy and the standard Gibbs free energy of the
−1; p , p 
components
components i,i, respectively, J·mol−1
respectively, J·mol , p,O ,prepresent
; pi ,i ptotaltotal , represent the partial
the partial pressure
pressure ofcomponents
of the the components
i, the
i,total
thepressure
total pressure of and
of all gas, all the
gas,standard
and theatmospheric standard atmospheric pressure,Pa,
pressure, respectively, respectively, Pa,325Pa;
and pO = 101, and
p 
=101325Pa ; α represents the number of atoms in the element; T, represents
αie represents the ienumber of atoms in the element; T, represents the thermodynamic temperature of the the thermodynamic
temperature
system, K; R,ofis the
the system,
ideal gasK;constant,
R, is thewhich
ideal isgas constant,
equal J·molis−1equal
which
to 8.314, ·K−1 ; ato 8.314, J·mol −1·K −1; a
i represents the activity,
i
pi n p total
when i is a gaseous state ai = pO = P ni · pO , when i ispia solid n state
p a i = 1. It should be noted that the
represents the activity, when i is a gaseous i state ai =  = i  total , when i is a solid state ai = 1 . It
real gas can be treated as an ideal gas under high temperature p  ni and
p low pressure.
shouldThe
beutilization
noted thatrates of Hgas
the real 2 , CO,
can CO + H2 are
be treated as defined
an ideal asgasthe ratiohigh
under of the changed amount
temperature and low of
reduction gas to corresponding initial amount of reduction gas, are shown in Formulas (9)–(11).
pressure.
The utilization rates of H2, CO, CO +in H2 are defined as the ratio of the changed amount of
nH − nout H
nout
H O
− nin
reduction gas to corresponding initial ηH amount
= 2 of reduction
2
= 2 gas,Hare 2 O shown in Formulas (9)–(11).
(9)
2
n in in
nHin
in H2 out out
nH − nH nH O − nH 2O
ηH2 = 2 in 2 = 2 in 2 (9)
nin n−Hn2
out nH2 − nin
nout
CO CO
ηCO = CO in CO = 2
in
2
(10)
out in
n
in
nCOCO − nCO out
nCO 2 − n CO
CO2
ηCO = in
= in (10)
(nin − n out ) + (nin − nCO
n out ) (nnCOout − nin ) + (nout − nin )
H2 H2 CO CO H2 O H2 O CO2 CO2
ηH +CO = = (11)
2
（nHin2 n−in
nout+
H2H 2
）+n（inn in − n out） （n out − n in ）
COCO CO H2O H2O n +（in n+ out in in
n− n ）
H2 CO2 COCO2
ηH2 +CO = = (11)
where in, out, represent the initial intake nHin2 + nCO
in
gas and equilibrium nHinexhaust
2
+ nCOin
gas, respectively; ηH , ηCO ,
2
ηH +CO , are the utilization rate of H2 , CO, H2 + CO, respectively; nH , nCO , nH O , nCO , are the amount
2 where in, out, represent the initial intake gas and equilibrium 2 exhaust 2gas, respectively;
2 ηH 2 ,
of H2 , CO, H2 O, and CO2 , respectively.
ηCO , η H 2 +CO , are the utilization rate of H2, CO, H2 + CO, respectively; nH2 , nCO , nH2O , nCO2 , are the
amount of H2, CO, H2O, and CO2, respectively.
Energies 2020, 13, 1986 5 of 13

Energy consumption per mole of Fe or per ton of Fe means the energy consumption of the
production of 1 mol Fe and 1 t Fe under sufficient material conditions and with certain temperature
conditions. When the reduction gas is not enough, metalized Fe cannot be produced fully, namely the
energy consumption is not 1 mol or 1 t Fe. When the amount of reduction gas is more than is needed,
unnecessary energy is wasted, in particular, needless sensible heat input of reduction gas is not 1mol
or 1 t Fe. These problems need to be calculated precisely.

3. Results and Discussion

Different amounts of reduction gas and different reduction temperatures were set to investigate
the effects on the reduction products, gas utilization, and energy consumption.

3.1. Effect of Amount of Reduction Gas

The conditions were set as follows: the initial reduction gas amount was 0.005–0.2 mol (increment
0.005 mol), 0.2–6.0 mol (increment 0.1 mol); the reduction temperature was 900 ◦ C; the initial gas was
composed of H2 and CO, and the H2 volume fraction was 0–100% (increment 10%); the total pressure
was 101,325 Pa; the initial solid was 0.5mol Fe2 O3 , and the maximum Fe output was 1mol. It should be
noted that the reduction reactions and water-gas shift reaction are heterogeneous reactions, as shown
in in Formulas (12)–(18), and other carbonization reactions and carbon decomposition reaction are not
considered in this study.
Reduction reactions:

3Fe2 O3 (solid) + H2 (gas) = 2Fe3 O4 (solid) + H2 O(gas) (12)

3Fe2 O3 (solid) + CO(gas) = 2Fe3 O4 (solid) + CO2 (gas) (13)

3
Fe3 O4 (solid) + H2 (gas) = Fe0.95 O(solid) + H2 O(gas) (14)
0.95
3
Fe3 O4 (solid) + CO(gas) = Fe0.95 O(solid) + CO2 (gas) (15)
0.95
Fe0.95 O(solid) + H2 (gas) = 0.95Fe(solid) + H2 O(gas) (16)

Fe0.95 O(solid) + CO(gas) = 0.95Fe(solid) + CO2 (gas) (17)

