Application of Solid Bed Combustion Models

Sangmin Choi Department of Mechanical Engineering KAIST

Thermal Engineering Lab

THERMAL ENGINEERING FOR INDUSTRIES

POWER WASTE INCINERATION

IRON & STEEL

Design Development (Needs & Parameter)

Identification Integrated System Design Design & Off Design Point Operation

Analysis
Modeling of Combustion System Bed Combustion Modeling F l Characterization Fuel Ch t i ti Computational Fluid Dynamics Physical Model Tests Process Simulation Modeling g of Dioxin Emissions

Thermal Engineering Lab

Combustion Modeling of Solid Beds

Combustion of solid fuel bed

C b i of Combustion f the h single i l particle i l +I Interaction i b between the h particles i l Material ate a flow: o Gas, So Solid, d, Multiple u t p e Co Componenets po e ets Reactions : Solid-gas reaction, Gaseous reaction Heat transfer : Conduction, Convection, Radiation Ph i l and Physical d geometrical t i l changes h
Generation of internal pore, Change of particle size Bed structural change : Porosity, height Melting, Sintering

Major phenomena

Reactors containing solid bed

Iron-making process
Coke oven, Sintering bed, Blast furnace

Waste incinerators (grate type)

Thermal Engineering Lab

Waste Incinerator

Bed combustion of mixed waste (solid fuel)

Waste heat boiler

Stoker type

Rotary kiln

Traditional stoker-type incinerator

Advanced incinerator : Stoker-type + Rotary kiln type

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Iron Making Process

Coking coal Iron ore Coke oven Sintering Blast furnace

Iron I M Making ki P Process

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Iron Ore Sintering Bed

Iron ore sintering process

~90% 90% of fi inert : Ph Physical i l changes h of fi inert (i (iron ore) )i is i important Self-sustaining combustion (no external heat source) once ignited No py pyrolysis, y very y slow p progress g of coke combustion
PSEUDO-PARTICLES CHARGING REROLLING STACK HEARTH BED EP FAN RETURN FINE SCREENING BLAST FURNACE COLD CRUSHING COG BURNER SINTERING BED WIND BOXES SINTERED ORE HOT CRUSHING COOLING MIXING ORE BIN YARD +WATER +COKE, LIME etc

Thermal Engineering Lab

Iron Ore Sintering

Sintering bed

Size
L Length th : 100 100m Height : 0.7m Width : 5m

Sintering time : about 1400s

Thermal Engineering Lab

Coke Oven

Each slice Batch type oven

CHARGING CAR

PUSHER COAL QUENCHING CAR

Charge : 27.8 ton/oven Coking time : about 20 hours

16.0m

6.7m 6m

Charging coal

. . . .
0.70m

0.45m

fuel air

More than 100 slices

Thermal Engineering Lab

Blast Furnace

Blast Furnace
<10 m

Iron ore + Coke + Limestone

Gas flow Maximum : ~1 110m Lumpy Zone

Cohesive Zone Molten Iron

Dripping Zone Tuyere Hearth Raceway

Thermal Engineering Lab

Blast Furnace Process

Phenomena in Blast Furnace

S k zone Stack
Alternate coke/ore layers Ore layer is heated up and partially reduced ( (wustite, tit FeO). F O)

Stack zone

Cohesive zone
Ore layer is softened and agglomerates. Low permeability of ore layer coke slit Wustite is transferred to Fe.

Cohesive zone Dripping zone

Dripping pp g zone
Ore starts to melt and fall down.

Raceway Reducing gas by coke combustion Deadman - Stagnant coke zone Deadman Raceway
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Advanced Technology

FINEX Process

Thermal Engineering Lab

Modeling Approach

Thermal Engineering Lab

Applicability to Various Systems

Reactors with bed of solid material : Solid flow: batch or continuous Common governing mechanism and physical/chemical phenomena but differ in the dimension, the boundary conditions and additional physical changes

Solid material Oxidizer

Solid material Solid material

Solid material

Oxidizer Fixed bed combustor Direct melting furnace Coke oven Co-current fixed bed gasifier

