Thermodynamic Model of COREX Melter Gasifier Using FactSage? and Macro Facility 2018 C. Srishilan.pdf

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ThermodynamicModelofCOREXMelterGasifier
UsingFactSageäandMacroFacility

Inthecurrentstudy,thethermochemicalmodeloftheCOREXmeltergasifierhasbeen
developedusingtheFactSageäthermodynamicsoftware,
meltergasifierwasconceptuallydividedintovariousequilibriumzonesdealingwiththe

-metal,
slag,,
onthefinalhotmetal,slag,andreducinggas,
variationsintheprocessparametersforthedifferentindustrialcoalgradesusedintheCOREX
,ash,andthemoisturecontentsofthe
coalonthehot-metalandthereducinggascompositionshavebeenreported.
/s11663-018-1476-4
ÓTheMinerals,Metals&MaterialsSocietyandASMInternational2018
,and3000plantswerescaledtoindustriallevelsat
SouthAfrica’sISCOR(1970),SouthKorea’sPOSCO
SMELTINGreductionisanapproachotherthanthe(1989),andPugang’sBaoshanironandsteelgroup
directreductionrouteamongtheprocessesofreducing(2007).[2]
:(1)areduction
desiredendproductisliquidhotmetalratherthanshaft,toreducetheoreintoDRI;and(2)amelter
spongeiron,whereasthelatteristheresultingendgasifiertoconductfinalreductionandmeltingofDRI,
.
stepslikesinteringandpelletizationandtheuseofThelumporeandpelletsarereducedtoDRIof~85pct
metallurgicalcokeofhighergradeforthereductionmetallizationinacounter-currentreactorknownasthe
processaretheprominentrequirementsoftheconven-~850°Candfed


oreusingnon-
~800°C,andpartiallyreducestheorebefore
Hasanbeigietal.[1]havereviewedtheavailablealterna-exitingfromthetopofthefurnaceat~450°
,alongwithcokeischargedfromthetopintothemelter
HYL,ITmk3,etc.,underthedirectreductionprocesses,,oxygenwhichisinjected
whichproducethedirectreducediron(DRI);andviatuyeressituatedatthebottomaroundthecircum-
COREX,FINEX,Tecnored,etcunderthesmeltingferenceofthemeltergasifierformsCObyreactingwith

COREXisoneofthecommerciallyrecognizedsmeltingachievedbystrippingCO2fromthetopgasand


andVoestAlpineInternational(VAI)developedtherecycled,basedontheCO/CO2ratioofthegas,
KohlReduktion(KR)-1000,determinestheefficiency.[3]
Manyproblemsrelevanttotheindustrialapplication
andacademicinteresthavebeenexploredsincethe

modeledbynumerousresearchers,toestimatethe
-
DepartmentofMetallurgicalandMaterialsEngineering,Indian
InstituteofTechnology,Madras(IITMadras),Chennai600036,(i)staticelemental
-mail:******@-basedmodels,[4–7]
ManuscriptsubmittedJuly24,(ii)steady-statetransportphenomena-based
METALLURGICALANDMATERIALSTRANSACTIONSB:.
models,[8–11]conceptualizingtheCOREXmeltergasi-otherprocessessuchasRHdegassingprocesshavebeen
.[5]havedevelopedathermochemicalmodeledbyPandeyetal.,[23]andtherotarycementkiln
modeltopredictthecoalandthefluxrequirementbasedprocesshasbeenmodeledbyThompsonetal.[24]using
onthequalityofrawmaterialanddesiredhot-metaltheFactSagemacrofacilityforlinkingequilibrium
-statemodelhasbeendevelopedbyreactorstothespreadsheetrepresentations.
Paletal.[10]which,accuratelypredictedthecompositionInthecurrentstudy,athermodynamicmodel,devel-
andtemperatureofreducinggasonlybutdidnotopedusingFactSageäandthemacroprogramming
successfullypredictthehot-metalandtheslagcompo-facility,isusedtostudythemeltergasifierofthe
.[12]
calculatetheracewayadiabaticflametemperaturegasifier,consistingofvariousreactionzones,either
(RAFT),-
othernumericalcodeshavebeenusedtomodelthepositionsandquantitiesofthehotmetal,slag,and
meltergasifierindividualzones,suchasthefreeboardreducinggasgeneratedfordifferentdegreesofmetal-
zone,[13]themovingbed,[14,15]thehearth,[16]andthelization,withraw-
cohesivezone.[17]modeldeterminestheeffectsofdifferentcoalgrades
FactSageäisausefultoolforthermodynamicmod-used.