Water-gas shift reaction:

H2 O(gas) + CO(gas) = H2 (gas) + CO2 (gas) (18)

3.1.1. Equilibrium Products and Gas Utilization

Figure 3 shows the relationship between the initial amount of reduction gas and the amount of
equilibrium products in the reduction of 0.5 mol Fe2 O3 by 50% H2 and 50% CO concentration at 900 ◦ C.
According to the trend of the product type and the amount of the material, the reduction process can
be divided into six stages in sequence.
I, the iron-containing products have Fe2 O3 and Fe3 O4 at the same time. As the amount of reduction
gas increases, Fe2 O3 gradually decreases to zero, and Fe3 O4 gradually increases to the maximum
amount; the chemical reactions can be expressed as Formulas (12) and (13).
II, the iron-containing products only have Fe3 O4 . As the amount of reduction gas increases,
the amount of Fe3 O4 remains unchanged.
III, the iron-containing products have Fe3 O4 and Fe0.95 O at the same time, as the amount of
reduction gas increases, Fe3 O4 gradually decreases to zero, and Fe0.95 O gradually increases to the
maximum amount; the chemical reactions can be expressed as Formulas (14) and (15).
IV, the iron-containing products only have Fe0.95 O, and as the amount of reduction gas increases,
Fe0.95 O content remains unchanged.
Energies 2020, 13, x FOR PEER REVIEW 6 of 13
Energies 2020, 13, 1986 6 of 13

IV, the iron-containing products only have Fe0.95O, and as the amount of reduction gas increases,
Fe0.95O
V,content remains unchanged.
the iron-containing products have Fe0.95 O and Fe at the same time, and as the amount of
Energies 2020, 13, x FOR PEER REVIEW 6 of 13
V, thegas
reduction iron-containing
increases, Fe0.95 products
O contenthave Fe0.95Odecreases
gradually and Fe attothe same
zero, and time, and as increases
Fe gradually the amount of
to the
reduction gas
maximumIV,amount; increases, Fe
the chemical O content gradually
reactions decreases to zero, and Fe gradually increases to the
onlycan
havebeFeexpressed
0.95O, and asas Formulas
amount of(16) and (17).
0.95
the iron-containing products the reduction gas increases,
maximum
VI, Oamount;
Fe0.95iron-containing the chemical
content remains products
unchanged.reactions
only havecan
Fe,be
asexpressed
the amount as of
Formulas (16)
reduction and
gas (17). the amount
increases,
of FeVI, iron-containing
remains
V, theunchanged. products
iron-containing only have
products have Fe, asOthe
Fe0.95 andamount of same
Fe at the reduction
time, gas
andincreases, the amount
as the amount of
of Fe reduction
remains unchanged.
gas increases, Fe0.95O content gradually decreases to zero, and Fe gradually increases to the
maximum amount; the chemical reactions can be expressed as Formulas (16) and (17).
VI, iron-containing products only have Fe, as the amount of reduction gas increases, the amount
of Fe remains unchanged.

Figure 3.
Figure The effect
3. The effect of
of the
the initial
initialamount
amountofofreduction
reductiongas
gasonon
the amount
the of of
amount equilibrium products
equilibrium in the
products in
reduction of 0.5 mol Fe O at 900 ◦ C.
the reduction of 0.5 mol2 Fe32O3 at 900 °С.
Figure 3. The effect of the initial amount of reduction gas on the amount of equilibrium products in
the 4a
Figure reduction
showsofthe0.5 mol Fe2O3 at 900between
relationship °С. the gas utilization rate of isolated reduction gas and
Figure 4a shows the relationship between the gas utilization rate of isolated reduction gas and
the initial amount of reduction gas at 900 ◦ C with varied H2 concentrations. It can be seen from
the initialFigure
amount 4a of reduction
shows gas at 900between
the relationship °С withthe varied H2 concentrations.
gas utilization It can
rate of isolated be seen gas
reduction from Figure
and
Figure theatinitial
at 900 ◦ofC,reduction
4a thatamount as the amount
gas
of reduction
at 900 °С with
gas increases, the gas
varied H2 concentrations.
utilization
It can be seen
rateFigure
of isolated
4a that 900 °С, as the amount of reduction gas increases, the gas utilization rate of from
isolated H2 and
H2 and isolated
4a that CO
°С, are 100% at the Ireduction
stage. The gasutilization rates of H2 and CO at isolated
the II stage drop to
isolated COatare
900100% asatthe
theamount
I stage. of The utilization increases,
rates oftheH2gas
andutilization
CO at the rate
II of
stage dropHto 2 and
76.87%
76.87% and
isolated 71.71%,
CO are respectively.
100% at the I The
stage. utilization
The rates
utilization of
rates Hof and CO at the III stage remain
2 H2 and CO at the II stage drop to 76.87% unchanged.
and 71.71%, respectively. The utilization rates of H2 and CO at the III stage remain unchanged. The
The utilization
and 71.71%,rate of H andThe
respectively. COutilization
at the IVrates stageofdecreases
H2 and COtoat37.58% and 31.46%.
the III stage The gas utilization
remain unchanged. The
utilization rate of H2 and2 CO at the IV stage decreases to 37.58% and 31.46%. The gas utilization rate
rate atutilization
the V stagerate of H2 and unchanged,
remains CO at the IV stage and at decreases to 37.58%
the VI stage and 31.46%.
continues The gasThe
to decline. utilization
increase rateof the
at the V stage remains unchanged, and at the VI stage continues to decline. The increase of the amount
amount at the ofVreduction
stage remains gas unchanged,
in the I, III,and andatVthe VI stage
stages continues
is used to decline.
for the reductionThereaction,
increase ofsothetheamount
utilization
of reduction
of gas gas
reduction in the
in I, III,
the I, and
III, andV Vstages
stages isis used
used for
for thereduction
the reductionreaction,
reaction, so so the
the utilization
utilization rateofrate
rate remains unchanged, and the initial H2 concentration does not affect the utilization rate H2
remains unchanged, and the initial H 2 concentration does not affect the utilization rate of H2 and CO
remains unchanged, and the initial H2 concentration does not affect the utilization rate of H2 and CO
and CO in these three stages. In the II, IV, and VI stages, no reduction reaction occurs, as the initial
in these threethree
in these stages. In the
stages. II, II,
In the IV,IV,
andand VIVIstages,
stages,no no reduction reaction
reduction reaction occurs,
occurs, as the
as the initial
initial gas amount
gas amount
gas amount increases, the H2 and CO utilization rates decrease. Meanwhile, the higher the initial H2
increases, the H
increases, 2 and
the H2 andCOCO utilization
utilization rates
ratesdecrease.
decrease. Meanwhile,
Meanwhile, the thehigher
higherthethe initial
initial H2 concentration
H2 concentration
concentration is, the smaller the Hrate
2 utilization rate is, and COthe greater the CO utilization rate is.
is, theis,smaller
the smaller
the the H2 utilization
H2 utilization rate is,is,and
andthe the greater
greater the
the COutilization
utilization rate is. is.
rate