Oxidizer Count-current fixed bed gasifier Blast furnace

Oxidizer Grate-type incinerator Iron I ore sintering i t i b bed d

Thermal Engineering Lab

Approach: Solid Solid-Gas Gas Material Flow Modeling

Solid Material

Gas Flow

Locally homogeneous & Porous Media Multiple components Assumed to be continuum Governing G i E Equations ti of f PDE
ACTUAL FUEL BED UNSTEADY 3-D 3 D MODEL

Continuous Flow through porous media

UNSTEADY 2-D 2 D MODEL

UNSTEADY 1-D 1 D MODEL

y time x
ACTUAL FUEL BED

y time x
UNSTEADY 3-D MODEL

y time x
UNSTEADY 2-D MODEL

y x (time)

Waste Incinerator Iron Ore Sintering Bed Fixed-bed Gasifier Coke Oven Blast Furnace

or

y time x

y time x

y time r

Thermal Engineering Lab

Applicability to Various Systems (Cont (Contd) d)

Flexibility in computation - In the model, user can define

Solid S lid components and d gaseous species i Combustion/reaction types and their rates Boundary y conditions Physical and geometric properties Numerical Scheme

Extension of 1-D, transient model to 2-D model

For moving bed, with constant traveling speed

y t=0 t t+ t tmax time

Thermal Engineering Lab

Numerical Models : Concepts

SOLID PHASE, K

Solid Phase and Gas Phase

SOLID PHASE, J SOLID PHASE, I N N W W P S GAS PHASE E P S W E N W P S E

N P S E

S lid phase Solid h

Assumed as the porous media : Combustion and radiation Combustion : Drying Pyrolysis - Char combustion Heat and mass transfer : Conduction Conduction, Convection Convection, Radiation Physical changes

Gas phase : Reactions I t Interactions ti btw. bt Two T phases h

Heat transfer Mass transfer and transport

Mass transport p - drying & condensation by solid-gas reactions - char reactions

Solid-gas reactions

Gas phase
Gas-gas Gas gas reactions
- combustion - water-gas shift reactions

Governing Equations (PDE) Mass, energy, component

( fV ) t r + ( u ) = ( eff ) + S

(combustion,gasification) - Limestone decomposition

Solid p phase J

Heat transfer btw. solid and gas

- convection - radiation - heat of reaction

gas conduction

Solid phase I Heat transfer btw.

solid phases

Geometrical changes of solid particles

-slumping - internal pore - sintering - melting

Solid phase K
Solid-solid interaction (radiative and conductive heat transfer)

Thermal Engineering Lab

Mathematical Model Governing Equations

Governing equations

S lid phase Solid h I:M Mass, E Energy, C Component

( s , I fV , I ) t + ( s , I vs , I ) y =
phase J I J

& M solid gas reactions , I J

( fV ,s , I hs , I ) t

vs , I hs ,I y

( s ,I fV , I ms ,I ,k ) t

( s , I vs , I ms ,I ,k ) y

Ts , I f v,I f k h A T T h A T T qrad + + + ( ) ( ) JI s , I s,J s ,I conv , g I s , I g s ,I V ,s , I s , I 1 y y J & H & + yI M M s , I ,rs r s , I ,rs C p , I Ts , I rs rs

& = M s , I ,k ,rs
rs

Gas phase : Mass, Energy, Species

g t + g vg y & = M s , I ,rs
I rs

( hg ) t
t

( vg hg ) y
+

Tg & & kg + hconv , g I As ,I (Ts ,I Tg ) + (1 yI ) M s ,I ,rs H rs + M s ,I ,rs C p ,I Ts ,I y y I rs rs

& & = M s , I ,k ,rs + M g ,k ,rg
rs I rg

( g mg ,k )

( g vg mg ,k ) y

Thermal Engineering Lab

Submodel - Reactions

Solid gas reactions & Gaseous reactions

solid

solid

M gas solid M solid + gas M gas M solid + gas

gas solid gas

Solid-gas g reactions

Drying : Boling(>373K) and Diffusion(<373K) :

& M moisture Qin s (1 ) mmoisture , min t = H fg C gWH2O d p n p Dwg ( X wp X wg ) (by ( y boiling) g) (by diffusion)

