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Stable blast furnace operation is required to reduce energy consumption in iron and steelmaking industry.
For the stable blast furnace operation, precise controlled drainage is one of the important factors. However,
the effects of the various in-furnace conditions on the stable operation were not examined well. Therefore,
in this work, basic characteristic features of drainage in a blast furnace hearth were examined.
Two- and three-dimensional mathematical model were developed based on the finite difference method
to simulate molten iron and slag flow in a hearth of a blast furnace. Pressure drop evaluation model in a taphole was developed to reflect pressure variation in a blast furnace hearth on drainage rate of molten iron
and slag for the three-dimensional mathematical model.
The two-dimensional mathematical model results were validated with measured interfaces shapes obtained using an experimental model. The three-dimensional mathematical model results were validated with
measured total, iron and slag drainage rate of Chiba No. 6 blast furnace. The results indicate that the
drainage behavior and residual iron and slag volume were affected by the conditions in the hearth. The taphole conditions dominate the total drainage rate under the term of assumed blast furnace conditions. In
order to reduce the residual slag volume, the taphole diameter change during the tap should be controlled.
The decrease of the coke diameter causes increase of the residual slag volume, decrease of the residual
iron volume.
KEY WORDS: iron and slag flow; residual slag volume; numerical simulation; VOF method; blast furnace
hearth; ironmaking.
1.
Introduction
2.
Two-dimensional Modelling
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Fig. 1.
u
u
u
u
v
t
x
y
p
u
u
S u ............(2)
x
x x y y
v
v
v
u
v
t
x
y
y
x
v
v
x y y S v g ...(3)
Fig. 2.
where u is the horizontal velocity (m/s), v is vertical velocity (m/s), x and y are coordinates (m), t is time (s), r is density of fluids (kg/m3), p is pressure of fluids (Pa), m is viscosity (Pa s), g is acceleration due to gravity (m/s2), and S
is an interaction force between fluid and 2 flat parallel
plates (m/s2). In the two-dimensional mathematical model,
gas, slag and iron were treated as one fluid having local
properties, which correspond to each phase.
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Fig. 3.
Fig. 4.
Fig. 5.
Three-dimensional Modelling
0.0626
e
5.74
0.9
log
Re
3.7 D
..................(4)
D PD
................................(5)
2 fL
Equations (4) and (5) contain taphole diameter D, taphole depth L, and surface roughness of the taphole e. If the
flow resistance in the taphole is the dominant factor, the
drainage rate is mainly determined by these three parameters, and the drainage rate should be a function of these parameters.
Figure 5 shows total, iron and slag drainage rates of
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Fig. 6.
variation of the taphole length during the tap from Eqs. (4)
and (5) by using temporal variation of the total drainage
rate shown in Fig. 5 and that of the measured taphole diameter. Although, the estimated taphole lengths are scattered,
at the beginning of the tap, the taphole length is about 4.0 m
which coincide with an actual measurement. At the end of
the tap, the taphole length is about 1.0 m which is slightly
shorter than an expected length, however, the trend is suitable. Therefore, the taphole behavior can be described by
this model.
The effect of each parameter on the drainage rate was investigated by fixing other parameters to certain representative values as shown in Figs. 79. The representative value
of taphole diameter D was 64 mm, because the measured
taphole diameter variation range during the tap was 60 mm
to 68 mm. The representative value of taphole length L was
2.5 m, and surface roughness of the taphole e was 1 mm.
The inflow pressure of the taphole was fixed to 3.5105 Pa
which was determined from a blasting pressure into tuyeres; the outflow pressure was 1.0105 Pa (atmospheric
pressure).
Variation of the taphole diameter has a great effect on the
drainage rate (Fig. 7). When the taphole diameter is 42 mm,
the drainage rate is 0.008 m3/s. When the taphole diameter
is 78 mm, the drainage rate is 0.05 m3/min. Thus, increase
of the taphole diameter from 42 to 78 mm provides about
five times drainage rate.
As decreasing the taphole length, the drainage rate increases gradually (Fig. 8). When the taphole length is about
1.02.0 m, variation of the taphole length has a large effect
on the drainage rate. Although, when the taphole length is
more than 3.0 m, variation of the taphole length has a small
effect on the drainage rate.
The effect of surface roughness on the drainage rate is
relatively smaller than that of the taphole diameter and the
taphole length (Fig. 9). When the surface is smooth, the
drainage rate is about 0.035 m3/s. When the surface roughness is even 9 mm, the drainage rate is about 0.018 m3/s.
Considering the fact that the measured taphole diameter
of Chiba No. 6 blast furnace during the tap is 6068 mm,
and the drainage rate is about 0.0170.05 m3/s, it is impossible to describe the drainage rate variation by one of these
parameters change. These parameters should change simultaneously. However, temporal variation of the taphole diameter has the greatest effect on the drainage rate variation.
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Fig. 7.
Fig. 8.
Fig. 9.
1
1 v
v z
0 .............(6)
(r vr )
r r
r
z
vr
vr
v vr
vr
v
vr
vz
v
t
r
r
z
r
p
S vr ............................(7)
r
v
v
v v
v
v
vr
vz
vr
t
r
r
z
r
1 p
S v .........................(8)
r
v z
v z
v v z
v z
vr
vz
t
r
r
z
p
S v z g .......................(9)
z
Fig. 10. Time evolution of relative slag surface and ironslag interface height from the taphole.
4.
4.1.
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Fig. 11. Slag surfaces, ironslag interfaces and velocity distributions in the hearth at the end of the tap. Coke diameter
in the packed bed is 30 mm.
Fig. 13. Effect of packed coke diameter on temporal variation of
iron, slag and total drainage rate. Coke packed bed is
uniform.
4.2.
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Therefore, wear rate of mud has to be small to reduce residual slag volume in a hearth.
(4) When the permeability of the hearth is low, the iron
considerably below the level of the taphole is able to drain
during the tap.
(5) The decrease of the coke diameter causes increase
of the residual slag volume, decrease of the residual iron
volume. It is impossible to reduce the residual iron and slag
volume at the same time.
Acknowledgement
Fig. 18. Concept to reduce residual slag volume by way of taphole conditions.
Nomenclature
dp : Particle diameter (m)
g : Acceleration due to gravity (m/s2)
p : pressure of fluids (Pa)
r : Radial axis (m)
S : Interaction force in 2D model, interaction force
between fluids and packed coke in 3D model
(m/s2)
t : Time (s)
u : Horizontal velocity (m/s)
u : Velocity of fluids (m/s)
v, vz : Vertical velocity (m/s)
vr : Radial velocity (m/s)
vq : Circumferential velocity (m/s)
x, y, z : Coordinates (m)
Greek symbols
e : Fluid fraction ()
m : Viscosity (Pa s)
q : Circumferential axis (m)
r : Density (kg/m3)
Conclusion
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