(a) (b)

Figure 4. The effect of(a)the initial amount of reduction gas on gas utilization(b)
rate in the reduction of
◦
0.5 mol Fe2 O3 at 900 C with varied H2 concentrations: (a) utilization rate of isolated reduction gas;
(b) utilization rate of H2 + CO mixture gas.
Energies 2020, 13, x FOR PEER REVIEW 7 of 13

Figure 4. The effect of the initial amount of reduction gas on gas utilization rate in the reduction of
Energies
0.5 2020, 13,2O
mol Fe 1986
3 at 900 °С with varied H2 concentrations: (a) utilization rate of isolated reduction gas; (b) 7 of 13

utilization rate of H2 + CO mixture gas.

The coincident points can be observed in Figure 4a at the reduction reaction occurring stages,
The coincident points can be observed in Figure 4a at the reduction reaction occurring stages,
which means that the initial concertation of H2 or CO does not affect the utilization rate of isolated
which means that the initial concertation of H2 or CO does not affect the utilization rate of isolated
gas, namely the water-gas shift reaction does not affect the utilization rate of isolated gas in gas-based
gas, namely the water-gas shift reaction does not affect the utilization rate of isolated gas in gas-based
direct ironmaking.
direct ironmaking.
It can be seen from Figure 4b that at the II, IV, and VI stages in which no reduction reaction has
It can be seen from Figure 4b that at the II, IV, and VI stages in which no reduction reaction has
occurred and at the I stage in which Fe O are reduced to Fe O , the points of the H + CO mixture
occurred and at the I stage in which Fe22O33are reduced to Fe33O4,4 the points of the H22+ CO mixture
utilization rate overlap, indicating that the H concentration and the amount of reduction gas have no
utilization rate overlap, indicating that the H22 concentration and the amount of reduction gas have
effect on H + CO mixture utilization rate of reduction gas in these four stages. In the III and V stage,
no effect on2 H2 + CO mixture utilization rate of reduction gas in these four stages. In the III and V
the 11 lines of the H + CO mixture utilization rate level are displayed in parallel, indicating that the
stage, the 11 lines of 2the H2 + CO mixture utilization rate level are displayed in parallel, indicating
H concentration has a linear effect on the H2 + CO mixture utilization rate. Since the initial reduction
that2 the H2 concentration has a linear effect on the H2 + CO mixture utilization rate. Since the initial
gas is composed of H2 and CO, namely ϕin H2
+ ϕin = 100%, so
H2ϕ in + ϕ in =100% , so
reduction gas is composed of H2 and CO, namely H2 H2

in in in in
ηH η = ϕ=CO ηCO
ϕ COηCO++ϕ
ϕHin η = ηCO （ϕ
ϕ Hin+ (η 2）− ηCO )
H 2η HH2=ηCO + ηH
H 2-ηH
(19)
(19)
2 +CO
H 2 + CO 2 2 2 2 CO

ItItisisknown
known from Figure
Figure4a4athat
thatthe
thegas
gasutilization
utilizationrate of of
rate isolated
isolatedreduction
reductiongasgas
in the
in III
theand
III V stage
and V
is independent of the amount of reduction gas and the reduction gas concentration.
stage is independent of the amount of reduction gas and the reduction gas concentration. From From Formula (19),
it can be (19),
Formula observed
it canthat the H2 + CO
be observed mixture
that the H2 utilization
+ CO mixture rate utilization
is proportionalrate to the initial H2 concentration
is proportional to the initial
Hof2 concentration
the reduction gas. The
of the H2 + COgas.
reduction mixture
The H utilization rate at 900
2 + CO mixture
◦ C is positively related to the initial
utilization rate at 900 °С is positively
H2 concentration,
related to the initialasHshown in the circle
2 concentration, in Figure
as shown 4b. circle in Figure 4b.
in the