Pyrolysis Char reactions : C(s)+O2, H2O, CH4, CO

Competitive reactions : Arrhenius rate + diffusion

Rio , g =

As vsWchar Cg ,i d p 1 1 1 + + kr km keff

Limestone decomposition
CaCO 3 CO 2 + CaO
Rl = 1 d p ( d p dl ) 2 K l 4.1868 d p + + km dl Ds kl RTs dl
Thermal Engineering Lab
* nl dl ( CCO CCO2 ) 2

Submodel Reactions(Cont Reactions(Contd) d)

Iron ore reduction : Fe2O3(s), Fe3O4, FewO, + CO

3 interface shrinking core model
6 f Rn = i i i di g W CO , g CO2 , g a K n,m m M M m =1,4 CO CO2

Solution loss : C+CO2->2CO Melting

Rn =

R = gCO2 , g M CO2
Aface )

Ak s film,CO2

) + ( k )
1 5

Competitive p reactions : Arrhenius rate + diffusion

T j Tmelt , j T j

inflow

( G
j

s , face

M j Volcell

Thermal Engineering Lab

Submodel- Heat transfer & Geometrical changes Submodel

Heat Transfer

Conduction C d i :I Included l d di in the h energy equations i Convections : Wakao and Kaguei(1982)s equation or Ranz-Marshall equation q Radiation : 2-flux model(Shin and Choi, 2000) Among solid phases
qss ,IJ = hIJ As ,I (Ts , J Ts ,I ) 2 where hIJ =
I

V ,I

ks ,I ( s C ps ) + k g g C pg I fV , J fV ,I ts + t g fV ,I I

Geometrical changes

Particle diameter Generation of the internal pores

3 3 dp = 1 F d + Fd ( ) u r

1/ 3

fV ,I ip ,I t

vs ip ,I y

= f ip ,i
i

& M comb ,i

& + ip ,loss , I

Bed structural changes : packing parameter, n

fV = f s1n fVo
Thermal Engineering Lab

Characteristics of the reactors summarized in this study

Waste Incinerator Moving bed Continuous Solid waste Iron Ore Sintering Bed Moving bed Continuous Iron ore +Limestone +Coke Suction air Coke Oven Fixed bed Batch Coking coal Blast Furnace Counter-current Fixed bed Continuous. Sintered ore+Coke

Bed type Feeding Solid material Mode of gas/air flow Heat source

Blowing air

Discharge of pyrolized gas

Volatile/Char combustion Change of bed height by combustion

Physical change

External Wall Heating, latent Heat of Pyrolysis Melting/sintering Swelling, Negligible change shrinkage of bed height

Coke combustion

Blowing of preheated blast air(or gas) Coke & PC(pulverized coal) combustion Melting of iron ore, coke diameter change(combustion)

Thermal Engineering Lab

Waste Incinerator

Thermal Engineering Lab

Waste Incinerator (II)

Major phenomena within the bed in waste incinerators

Ignition I ii b by radiation di i f from wall/hot ll/h gas Drying Pyrolysis Char combustion Combined closely y with the gas g flow in the incinerator

(1) Raw waste (2) Drying (3) Pyrolysis (4) Char reaction RADIATION ( ) Ash (5)

SECONDARY AIR COM BUSTION GAS

(4)

WASTE FEEDER GRATES

(3) BED (1) (2) WASTE

(5)

PRIM ARY AIR

ASH HOPPER

Thermal Engineering Lab

Waste Incinerators Calculation Parameters

Single solid phase Bed height : 0.68 m The particle size and porosity are not changed during the process

Bed height change is very important

0.68 150 6000 1 30mm 45% 39% 6% 10% 0.54 1790 1 YES Gaseous reaction Char Pyrolysis Type T vave Type Value A E A E
Air 300K 0.136m/s Radiation CFD resultsa 1.5104 30kcal/km ol 2.3 22kcal/km ol

Calculation time : 6000 sec

O idi Oxidizer

Bed height (m) # of f cells ll tmax (sec) t (sec) Size Moisture Solid mat. (i l di (including mass-base composition) Volatile Char Ash o LHVa n Shrinkage of grid

