Restricted accessResearch articleFirst published online 2020-4
The effects of operational parameters on flue gas recirculation iron ore sintering process: sensitivity analysis based on numerical simulation and industrial onsite experimental validation
A one-dimensional mathematical model is adopted to analyse influences of operational parameters on process performance during flue gas recirculation sintering (FGRS). Simulation results show that FGRS can enhance combustion characteristics and improve distribution of heat. Subsequently, the sensitivity coefficient is used to study contribution of operational parameters to quality and productivity of sintered ore. Sensitivity analysis shows the order of sensitivity of productivity is O2 content > gas supply > temperature, while that of quality is O2 content > temperature > gas supply. The optimal regulation strategy is that O2 content should be controlled first before temperature and that gas supply should be closely controlled. The optimum O2 content range is 19–20 vol.-% and the optimum temperature is around 200°C. Gas supply of FGRS should increase by 4.17%. Finally, an industrial test was carried out, which indicated that the optimal regulation strategy is reasonable.
Get full access to this article
View all access options for this article.
References
1.
FanXHYuZYGanMet al.Influence of O2 content in circulating flue gas on iron ore sintering. J Iron Steel Res Int. 2013;20(6):1–6. doi: 10.1016/S1006-706X(13)60103-X
2.
ShibataJ.Analysis of sintering process by the mathematical model. Math Comput Model. 1988;11:956–961. doi: 10.1016/0895-7177(88)90635-8
3.
PatissonFBellotJPAblitzerD.Study of moisture transfer during the strand sintering process. Metall Trans B. 1990;21(1):37–47. doi: 10.1007/BF02658114
4.
VenkataramanRGuptaSSKapurPCet al.Mathematical modelling and simulation of the iron ore sintering process. Tata Search (India). 1998: 25–30.
5.
RamosMVKasaiEKanoJet al.Numerical simulation model of the iron ore sintering process directly describing the agglomeration phenomenon of granules in the packed bed. ISIJ Int. 2000;40(5):448–454. doi: 10.2355/isijinternational.40.448
6.
MitterlehnerJLöfflerGWinterFet al.Modeling and simulation of heat front propagation in the iron ore sintering process. ISIJ Int. 2004;44(1):11–20. doi: 10.2355/isijinternational.44.11
7.
YangWRyuCChoiSet al.Modeling of combustion and heat transfer in an iron ore sintering bed with considerations of multiple solid phases. ISIJ Int. 2004;44(3):492–499. doi: 10.2355/isijinternational.44.492
8.
YangWRyuCChoiSet al.Mathematical model of thermal processes in an iron ore sintering bed. Met Mater Int. 2004;10(5):493–500. doi: 10.1007/BF03027355
9.
NathNKDa SilvaAJChakrabortiN.Dynamic process modelling of iron ore sintering. Steel Res Int. 1997;68(7):285–292. doi: 10.1002/srin.199701791
10.
NathNKMitraK.Mathematical modeling and optimization of two-layer sintering process for sinter quality and fuel efficiency using genetic algorithm. Mater Manuf Process. 2005;20(3):335–349. doi: 10.1081/AMP-200053418
11.
YamaokaHKawaguchiT.Development of a 3-D sinter process mathematical simulation model. ISIJ Int. 2005;45(4):522–531. doi: 10.2355/isijinternational.45.522
12.
KomarovSVShibataHHayashiNet al.Numerical and experimental investigation on heat propagation through composite sinter bed with non-uniform voidage: part I mathematical model and its experimental verification. J Iron Steel Res Int. 2010;17(10):1–7. doi: 10.1016/S1006-706X(10)60174-4
13.
KangHChoiSYangWet al.Influence of oxygen supply in an iron ore sintering process. ISIJ Int. 2011;51(7):1065–1071. doi: 10.2355/isijinternational.51.1065
14.
ZhouHZhaoJPLooCEet al.Numerical modeling of the iron ore sintering process. ISIJ Int. 2012;52(9):1550–1558. doi: 10.2355/isijinternational.52.1550
15.
CastroJADSazakiYYagiJ.Three-dimensional mathematical model of the iron ore sintering process based on multiphase theory. Mater Res. 2012;15(6):848–858. doi: 10.1590/S1516-14392012005000107
16.
de CastroJANathNFrancaABet al.Analysis by multiphase multicomponent model of iron ore sintering based on alternative steelworks gaseous fuels. Ironmak Steelmak. 2012;39(8):605–613. doi: 10.1179/1743281212Y.0000000008
17.