researchersformodelingthealternateironmaking
-
beenpredictedusingthethermodynamicmodelsoftheMELTERGASIFIERBASEDONFACTSAGE
process.[18–21]Srivastavaetal.[18]developedamodelfor
meltergasifieroftheCOREXprocesstopredicttheSiTheproposedmodelconsidersnineequilibrium/
,whichwasnotablestoichiometricreactors,namelyR1,R2,R3,R4,R5,
topredicttheexactgascomposition,wasfurtherR6,R7,R8,andR9,
developedbyKadrolkaretal.[20]byincorporatingaenergyminimizationroutinesofFactSageä
separatemoduleforreductionshafttopredictprecisely(CRCT,Montreal,Quebec,Canada)[25]wereusedforall
,FToxid,andFTmiscdata-
-
odssuchasrotaryhearthprocesshavebeenmodeledbysolutionandcompounddatabasecontainthedatafor
Kumaretal.[22]usingFactSageä
2

,andcompounddatabasecontainthedataformetaland
—Flowsheetofthemacroprogramformeltergasifier.
METALLURGICALANDMATERIALSTRANSACTIONSB:.

oxidecomponents,

FeLQsolutioncontainstheliquidFewithotherburnedusingsecondaryoxygencomingfromadust
elements,
model.[26]Thisphaseisbettersuitedforcalculationsreactiontakesplaceinthefreeboardzonealongwiththe
involvingironmakingandsteelmakingprocesses,eval-decompositionoftarandpartialgasificationofchar
uatedandoptimizedforiron-.
stoichiometricsolidandliquidcompoundsandsolutionTheadiabaticcombustionofthecharfromreactorR2
databasesareevaluated/
group.[27]
-R6,at1773Kand3bar,receivesthemixtureof
opedusingthemacroprogram-basedapproachtometallizedDRI,heatedflux,andganguecompounds

loopedcomputationfortheiterativevaluestoapproachfromthereactorR6afterbeingreducedissmeltedinthe

pyrolysisandgasificationphenomena,whereasthethisreactortoproducethehot-metalandslagcom-
-currentflow,betweenthesolidand
iron(DRI)receivedfromthereductionshaftaregasreactants,issimulatedbythesequentiallyarranged
.
asreactors,R3andR5,forwhichDHwasconsideredtoThedegreeofDRImetallizationreceivedfromthe
bezero,
GasstreamsfromthereactorsR1,R2,R5,andR6werereactorR5,whichmodelstheregionjustabovethe
-
aturesandpressuresofthesereactorsareshowninhot-metalandslagcompoundsobtainedinsmelting
,reactorR4,andproduceshotmetalandslagassolutions
devolatilizationofcoal,partialgasificationofchar,
anddecompositionofvolatilematteroccurredinsolutionsfromreactorR5arecooledtolowtempera-
reactorsR1,R2,,respectively.
(PerOneTonofHotMetal)
ReactantElements/ComponentsProductElements/Components
CoalMoles/ThmAshMoles/ThmGasMoles/ThmSolidMoles/Thm
++++02
++++02
++++02
++–+02
+++04
++02(P2O5)+00
+++02
(PerOneTonofHotMetal)
ReactantElements/ComponentsProductElements/Components
SolidMoles/ThmGasMoles/ThmGasMoles/ThmSolidMoles/Thm
++++02
+++02
++02
++02
++04
(P2O5)+00(P2O5)+00
++02
METALLURGICALANDMATERIALSTRANSACTIONSB:.
(PerOneTonofHotMetal)
ReactantElements/Components
SolidMoles/ThmCokeMoles/ThmAshMoles/ThmGasMoles/Thm
++++04
+++01
++01
++02
+04
(P2O5)+00
+02
ProductElements/Components
GasMoles/ThmLiquidMoles/Thm
-+02
+03
+04
+03
+02
-01
+02
(P2O5)+00
+02
+02
(PerOneTonofHotMetal)
ReactantElements/Components
GasMoles/ThmLiquidMoles/ThmSolidMoles/ThmCokeMoles/ThmAshMoles/Thm
++++00
++++00
+++00
+++00
++03
+00
++03
(P2O5)++01
++01
++04
ProductElements/Components
GasMoles/ThmLiquidMoles/Thm
++01
++03
+02
+03
+00
+03
+01
+01
+04
+02
GasesfromtheoutputstreamsofreactorsR1,R2,R5,Themacroprogram-basedmodeliteratesand
andR6areequilibratedinanotherreactorR7(1303K,approachestoequilibriuminreactorR4,whichisin
3bar),-currentflowofchargeandgaswithreactorR6.
METALLURGICALANDMATERIALSTRANSACTIONSB:.