Waste incinerator (Moving bed, Continuous feeding)

Ignition by radiation from hot gas or wall (2)

Ignition

Solid waste (30~60% combustible)

Time = 0 Time = t1

Combustion gas Ash

Volatile+O2CO+ H2 CO+H2OCO2+H
2

Air

Time = tmax

H2+0.5O2H2O

Thermal Engineering Lab

Waste Incinerators - Calculation Results

Model is well describing the physico-chemical process in the waste bed

T Temperature distribution di ib i and d gas composition ii

0.4

RADIATION

0.6

13
0.3

O2 H 2O H2
H2O

CO2 CO CxHyOz
O2

Bed Height ( (m)

3 .7
04 0.4

Mole Fractio on

COMBUSTION GAS

0.2

14
0.2
AIR

CO2
0.1

H2 CO

13 10

8 6
10

4
12
0.0 0 1000 2000 3000

0.0 0 2 4 6 8

Location on the grate (m)

4000

5000

6000

Ti ( Time(sec) )

Predicted temperature distribution (x100k)

Predicted gas composition (x100k)

Thermal Engineering Lab

Application of the Model : Combined Simulation Method

FURNACE ENCLOSURE GAS FLOW FIELD : Mass, Energy, Momentum and Species Conservation Equations +Turbulence, Radiation, Reaction Models Temperature, Heat Transfer Velocity, Turbulent Mixing, Chemical Species and Reaction

CFD

MGAS, TGAS, VGAS

QRAD
FUEL BED COMBUSTION MODEL FUEL BED: Combustion, Gas Reaction Heat Transfers x=0 (t=0) PRIMARY AIR(x) Fuel Components and Temperature Gas Species and Temperature Bed Height, etc. x = Grate Length (tmax: Fuel Residence Time)
Thermal Engineering Lab

Simulation Results for Waste Incinerator

TEMPERATURE [ UNIT : K ]
1300

TEMPERATURE [ UNIT : K ]
1200
1500

Tgas

1100

Gas Temperature (K)

1100

CO2
0.2
1500

700
0.1

Tgas

Mole Fraction

1400

CxHyOz+CO+H2
300
0.0

1200
1100

CO2

x=0.8m ( t=6.6 min )

SECONDARY AIR 1500 1550
Bed H Height (m)
0.70

0.2

700

CxHyOz+CO+H2
300

01 0.1

0.0

1300
0.35

0.00 0 4 8 12

500
Distance (m)
Bed Height ( (m) 0.70

1400 1500 1400 1100

1500

0.35

13 12 11 31 12

700

0.00 0

4 Distance (m)

Thermal Engineering Lab

Iron Ore Sintering

Thermal Engineering Lab

Iron Ore Sintering

Major Phenomena in the sintering bed

AIR

AIR IGNITION

SINTERED ZONE
SINTERED ZONE

COOLING

RAW MIX

COMBUSTION ZONE RAW MIX ZONE

Hearth Bed

COMBUSTION ZONE RAW MIX ZONE

SINTERING CHAR COMBUSTION

MOISTURE EVAPORATION MOISTURE OS CO CONDENSATION S O HEARTH BED

y x
COMBUSTION GAS

COMBUSTION GAS

Thermal Engineering Lab

Iron Ore Sintering Bed Calculation Parameters

Bed height (m) # of cells tmax (sec) t (sec) Size(mm) Solid mat. (including massbase compositi on) Moisture Coke Iron ore Limeston e o n 0.57 57 1500 1 1.6/3.2 7.0% 7 0% 3.8% 83.2% 13.0% 0.4 0.6 Typ e T vave Typ e Val ue A E A E Air 300K 0.450m/s Gas burner 4 m/s, 1400K 2.3 22kcal/kmol

Oxidi zer

Iron ore sintering bed (Moving bed, Continuous feeding)

Ignition by burner

Igniti on Pyroll P ysis Char Gas eous react ion

Solid materiala
Time = 0
a

Air Sintered ore

Time = t1 Time = tnax

Combustion g gas

: Iron ore + Coke + Limestone (~4% combustible)