AhnHChoiSChoB.Process simulation of iron ore sintering bed with flue gas recirculation: part 1 – modelling approach. Ironmak Steelmak. 2013;40(2):120–127. doi: 10.1179/1743281212Y.0000000071
18.
AhnHChoiSChoB.Process simulation of iron ore sintering bed with flue gas recirculation. Ironmak Steelmak. 2013;40(2):128–137. doi: 10.1179/1743281212Y.0000000072
19.
ZhaoJPLooCEDukinoRD.Modelling fuel combustion in iron ore sintering. Combust Flame. 2015;162(4):1019–1034. doi: 10.1016/j.combustflame.2014.09.026
20.
PahlevaninezhadMEmamiMDPanjepourM.The effects of kinetic parameters on combustion characteristics in a sintering bed. Energy. 2014;73:160–176. doi: 10.1016/j.energy.2014.06.003
21.
WangGWenZLouGFet al.Mathematical modeling and combustion characteristic evaluation of a flue gas recirculation iron ore sintering process. Int J Heat Mass Tran. 2016;97:964–974. doi: 10.1016/j.ijheatmasstransfer.2016.02.087
22.
WangGWenZLouGFet al.Mathematical modeling of and parametric studies on flue gas recirculation iron ore sintering. Appl Therm Eng. 2016;102:648–660. doi: 10.1016/j.applthermaleng.2016.04.018
23.
CrawfordCW.The influence of surface roughness on pressure drop and fluid velocities through beds of particulates. J Fluids Eng. 1986;180:343–347. doi: 10.1115/1.3242584
24.
HobbsMLRadulovicPTSmootLD.Combustion and gasification of coals in fixed-beds. Prog Energ Combust. 1993;19:505–586. doi: 10.1016/0360-1285(93)90003-W
25.
YoungRW.Dynamic mathematical model of (iron-Ore) sintering process. Ironmak Steelmak. 1977;4:321–328.
26.
HartmanMTrnkaOVeselýVet al.Predicting the rate of thermal decomposition of dolomite. Chem Eng Sci. 1996;51:5229–5232. doi: 10.1016/S0009-2509(96)00363-6
27.
IrabienAViguriJROrtizI.Thermal dehydration of calcium hydroxide. 1. kinetic model and parameters. Ind Eng Chem Res. 1990;29:1599–1606. doi: 10.1021/ie00104a004
28.
JozwiakWKKaczmarekEManieckiTPet al.Reduction behavior of iron oxides in hydrogen and carbon monoxide atmospheres. Appl Catal A. 2007;326:17–27. doi: 10.1016/j.apcata.2007.03.021
29.
PineauAKanariNGaballahI.Kinetics of reduction of iron oxides by H2. Thermochim Acta. 2006;447:89–100. doi: 10.1016/j.tca.2005.10.004
30.
ZhouHZhouMLiuZet al.Factors controlling high-temperature zone resistance to airflow during iron ore sintering. ISIJ Int. 2015;55:2556–2565. doi: 10.2355/isijinternational.ISIJINT-2015-311
31.
LooCELeaneyJ.Characterizing the contribution of the high-temperature zone to iron ore sinter bed permeability. Min Proc Extractive Metall. 2002;111:11–17. doi: 10.1179/mpm.2002.111.1.11
32.
YangWChoiSChoiESet al.Combustion characteristics in an iron ore sintering bed—evaluation of fuel substitution. Combust Flame. 2006;145:447–463. doi: 10.1016/j.combustflame.2006.01.005
33.
ZhaoJP.Numerical simulation and experimental verification of iron ore sintering process (in Chinese) [PhD Dissertation of Zhejiang University]. 2012.
34.
ZouLJHong-FuLIDuanFet al.Experiment researching of saving energy technology in sintering process by using Hot Air. Industrial Furnace. 2007;29:9–11.
35.
YuanH.Influence of FeO content on mineral composition and microstructure of sinter. China Metall. 2008;18:6–9.
36.
LiuC.Research on behavior of NOX/COX/SO2 in the Process of flue gas circulation sintering of iron ores [MD Dissertation Central South University]. 2013.