3.1.2.Energy
3.1.2. EnergyConsumption
Consumption
Figure55shows
Figure showsthetheeffect
effectofofthe
theinitial
initialamount
amountofofreduction
reductiongas gasononthe
theenergy
energyconsumption
consumptionfor for
the reduction of 0.5 mol Fe O at 900 ◦ C with varied H concentrations. The X-axis is the increasing
the reduction of 0.5 mol Fe22O3 3at 900 °С with varied H2 2concentrations. The X-axis is the increasing
reduction gas,
reduction gas, and
andthetheY-axis is the
Y-axis is energy consumption
the energy for thefor
consumption corresponding definition.
the corresponding The horizontal
definition. The
dashed line is 0, ∆H < 0 is exothermic, and ∆H > 0 is endothermic; the oblique dashed
horizontal dashed line is 0, ΔH < 0 is exothermic, and ΔH > 0 is endothermic; the oblique dashed line is shown
lineas
the energy consumption of the system when 0.5
is shown as the energy consumption of the system when2 0.5mol Fe O is completely reduced.
3 mol Fe2O3 is completely reduced.

(a) (b)

Figure 5. Cont.
Energies 2020, 13, 1986 8 of 13
Energies 2020, 13, x FOR PEER REVIEW 8 of 13

(c) (d)
Figure 5. The effect of the initial amount of reduction gas on energy consumption of the reduction of
Figure 5. The effect of the initial amount of reduction gas on energy consumption of the reduction of
0.5 mol Fe2O3 at 900 °С with varied H2 concentrations: (a) reaction heat; (b) heat input; (c) heat output;
0.5 mol Fe2 O3 at 900 ◦ C with varied H2 concentrations: (a) reaction heat; (b) heat input; (c) heat output;
(d) total heat.
(d) total heat.

It
It can
can be be seen
seen from Figure 5a
from Figure that the
5a that the change
change of the reaction
of the reaction heatheat of the system
of the system occurs
occurs in in the
the
reduction
reduction reaction
reaction stages
stages I, I, III
III and
and V. According to
V. According to the
the calculation
calculation principle,
principle, the the reaction
reaction heatheat ofof the
the
latter stage includes the reaction heat of all the previous stages, that is, the reaction heat of stage Ⅲ
latter stage includes the reaction heat of all the previous stages, that is, the reaction heat of stage III
includes
includes the the stages
stages I,I, IIII and
and III, III, and
and thethe reaction
reaction heatheat of of stage
stage VVincludes
includesthe thestages
stagesI,I,II,II,III,
III,IVIVand
andV. V.
The reaction heat of the I stage is an exothermic reaction, and the larger
The reaction heat of the I stage is an exothermic reaction, and the larger the initial H2 concentration is, the initial H 2 concentration

is,
thethe smaller
smaller thethe exothermic
exothermic amount
amount is. At
is. At thethe III stage,
III stage, as the
as the amountamount of reduction
of reduction gas gas increases,
increases, the
the reaction
reaction heat changes
heat changes from an from an exothermic
exothermic reaction to reaction to an endothermic
an endothermic reaction for an reaction for an H2
H2 concentration
concentration
of 10% to 100%, of and
10%the to 100%,
larger and the larger
the initial the initial H2 concentration
H2 concentration is, the greater is, thethe greater
reaction theis.
heat reaction
In the
heat is. In the V stage, for H 2 concentration of 50%–100%, the reaction heat gradually increases with
V stage, for H2 concentration of 50–100%, the reaction heat gradually increases with the growth of
the
the growth
amountof ofthe amountgas,
reduction of reduction
and the largergas, and the larger
the initial the initial H2 concentration,
H2 concentration, the greater thethe greaterheat,
reaction the
reaction heat, and the maximum reaction heat is 31.747 kJ by pure
and the maximum reaction heat is 31.747 kJ by pure H2 reduction. For H2 concentration of 50%, the H 2 reduction. For H2 concentration