Shrinkage g of g grid

No

CO+0.5O2CO2

Thermal Engineering Lab

IRON ORE SINTERING BED COMPARISON WITH SINTERING POT TEST RESULTS

Bed Type: Fixed Bed of Mixed Materials without a Gas Plenum Extension of 1-D Unsteady Model to 2-D Steady Model
& Q air
Air

y=490mm 600mm m

Sintering bed
ID=205mm

R-type T/C

y=300mm y=110mm

Tbed
P

Sintered Ore Raw Mix

& Q gas

Tgas
y t=0
Combustion zone

Grate Bar T/C Suction Blower Gas Analyzer

t t+ t x = time traveling speed

time tmax

Wind Box

Concept and schematic diagram of sintering pot

Thermal Engineering Lab

IRON ORE SINTERING BED COMPARISON WITH SINTERING POT TEST RESULTS
2000 1800 1600 1400 1200 1000 800 600 400

25

Computed p Measured y=0.49m

y=0.30m

y=0.11m

20

Gas composition (Vol.%)

Tempera ature(K)

15

O2-Computed CO2-Computed CO-Computed O2-Measured CO2-Measured CO-Measured

10

0
0 200 400 600 800 1000 1200 1400

200

400

600

800

1000

1200

1400

Time (sec)

Time(sec)

Temperature profile Flame front speed (FFS) and Sintering time for various air velocities and particle diameters

flue gas composition in the sintering bed

5 2000

Sintering time
Flam me Front Speed (cm m/min)
4

Extingushed
1600

1200 3

Quantification of the Combustion Propagation (Flame Front Speed, Sintering Time)

FFS
2

800

Coke diameter : 1.2mm Coke diameter : 1.4mm Coke diameter : 1.6mm

400

1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Averaged Air Velocity (m/s)

Thermal Engineering Lab

Sintering Time (sec)

Characterization of Bed Combustion

Flame Front Speed (FFS) Combustion Zone Thickness (CZT) Melting Zone Thickness (MZT) : for an Iron Ore Sintering Bed CZT : Combustion Zone Thickness Maximum Temperature (MaxT) MZT : Melting Zone Thickness
40 35 30

Thicknes ss (cm)

Sintered Zone

1600

25 20 15

CZT
Combustion Zone Melting Zone

1400

1200 10

MZT
Te emperature

1000 5 0 0 400 800 1200 1600 800 2000

MaxT

Raw Mix

1373K 1000K

Time (sec)

Quantified results : CZT, MZT, MaxT (for various air Thermal Engineering Lab supply)

Maximum Te emperature (K K)

CZT(AirV=0.26m/s) CZT(AirV=0.32m/s) CZT(AirV=0.45m/s) CZT(AirV=0.52m/s) MZT(AirV=0 26m/s) MZT(AirV=0.26m/s) MZT(AirV=0.32m/s) MZT(AirV=0.45m/s) MZT(AirV=0.52m/s)

2000
MaxT(AirV=0.26m/s) MaxT(AirV=0.32m/s) MaxT(AirV=0.45m/s) MaxT(AirV=0.52m/s) MaxT(AirV 0.52m/s)

1800

Coke Oven

Thermal Engineering Lab

Coke Oven
Plastic layer
Flue Flue
(1) Wet Coal (<100oC) (2) Dried Coal (100~400oC) (3) Semi-Coke (4) Coke

Hea at From Heating Wall

(4)

(3) (2) (1)

Coking Front g Front Boiling

Coal

Air Fuel

Coke

Air Fuel

Thermal decomposition of bituminous coal with final temperatures of about 900 in the absence of air 0.45m width, 6m height and 16m length, Slot -type furnace Oven wall is heated by fuel gas combustion in the combustion chamber
Thermal Engineering Lab

Coke Oven Calculation Parameter and results

Bed width (m) # of cells tmax (sec) t (sec) Size Moisture Solid Volatile mat. (including Char mass-base b Ash composition) o n 0.22 44 54000 10 3mm 7% 24.2% 60.5% 8.3% 0.4 1 Type T vave Type Value A E A E

