Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations

In combination with a complex global market environment, the iron and steel industry is dealing with increasing demands for reduction of environmental and greenhouse emissions. Alternative iron making technologies such as Corex® and Finex® can offer solutions for these challenges. The melter gasifie...

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Main Authors: Andreas Spanlang, Bernd Weiss, Johann Wurm, Walter Wukovits
Format: Article
Language:English
Published: AIDIC Servizi S.r.l. 2018-08-01
Series:Chemical Engineering Transactions
Online Access:https://www.cetjournal.it/index.php/cet/article/view/544
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spelling doaj-0372dcd9f139402cb8096f6ddb636fcb2021-02-17T20:59:27ZengAIDIC Servizi S.r.l.Chemical Engineering Transactions2283-92162018-08-017010.3303/CET1870114Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations Andreas SpanlangBernd WeissJohann WurmWalter WukovitsIn combination with a complex global market environment, the iron and steel industry is dealing with increasing demands for reduction of environmental and greenhouse emissions. Alternative iron making technologies such as Corex® and Finex® can offer solutions for these challenges. The melter gasifier is the central unit operation of these well-established alternative iron making processes. Both offer considerable advantages with respect to economic characteristics and environmental emissions. Similar to the conventional iron making process of the blast furnace route, a variety of different input materials is required for these processes including coal, coke, lump or fine ore, iron ore pellets as well as limestone and dolomite. Most of these raw materials also carry minor amounts of unwanted compounds such as alkali or zinc-based species. The presence of these materials inside a melter gasifier can lead to instability, problematic process conditions and refractory damages. A better understanding of the distribution of these problematic species is therefore of great importance to plant manufacturers and operators. A variety of different multiphase reactions are responsible for the distribution of trace materials within the melter gasifier. In order to get a better understanding of the complex nature of these reactions, a thermodynamic investigation was carried out using calculation routines of HSC Chemistry and FactSage. Based on the findings of this investigation, a multi-zone model was developed using the simulation platform of the gPROMS ModelBuilder®. The model is separated into distinct reaction zones across the height of the melter gasifier to depict the main iron ore reduction process as well as the governing reactions of trace material components. Validation of the model was carried out using reference data of existing plants. The model described in this work is used to analyse the behaviour of trace materials within a melter gasifier. Due to the highly integrated material flows of the Corex® and Finex® iron making processes, the impact on their operational characteristics can be investigated as well. Through this it is possible to optimise the raw material input of these processes, potentially leading to reduced fuel demand and environmental emissions. https://www.cetjournal.it/index.php/cet/article/view/544
collection DOAJ
language English
format Article
sources DOAJ
author Andreas Spanlang
Bernd Weiss
Johann Wurm
Walter Wukovits
spellingShingle Andreas Spanlang
Bernd Weiss
Johann Wurm
Walter Wukovits
Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations
Chemical Engineering Transactions
author_facet Andreas Spanlang
Bernd Weiss
Johann Wurm
Walter Wukovits
author_sort Andreas Spanlang
title Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations
title_short Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations
title_full Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations
title_fullStr Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations
title_full_unstemmed Modelling of Trace Material Flow Distribution in a Melter Gasifier based on Thermodynamic Multiphase Equilibrium Calculations
title_sort modelling of trace material flow distribution in a melter gasifier based on thermodynamic multiphase equilibrium calculations
publisher AIDIC Servizi S.r.l.
series Chemical Engineering Transactions
issn 2283-9216
publishDate 2018-08-01
description In combination with a complex global market environment, the iron and steel industry is dealing with increasing demands for reduction of environmental and greenhouse emissions. Alternative iron making technologies such as Corex® and Finex® can offer solutions for these challenges. The melter gasifier is the central unit operation of these well-established alternative iron making processes. Both offer considerable advantages with respect to economic characteristics and environmental emissions. Similar to the conventional iron making process of the blast furnace route, a variety of different input materials is required for these processes including coal, coke, lump or fine ore, iron ore pellets as well as limestone and dolomite. Most of these raw materials also carry minor amounts of unwanted compounds such as alkali or zinc-based species. The presence of these materials inside a melter gasifier can lead to instability, problematic process conditions and refractory damages. A better understanding of the distribution of these problematic species is therefore of great importance to plant manufacturers and operators. A variety of different multiphase reactions are responsible for the distribution of trace materials within the melter gasifier. In order to get a better understanding of the complex nature of these reactions, a thermodynamic investigation was carried out using calculation routines of HSC Chemistry and FactSage. Based on the findings of this investigation, a multi-zone model was developed using the simulation platform of the gPROMS ModelBuilder®. The model is separated into distinct reaction zones across the height of the melter gasifier to depict the main iron ore reduction process as well as the governing reactions of trace material components. Validation of the model was carried out using reference data of existing plants. The model described in this work is used to analyse the behaviour of trace materials within a melter gasifier. Due to the highly integrated material flows of the Corex® and Finex® iron making processes, the impact on their operational characteristics can be investigated as well. Through this it is possible to optimise the raw material input of these processes, potentially leading to reduced fuel demand and environmental emissions.
url https://www.cetjournal.it/index.php/cet/article/view/544
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