of 50%, heat
reaction the reaction
increasesheat veryincreases
slowly as very slowly of
the amount asreduction
the amount of reduction
gas raises, and thegas raises, and
maximum the
reaction
maximum
heat is 8.874reaction
kJ. For H heatconcentration
is 8.874 kJ. For of 0%H2 toconcentration
40%, the reaction of 0%heat to 40%,
increasesthe reaction
with theheatgrowth increases
of the
2
with the growth of the amount of reduction gas. The increase gradually
amount of reduction gas. The increase gradually decreases, and the larger the initial H2 concentration decreases, and the larger the
initial H2 concentration
is, the greater the endothermic is, the greater
energy is. theTheendothermic
maximumenergy reactionis.heat
Theoccurs
maximum at purereaction heat occurs
CO reduction and
at
is −18.445 kJ, and the minimum reaction energy occurs at 30% H2 concentration and is 1.452 kJ. H2
pure CO reduction and is −18.445 kJ, and the minimum reaction energy occurs at 30%
concentration
The sensible andheatis 1.452
input kJ.of 0.5 mol Fe O from 25 ◦ C to 900 ◦ C is 62.737 kJ. When the amount of
2 3
The sensible
reduction gas is 4 heat
mol and input of 0.5the
5 mol, mol Fe2O3 from
sensible 25 °С to
heat inputs of900
pure °СCO is 62.737
from 25 kJ.◦ C
When
to 900the◦ Camount
and from of
reduction
◦ gas◦ is 4 mol and 5 mol, the sensible heat inputs of pure
25 C to 900 C are 109.944 kJ and 137.43 kJ, respectively, and the sensible heat inputs of pure H2 gas CO from 25 °С to 900 °С and from
25
from°С 25to ◦900C to°С900are◦ C109.944 kJ andkJ137.43
are 104.384 kJ, respectively,
and 130.480 and the sensible heat inputs of pure H2 gas
kJ, respectively.
fromFigure25 °С to 5b900shows°С arethat104.384
the larger kJ and
the 130.480
amountkJ, respectively.
of reduction gas, the greater the heat input of system.
Figure 5b shows that the larger the
Under the same reduction gas condition, the greater the initial amount of reduction gas,
H2the greater the heat
concentration, the input
greater of the
system.
heat
Under
input ofthe same When
system. reduction gas condition,
the amount the greater
of reduction the initial
gas is greater than H42 concentration,
mol, the heat input the greater the heat
of the reduction
input
systemofbysystem.each H2When the amount
concentration of reduction parallel,
is approximately gas is greater
because than
the 4sensible
mol, the heatheat input
of gas andofsolid
the
reduction system by each H 2 concentration is approximately parallel, because the sensible heat of gas
are much larger than the reaction heat of the system. When the amount of reduction gas is 4 mol,
and solid are much
the maximum value larger
of heatthan input theis reaction
198.869 kJ heat
with ofpure
the system. When and
H2 reduction, the amount
the minimum of reduction
value ofgas heatis
4input
mol,isthe maximum value of heat input is 198.869 kJ with pure H 2 reduction, and the minimum value
158.387 kJ with pure CO reduction. When the amount of reduction gas is 5 mol, the maximum
of
valueheatofinputheat is 158.387
input kJ withkJpure
is 222.355 withCO reduction.
pure When the
H2 reduction, andamount
the minimum of reductionvaluegas is 5 mol,
of heat inputtheis
maximum value of heat input is 222.355 kJ with pure H 2 reduction, and the minimum value of heat
181.722 kJ with pure CO reduction. The difference between the maximum and the minimum values are
input
40.482iskJ181.722
and 40.633kJ with pure CO reduction.
kJ, respectively, which are Theapproximately
difference between the same.the maximum and the minimum
values are 40.482 kJ and 40.633 kJ, respectively, which
It can be seen from Figure 5c that the more reduction gas there is, the are approximately the same.the recovery heat
greater
output It can
willbe be.seen
Under from theFigure 5c that thegas
same reduction more reduction
amount gas there
condition, is, thethe
the larger greater
initialthe
H2 recovery
concentration heat
output will be. Under the same reduction gas amount condition, the larger the initial H2 concentration
is, the smaller the system recoverable heat is. When the amount of reduction gas is 4 mol, the
maximum absolute value of heat output is −172.066 kJ with pure CO reduction, and the minimum
Energies 2020, 13, 1986 9 of 13

is, the smaller the system recoverable heat is. When the amount of reduction gas is 4 mol, the maximum
absolute value of heat output is −172.066 kJ with pure CO reduction, and the minimum absolute
value of heat output is −163.189 kJ with pure H2 reduction. When the amount of reduction gas is
5 mol, the maximum absolute value of heat output is −202.503 kJ with pure CO reduction, and the
minimum absolute value of heat output is −185.678 kJ with pure H2 reduction. The difference between
the maximum and the minimum values are −8.877 kJ and 16.825 kJ, respectively.
From Figure 5d, it can be seen that for the H2 concentration of 40–100%, the total heat of the
system increases as the initial H2 concentration increases. For the H2 concentration of 0–30%, the
smaller the initial H2 concentration is, the larger the system total heat is. For the H2 concentrations
of 30% and 40%, the optimal amount of reduction gas is 4.4 mol and 4.5 mol, respectively, and the
system total heat is −1.545 kJ and 4.056 kJ, respectively. If the linear difference method is used, when
the system total heat is 0, the H2 concentration is about 32.8%. In addition, after metalized Fe is fully
obtained, increasing the amount of reduction gas will greatly increase the total energy consumption,
which is not worthwhile. At 900 ◦ C, 0.5 mol Fe2 O3 is reduced to 1 mol Fe. The system total heat is
35.680 kJ for pure H2 reduction and −21.527 kJ for pure CO reduction. For other initial concentrations,
the system total heat is in between.