Oxidizer Ignition Pyrolysis Char Gaseous reaction

No oxidizer 1.5104 30kcal/kmol -

Height (6m) is much longer than width(0.45m) 1D model Charging coal is assumed to be not a coal blend but a single coal Input data - Elemental/Proximate analysis data Homogeneous porous media

Shrinkage g of g grid

No

Coke oven (Batch type fixed bed) Gas Heat from hot wall Raw
coking coal

Coke

Time = 0

Time = t1

Time = tmax

Thermal Engineering Lab

Coke Oven - Temperature Profile

Experimental data
1100 1000 900
1coke plant No. 2, No. 2 oven Moisture : 5.8% #2 charging hole #3 charging hole

Temperature distribution within the oven

450 400 350 300 250 200 150 100 50

Temperature e (oC)

800 700 600 500 400 300 200 100 0

0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Time (h)

Temperature change at the center

1400

Internal gas pressu ure (mmH2O)

Time

Temperature change at the wall

1400

Temperature (K)

Tempera ature(K)

1200 1000 800 600 400 200 0

LV(0.15) MV(0.25) HV(0.35)

1200 1000 800 600 400 200

LV(0.15) MV(0.25) HV(0.35)

10

15

20

10

15

20

Time (hour)

Time (hour)

Thermal Engineering Lab

Blast Furnace

Thermal Engineering Lab

Blast Furnace Modeling & Calculation Parameter

Modeling

2D axi-symmetric model Assumptions

2 phases - Gas and solid phases Layer structure is obtained by Lo/Lc data & solid velocity Sh Shape of f cohesive h i zone is i defined d fi d b by range of f solid lid temperature t t (1050oC~1350 C 1350oC) Shape of deadman(stagnant zone) is assumed Layer properties (Dp, porosity) are function of locations Raceway is treated as a boundary condition
# of cells Size Solid mat. Feeding rate(kg/s) T(oC) P(MPa) Blast air V(Nm3/min) PCRd(kg/s) 24x76 20.0mma 50.0mmb 0.36 0 36a 0.45b 0.10c 180.8 a 36.7 b 1191 0.42 6150 15.9 Reduction 3Fe2O3+CO ->2Fe3O4+CO2 Fe3O4+CO+CO >FeO+CO2 FeO+CO>Fe+CO2 1/4Fe3O4+CO ->3/4Fe+CO 3/4F CO2 Solution-loss C+CO2->2CO Rate [18] Rate

Sold material : sintered ore + coke + flux(limestone) Blast furnace gas

... . . . . . . .. . . .. . . . .. .. . ... . .. . . . . .. .... . .. . . . . . . . .. . .. . . .. . . . . . . . . .. .. . .. .. . .. ..... . ore .

[17]

coke

Solid flow

G Gas

G Gas Liquid : pig iron + slag Thermal Engineering Lab

a:

Iron ore, b: Coke, c: Cohesive zone, d: Pulverized coal rate

Simplification
Height(m)

30.5 30 29.5

Profilemeter

OS O.S 29 28.5 28 27.5 27 0 1 2 3 4 Coke+Ore O.L C.COKE O.S COKE

R di ( ) Radius(m)

30 29.5

7 6 5

L o/Lc sm ooth ing o f Lo/Lc

Height t(m)

29 28.5 28 27.5 27 0 1 2

Lo/Lc
4

ORE COKE
3

4 3 2 1 0 0 1 2 3 4

Radius(m)

R a diu s(m )

Thermal Engineering Lab

Lo/Lc data & Layer Distribution

7 6 5

Case A Case B Case C

Lo/L Lc

4 3 2 1 0 0 1 2 3 4 5

Radius(m)

Lo/Lc data (Case A : Base)

Case A

Case B

Case C

Thermal Engineering Lab

Result - Temperature Distribution within the Furnace

Case A

Case B

Case C
Thermal Engineering Lab

Mass Fraction of Ore

Fe2O3

Fe3O4

FewO

Fe
Thermal Engineering Lab

Mass Fraction of Ore & Gas (r/R (r/R=2/3) 2/3)

1.0

0.40 0.35

CO2 CO

08 0.8

Fe2O3 FewO Fe

Mass Fr raction

Fe3O4

0.30 0.25 0.20 0.15 0.10 0.05

Mass fr raction

0.6

0.4

0.2

0.0 10 15 20 25

0.00 5 10 15 20 25 30

Height(m)

Height(m)

Mass Fraction of Ore

Mass Fraction of Gas

Thermal Engineering Lab

Chemical Reaction

Reactions of Indirect Reduction

3 Fe2 O3 ( s ) + CO ( g ) 2 Fe3O4 ( s ) + CO2 ( g )
w 3 Few O ( s ) + CO2 ( g ) Fe3O4 ( s ) + CO ( g ) 4w 3 4w 3

3 Interphase Shrinking Core Model

F w O ( s ) + CO ( g ) wFe Fe F ( s ) + CO2 ( g )
1 3 Fe3O4 ( s ) + CO ( g ) Fe ( s ) + CO2 ( g ) (Ts < 848 K ) 4 4
6 f Rn = i i i d i g W CO , g CO2 , g a n ,m K m M M CO2 m =1,4 CO

a1,1 = A3 ( A2 + B2 + B3 + F ) + ( A2 + B2 ) ( B3 + F ) a 2,2 = ( A1 + B1 + B2 )( A3 + B3 + F ) + A3 ( B3 + F )
* a3,3 = ( A1 + B1 )( A2 + B2 + B3 + F ) + A2 ( B2 + B3 )

a1,2 = a 2,1 = A3 ( B2 + B3 + F ) + B2 ( B3 + F ) a 2,3 = a3,2 = ( A1 + B1 )( B3 + F ) a3,1 = a1,3 = A2 ( B3 + F )

Thermal Engineering Lab Back to the contents

Chemical Reaction (contd)

An =
1
2 Xn

k n (1+11 K n )

Bn = F=
2

X n +1 X n X n +1 X n 1 k film,CO2

i 2d Dn

X1 = X2 =
50.2

d Fe2O3 ds d Fe3O4 ds

X3 =

d FewO ds

W = ( A1 + B1 ) a1,1 A2 a1,2
K 1 = exp 7.255 +
3720 Ts 1

X4 =1

K2 K3
K3

( ) k = 10 exp (3.16 = exp ( 5.289 ) k = 10 exp ( 2.09 = exp ( 3.127 3 127 + 5 42 ) k = 10 exp (5.42 = exp ( 1.032 + ) k =k D =D
4711 Ts 2 2 2879 Ts 2 3
981.5 Ts 4 1 4 2 Tave DCO g 1 2 ,N2 2 + 0.39 Re ig2 = Tave g DCO ds 2 ,N2
1

8.314610 3 Ts

40

8.314610 3 Ts 61 4 61.4

) )

8.314610 3 Ts

( ) D = 10 exp ( 2.77 ) 5 09 ) ) D = 10 exp ( 5.09

D1 = 10 4 exp 8.76 14100 Ts
4 2 7200 Ts 4 3 8800 Ts

k film,CO2

Tave =

Ts + Tg 2
3 Fe w Fe 1 2 Fe F 2 O3 F 3 O4 F wO = + + M Fe2 O3 M Fe3O4 M Few O
1

d Fe F 2 O3 ds

1 2 Fe F 2 O3 = M Fe2 O3

d Fe F 3 O4 ds

3 Fe 1 2 Fe F 2 O3 F 3 O4 = + M Fe2 O3 M Fe3O4

d Fe F wO ds

3 =

2 Fe2O3 M Fe2 O3

3 Fe3O4 M Fe3O4

w Few O M Few O

Fe
M Fe

Thermal Engineering Lab Back to the contents

Chemical Reaction (cont (contd) d)

Solution loss
C ( s ) + CO2 ( g ) 2CO ( g )
R5 = g CO2 , g M CO2 As k film,CO2

1 + ( k 5 )

As =

6(1 ) d s s

k5 =

k 5,1 51
1 + k 5,2 PCO + k 5,3 PCO2

s (1 ) 82.056 82 056 10 3 Tg
Tave = 0.5 (Tg + Ts )
21421 k 5,2 = exp 6.688 + 1.987 Ts