3.2. Effect of Reaction Temperature

3.2.1. Optimal Demand of Reduction Gas

Because the initial concentration and the amount of reduction gas have no effect on the utilization
rate of H2 and CO at the V stage, the amount of reduction gas was set, which was used to calculate
the utilization rate of total gas in the temperature range 790–1100 ◦ C. The conditions were set as
follows: the reduction temperature was 790–1100 ◦ C, and the increment was 10 ◦ C; the initial amount
of reduction gas was 3 mol; the initial gas was composed of H2 and CO, and H2 volume fraction was
0–100%, and the increment was 10%; the total pressure was 101325 Pa; initial amount of solid was
0.5 mol Fe2 O3 .
From the gas utilization rate of H2 and CO, according to the material conservation and enthalpy
change formulas, the optimal demand of reduction gas, reaction heat of the system, heat input of the
system, and heat output of the system can be calculated in turn, as shown in Figures 6 and 7.
Obviously, after the metalized iron was completely gained, increasing the amount of reduction
gas cannot increase the production, so the amount of reduction gas just enough for full reduction was
defined as the optimal demand of reduction gas.
It can be seen from Figure 6a that under the same temperature conditions, the greater the H2
concentration is, the greater the utilization rate of total gas is; at 790–810 ◦ C, the opposite is true.
At 820–1100 ◦ C, for the H2 concentration of 60–100%, a higher temperature corresponds with a greater
the utilization rate of total gas, and a smaller increased amplitude of the utilization rate of total gas.
For the H2 concentration of 0–40%, the higher the temperature is, the smaller the utilization rate of
total gas, and the smaller the effect of temperature on the utilization rate of total gas. The minimum
and maximum utilization rates of total gas are 33.184% (pure CO reduction) and 35.832% (pure H2
reduction) at 850 ◦ C, 31.460% (pure CO reduction) and 37.575% (pure H2 reduction) at 900 ◦ C, and
29.923% (pure CO reduction) and 39.159% (pure H2 reduction) at 950 ◦ C, respectively.
It can be seen from Figure 6b that at 820–1100 ◦ C, for H2 concentration of 60–100%, the higher the
temperature is, the lower the optimal demand for reduction gas is. For the H2 concentration of 0–40%,
the optimal demand for reduction gas is greater as the temperature increases. For the H2 concentration
of 50%, the temperature has little effect on the optimal demand for reduction gas. At 790–820 ◦ C,
the opposite is true. The optimal demand of reduction gas for 0.5 mol Fe2 O3 is 4.186 mol (pure H2
reduction) and 4.520 mol (pure CO reduction) at 850 ◦ C, 3.992 mol (pure H2 reduction) and 4.768 (pure
CO reduction) mol at 900 ◦ C, and 3.831 mol (pure H2 reduction) and 5.013 mol (pure CO reduction) at
950 ◦ C.
Energies 2020, 13, 1986 10 of 13
Energies 2020, 13, x FOR PEER REVIEW 10 of 13

Energies 2020, 13, x FOR PEER REVIEW 10 of 13

(a) (b)
Figure 6. The effect of reduction temperature on the reduction of Fe2O3 at 790–1100 °С with
Figure 6. The effect of reduction temperature on the reduction of Fe2 O3 at 790–1100 ◦ Cvaried H2
with varied H2
concentrations: (a) utilization rate of H2 + CO mixture gas; (b) optimal demand of H2 + CO mixture gas.
(a) rate of H2 + CO mixture gas; (b) optimal demand
concentrations: (a) utilization (b) of H2 + CO mixture gas.
3.2.2. Energy Consumption
Figure 6. The effect of reduction temperature on the reduction of Fe2O3 at 790–1100 °С with varied H2
3.2.2. Energy Consumption
concentrations:
Figure 7 shows(a) utilization
the effect rate of H2 + CO
of reduction mixture gas;on
temperature (b)the
optimal demand
energy of H2 + CO
consumption ofmixture
0.5 mol gas.
Fe2O3
Figure 7 shows
reduction under the
theeffect of reduction
conditions of 790–1100 temperature
°С and varied onHthe energy consumption of 0.5 mol Fe2 O3
2 concentrations.
3.2.2. Energy
reduction under Consumption ◦
It can the conditions
be seen from Figure of 790–1100 C and varied
7a that the temperature hasH concentrations.
a 2small effect on the reaction heat of the
It can Figure 7 shows the effect of reduction temperature on the energyeffect
systembe seen
at from
790–1100 Figure
°С. For 7a
the Hthat the temperature
2 concentration of 0% to has
30%, a small
the reaction heaton
consumption the reaction
is exothermic;
of 0.5 molforheat
Fe2Oof
the 3 the