Tave k film,CO2 = DCO Sh s 2 ,N2

( d s s )

k 5,1 =

1 60

66350 exp 19.875 1.987 Ts

88168 k 5,3 = exp 31.615 1.987 Ts

)
k 5 s Tave s DCO 2 ,N2

Pj =

82.056 10 M
j

g Tg

j,g
ds 6

Sh s = 1.5 Re 0.55 sg

1 1 tanh ( 3 ) 3

Thermal Engineering Lab Back to the contents

CONCLUSIONS

A Unified Approach in the Numerical Modeling of the Bed Combustion

Reacting R i fl flow of f solid, lid liquid li id and d gas phase h of f multiple l i l component Discretization of the solid flow in the same manner as the usual discretization of gas phase Common governing equations for gas and solid phases Easy to accommodate various configurations of gas and solid flow by treating them as boundary y conditions User can define the dimension, phenomena, boundary conditions, etc.

Examples of the Approach

Moving bed in waste incinerator I Iron ore sintering i t i b bed d Coke oven Blast furnace

Thermal Engineering Lab

CONCLUSIONS (cont (contd) d)

Strong Points of the Mathematical Modeling of Complex Processes

Physicsbased Computational Model: Critically beneficial for design and operation A li bl t Applicable to very i important t t engineering i i processes Validity shown for application in incinerators, sintering, coking and blast furnace Maybe applicable to food and bio processing

Weak Points of the Mathematical Modeling

Sub-processes are not comprehensively modeled Difficult to validate: measurable quantities are limited

Thermal Engineering Lab

THANK YOU

Thermal Engineering Lab

Temperature in Raceway

Obtained from the heat and mass balance in the raceway Boundary condition of the energy equation of gas phase

A : Base, B: High PCR, C: High Productivity

In high PCR, temperature in raceway is lowest

Since temperature of PC is 300K while temperature of coke is 1800K

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Temperature Distribution

Measured Results

Base

High PCR

High productivity Thermal Engineering Lab

Position of CZ

Distance from tuyere level to Ts=1050oC

Distance form the tu uyere level (m)
Base Hi h PCR High High Productivity
18

Distance form the tu uyere level (m)

18

16

16

Base Hi h PCR High High Productivity

14

14

12

12

10

10

6 1 2 3 4 5

6 1 2 3 4 5

Radius(m)

Radius(m)

Measured result

Simulated result
Thermal Engineering Lab

Pressure Drop

0.60 0.55 0.50

Pressure drop in the wall

Base High PCR High Productivity
0.36 0.35 0.34

Measurement

Press sure(MPa)

0.45 0.40 0.35 0.30

Press sure (MPa)

0.33 0.32 0.31 0.30 0.29

0.25

0.28
0 5 10 15 20

2.1

3.2

4.4

5.6

6.7

7.9

10.2 11.3 12.5 14.5 17.6

--

Distance form the raceway (m)

Distance form tuyere level (m)

Calculated data

Measurement data

A major portion of pressure drop occurs in a cohesive zone

Thermal Engineering Lab

Simulation Condition
<Operation condition>
Top gas pressure (MPa) Blast volume (Nm3/min) Blast pressure (MPa) Blast temperature (oC) Production rate of pig iron(t/d) PCR (kg/t) O2 rate t (Nm (N 3/hr) /h ) Blast moisture(g/Nm3) R.R (kg/t) Ore ratio (-) 0.277 6150 0 4192 0.4192 1191 9284 147.6 20000 22.3 489.2 1.683

<Calculation cases>
Case A : Case B : (0.5m) Case C : (1.0m)

<Layer property>
Layer Ore layer Coke layer Cohesive layer Raceway Deadman zone for gas Particle diameter (m) 0.0214 0.0477 0.0214 0 0477 0.0477 0.0477 Shape factor ( (-) ) 0.84 0.90 0.84 0 90 0.90 0.90 Voidage (-) () 0.36 0.45 0.10 0 80 0.80 0.10 Thermal Engineering Lab