system H
at2 concentration
790–1100 ◦ C.of For40% theto H100%, the reaction
concentration heat
of
reduction under the conditions2 of 790–1100 °С and varied H2 concentrations. 0%is endothermic.
to 30%, the Taking
reaction 50% H
heat 2 concentration as
is exothermic; for the
an example, the reaction heat per mole of Fe is 5.956 to 10.297 kJ at 790–1100 °С.
H2 concentration
It can be of 40%
seen fromto 100%,
Figure the reaction
7a that heat is endothermic.
the temperature has a small Taking effect on50% the H 2 concentration
reaction heat of theas an
It can be seen from Figure 7b that the sensible heat input of solid Fe2O3 per ◦ C.mole of Fe is 54.988–
system
example, the atreaction
790–1100heat °С. Forper the
moleH2 concentration
of Fe is 5.956 ofto0% to 30%,
10.297 kJ the
at reaction heat
790–1100 is exothermic; for the
76.943 kJ at 790–1100 °С.
H2can
It concentration
be seen of 40%
from to 100%,
Figure the
7bthatthatreaction heat is endothermic.
the sensible Taking 50%Fe2HO2 3concentration
moletoofasFe is
It can be seen from Figure 7c at 790–1100 °С, theheatlargerinput of Hsolid
the initial 2 concentration per
correlates
an example,
54.988–76.943 the
kJ at reaction
790–1100 heat
◦ per mole of Fe is 5.956 to 10.297 kJ at 790–1100
C. of reduction gas. Taking 900 °С as an example, for every 10% increase in °С.
the smaller sensible heat input
H2Itconcentration,
It can
can be seen from
be seen fromtheFigure
Figureheat
sensible 7b that
7c that input the sensible◦ heat
of reduction
at 790–1100 gasthe
C,
input
per mole
larger
ofofsolid Fe2O3 per mole
Fe decreases
the initial Hby 2.3–3.0 ofkJ.
2 concentration
Fe is 54.988–
correlates
76.943 kJ It at
can 790–1100
be seen °С.
from Figure 7d that at 790–980 °С, the larger
◦ the initial H 2 concentration is, the
to the smaller sensible heat input of reduction gas. Taking 900 C as an example, for every 10% increase
It can the
greater be seen
heat from
inputFigure 7c that at °С,
is; at 990–1100 790–1100 °С, the is
the opposite larger
true.the initial50%
Taking H2 concentration
H2 concentration correlates
as an to
in H2the
concentration,
smaller sensible the sensible
heat input heat input gas.of reduction 900gas peranmole of Fe decreases by 2.3–3.0 kJ.
example, the minimum and of reduction
maximum of theTaking
heat input °Сper as mole example,
of Fe for161.920
are every 10%
◦ C, the larger the initial H concentration is, the greater
kJ at increase
790 °С in
It can be
H2 reduction seen
concentration, from Figure
the sensible
and 231.927 7d
kJ at heat that
1100 input at 790–980
of reduction
°С reduction, gas per mole of Fe decreases
respectively. 2 by 2.3–3.0 kJ.
the heat input is; at 990–1100 ◦ C, the opposite is true. Taking 50% H concentration as an example,
It can
It canbebeseen
seen from
fromFigure
Figure 7d7e that 790–980°С,
that at 790–980 °С,the thehigher
largerthe thetemperature
initial
2 H2 concentration
is, the greater is, thethe
the minimum
greater theand
heat output heat maximum
is; input is; atof990–1100
the greater theinitial
the heat°С,
Hinput the per moleis
opposite
2 concentration, oftrue.
the Fe are 161.920
Taking
smaller heat50% kJ
outputH2at 790 ◦ C reduction
concentration
is. Taking 50% asH2 an and
concentration
example,
231.927 kJ at 1100 ◦C asreduction,
the minimum an example, the minimum
and maximum
respectively. of andthe maximum
heat inputofper the mole
heat input
of Feper mole
are of Fe are
161.920 kJ 155.982
at 790 °С
kJ at 790and
reduction °С reduction
231.927 kJand 217.666
at 1100 kJ at 1100 °Сrespectively.
reduction,
◦ C, therespectively.
It can be seen from Figure 7e °Сthat reduction,
at 790–980 higher the temperature is, the greater the
It can be seen from Figure 7e
heat output is; the greater the initial H2 concentration, that at 790–980 °С, thethe higher the temperature
smaller heat output is,is.
theTaking
greater 50%
the H
2
heat output is; the greater the initial H2 concentration, the smaller heat output is. Taking 50% H2
concentration as an example, the minimum and maximum of the heat input per mole of Fe are 155.982 kJ
concentration as an example, the minimum and maximum of the heat input per mole of Fe are 155.982
at 790 ◦ C reduction and 217.666 kJ at 1100 ◦ C reduction, respectively.
kJ at 790 °С reduction and 217.666 kJ at 1100 °С reduction, respectively.

(a) (b)

(a) (b)

Figure 7. Cont.
Energies 2020, 13, 1986 11 of 13

Energies 2020, 13, x FOR PEER REVIEW 11 of 13

(c) (d)

(e) (f)
Figure 7. The effect of reduction temperature on energy consumption of the reduction of 0.5 mol Fe2O3
Figureat 7. The effect
790–1100 of reduction
°С with varied H2 temperature
concentrations: on(a)
energy consumption
reaction of theheat
heat; (b) sensible reduction
input ofof 0.5 Fe
solid mol Fe O
2O3; 2 3
at 790–1100 ◦ C with varied H concentrations: (a) reaction heat; (b) sensible heat input of solid Fe O ;
(c) sensible heat input of reduction
2 gas; (d) heat input; (e) heat output; (f) total heat. 2 3
(c) sensible heat input of reduction gas; (d) heat input; (e) heat output; (f) total heat.
From Figure 7f, it can be seen that at 790–1100 °С, for the H2 concentration of 90–100%, the total
From ◦ C, for the H concentration of 90–100%, the total
heat isFigure
more than 7f, it can itbedecreases
0 and seen that asat
the790–1100
temperature increases; for 2 H2 concentration of 40–80%, the
heat total
is more
heatthan
is also0 and it decreases
greater than 0 and as the temperature
it increases with increases;
the increasing for Htemperature.
2 concentration For the of 40–80%,
H2
concentration of 30%, the total energy consumption per ton of iron
the total heat is also greater than 0 and it increases with the increasing temperature. For the at 790–980 °С is less than 0, and it H2
is more than 0 at 980–1100 °С.
concentration of 30%, the total energy consumption per ton of iron at 790–980 C is less than 0, and it is ◦

more thanWhen the H2 concentration

0 at 980–1100 ◦ C. is 100%, the heat input per ton of iron is 115.551 kgce at 790 °С
reduction and 133.439 kgce at 1100 °С reduction, the total heat per ton of iron is 22.850 kgce at 790 °С ◦
When the H2 concentration is 100%, the heat input per ton of iron is 115.551 kgce at 790 C
reduction and 20.694 kgce at 1100 °С reduction.
reduction and 133.439 kgce at 1100 ◦ C reduction, the total heat per ton of iron is 22.850 kgce at 790 ◦ C
When the CO concentration is 100%, the heat input per ton of iron is 83.380 kgce at 790 °С
reduction and and20.694 kgcekgceat 1100 ◦ C reduction.
reduction 155.553 at 1100 °С reduction, the total heat input per ton of iron is −14.495 kgce at
When the CO concentration
790 °С reduction and −10.996 kgce isat100%,
1100 °Сthe heat input per ton of iron is 83.380 kgce at 790 ◦ C
reduction.
reductionWhen
and 155.553 kgce at 1100is 30%,◦ C reduction, the total heat input per ton of iron −14.495
the H2 concentration the heat input per ton of iron is 92.640 kgce at 790is°С reductionkgce at
◦
790 C andreduction
146.405 kgce and at −10.996
1100 °Сkgce ◦
at 1100theCtotal
reduction, reduction.
heat input per ton of iron is −3.746 kgce at 790 °С
reduction
When the and 2.113 kgce at is
H2 concentration 1100°С
30%, thereduction. So, when
heat input per ton theofH 2 concentration
iron is 92.640 kgce is at
30%790at◦ C
973 °С
reduction
reduction,
and 146.405 the at
kgce total heat C
1100 ◦ input per ton ofthe
reduction, iron is zero.
total heat input per ton of iron is −3.746 kgce at 790 ◦ C
reductionItandcan2.113
be seen kgce from Figure
at 1100 ◦C 8 that at 790–1100
reduction. So, when°С, the
the Hlarger the initial H2 concentration
2 concentration is 30% at 973 C reduction,
◦ is, the
lower the heat recoverable rate is. For the H2 concentration of 0%–30%, the heat recoverable rate is
the total heat input per ton of iron is zero.
greater than 100%. For the H2 concentration of 40%–100%, the heat recoverable rate is less than 100%.
It can be seen from Figure 8 that at 790–1100 ◦ C, the larger the initial H2 concentration is, the lower
For the H2 concentration of 0%–60%, the higher the temperature is, the smaller the heat recoverable
the heat
raterecoverable
is. For the H rate is. For the H2 concentration
2 concentration of 80%–100%, theofhigher 0–30%, thethe heat recoverable
temperature rate iswith
corresponds greater
the than
100%. For the H2 concentration of 40–100%, the heat recoverable rate is less than 100%. For the H2
concentration of 0–60%, the higher the temperature is, the smaller the heat recoverable rate is. For the
H2 concentration of 80–100%, the higher the temperature corresponds with the higher heat recoverable
rate. For the H2 concentration of 70%, the effect of the temperature on the heat recovery rate is small.
Energies 2020, 13, x FOR PEER REVIEW 12 of 13

Energies 2020, 13, 1986 12 of 13

higher heat recoverable rate. For the H2 concentration of 70%, the effect of the temperature on the
heat recovery rate is small.

Figure 8. The effect of reduction temperature on the heat recovery rate of the reduction of 0.5 mol
Figure 8. The effect of reduction temperature on the heat recovery rate of the reduction of 0.5 mol
Fe2 O3 at 790–1100 ◦ C with varied H2 concentrations.
Fe2O3 at 790–1100 °С with varied H2 concentrations.
4. Conclusions
4. Conclusions
Through the analysis of the energy consumption of the reduction of Fe2 O3 by CO and H2 , the
Through
following the analysis
conclusions of the energy consumption of the reduction of Fe2O3 by CO and H2, the
are drawn:
following conclusions are drawn:
(1) In the stage of the reduction reaction, the utilization rates of H2 and CO do not change with
(1) In the
the increase in stage of the reduction
the amount of reduction reaction, the increase
gas or the utilization rates
in the of H2Hand
initial CO do not change with
2 concentration.
the increase in the amount
◦ of reduction gas or the increase in the initial H concentration.
(2) At 790–980 C, the heat input per ton of iron increases with the increase in the initial H2
2

(2) At 790–980
concentration; °С, the◦ C,
at 980–1100 heat
theinput per iston
opposite of iron increases with the increase in the initial H2
true.
concentration; at 980–1100
(3) At 790–1100 ◦ C, for°С,
thethe
H2opposite is true.of 40–100%, the total heat per ton of iron increases
concentration
(3) At 790–1100 °С, for the H 2 concentration
with the increase in the initial H2 concentration; for of 40%–100%, the total heat
the H2 concentration per tonthe
of 0–30%, of iron
totalincreases
heat per
withofthe
ton ironincrease in the
is negative, andinitial H2 concentration;
the absolute for the
value increases H2the
with concentration
increase of theof initial
0%–30%, the total heat
H2 concentration.
per ton of iron is negative, and the absolute value increases with the increase of the initial H2
Author Contributions: Conceptualization, H.G., and J.G.; methodology, B.L.; software, B.L. and W.Y.; data
concentration.
curation, writing—original draft preparation, writing—review and editing, G.S. All authors have read and agreed
to the published version of the manuscript.
Author Contributions: Conceptualization, H.G., and J.G.; methodology, B.L.; software, B.L. and W.Y.; data
Funding: This work was supported
curation, writing—original by the Science
draft preparation, and Technology
writing—review Program
and editing, G.S.ofAll
Sichuan
authorsProvince,
have readChina
and
(Grant NO.·18SYXHZ0069).
agreed to the published version of the manuscript.
Conflicts of Interest: The authors declare no conflict of interest.
Funding: This work was supported by the Science and Technology Program of Sichuan Province, China (Grant
NO. 18SYXHZ0069).
References
Conflicts of Interest: The authors declare no conflict of interest.
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