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ABSTRACT: Biomass is a carbon-neutral fuel and has potential to be used in pulverized coal injection (PCI) technology in
ironmaking blast furnaces (BFs). In comparison to pulverized coal particles, biomass particles vary considerably in particle shape,
and thus, the change of the aspect ratio of biomass particles may affect the motion and conversion of biomass particles. In this
study, a computational fluid dynamics (CFD) model is developed to simulate the flow and thermochemical behaviors related to
biomass injection into BFs. The model features non-spherical particle shapes and an improved devolatilization model. The model
is then applied to a pilot-scale test of charcoal injection using a pilot-scale PCI test rig under simulated BF conditions for model
validation. The burnout comparisons between simulation and measurement indicate that, in comparison to spherical particles,
the non-spherical particles show smaller burnouts as a result of the shorter traveling time in the chamber; moreover, the burnouts
predicted by the model considering cylindrical particles and improved devolatilization model are more comparable to the
measurements. This confirms the model validity and also concludes that it is necessary to include the effect of the particle shape
in the modeling of biomass injection in BFs. Then, to give a full picture of charcoal injection, other typical phenomena
of flow and combustion behaviors are analyzed in detail for charcoals in cylindrical particle shape, aspects of gas−charcoal flow,
their temperature distribution, and gas composition distribution. This model provides an effective way for understanding and
optimizing biomass injection in BF practice.
Figure 1. Schematic of the PCI test rig: (a) schematic of the PCI test rig and (b) geometry details of the computational domain (mm).30
Table 1. Governing Equations for the Gas and Particle Phases in the Model25
for the Gas Phase
mass
∇(ρU) = ∑ ṁ
np
⎛ 2 ⎞
∇(ρUU) − ∇((μ + μt )(∇U + (∇U)T )) = −∇⎜p + ρk ⎟ + ∑ fD
momentum ⎝ 3 ⎠ np
⎛ ⎛ λ μ ⎞ ⎞
energy ∇⎜⎜ρUH − ⎜ + t ⎟∇H ⎟⎟ = ∑q
⎝ ⎝ CP σH ⎠ ⎠ np
⎛ ⎛ μ ⎞ ⎞
gas species i ∇⎜⎜ρUYi − ⎜⎜Γi + t ⎟⎟∇Yi ⎟⎟ = Wi
⎝ ⎝ σYi ⎠ ⎠
⎛ ⎛ μ⎞ ⎞
turbulent kinetic energy ∇⎜⎜ρUk − ⎜μ + t ⎟∇k ⎟⎟ = (Pk − ρε)
⎝ ⎝ σ k⎠ ⎠
⎛ ⎛ μ⎞ ⎞ ε
turbulent dissipation rate ∇⎜⎜ρUε − ⎜μ + t ⎟∇ε⎟⎟ = (C1Pk − C2ρε)
⎝ ⎝ σε ⎠ ⎠ k
for a Particle in the Particle Phase
dm p
mass = − ṁ
dt
dUp
mp = −fD
dt
momentum
1
−fD = πd p2ρC D|U − Up|(U − Up)
8
dTp
mpCp = −q
dt
energy
dm p
− q = πd pλNu(Tg − Tp) + ∑ Hreac + A pεp(πI − σBTp 4)
dt
Shen et al.25 developed a 3D CFD model to simulate the the charcoal type, such as the VM content. Castro et al.26,27
injection of different charcoals in BFs to evaluate the effect of reported CFD studies of simultaneous injection of pulverized
B DOI: 10.1021/acs.energyfuels.7b03150
Energy Fuels XXXX, XXX, XXX−XXX
Table 2. Reactions Considered in This Charcoal Injection Model with Respective Reaction Kineticsa
reaction reaction rate expression reaction kinetics38
k
⎛ E ⎞
moisture(l) → H 2O(g) k = A exp⎜− ⎟ A = 5.13 × 108 s−1; E = 88 kJ mol−1
⎝ RTP ⎠
Energy & Fuels
k v1
⎛ E ⎞
charcoal ⎯→
⎯ α1fuel gas + (1 − α1)char k = A exp⎜− ⎟ A1 = 4.3 × 107 s−1; E1 = 136 kJ mol−1; α1 = VM (daf); CS = 0
⎝ RTP ⎠
k v2 d ṁ
charcoal ⎯→
⎯ α2 fuel gas + (1 − α2)char d = CSd0 ref A2 = 1.46 × 1013 s−1; E2 = 251 kJ mol−1; α2 = Q × VM (daf) + 0.14; CS = 0
dt mref,0
⎛ E ⎞
CH4 + 0.5O2 → CO + 2H2 k = [i]A exp⎜− ⎟ A = 2.3 × 107 s−1; E = 125.5 kJ mol−1; [i] = [CH4]−0.3[O2]1.3
⎝ RTP ⎠
ε ⎛ [i] ⎞
CO + 0.5O2 → CO2 ri = CA min⎜ ⎟ A = 1014.6 s−1 mol−1 cm2.25; E = 167.3 kJ mol−1; [i] = [CO][O2]0.5
κ ⎝ vt′ ⎠
CO2 → CO + 0.5O2 A = 5 × 108 s−1; E = 167.3 kJ mol−1; [i] = [CO2]1
H2 + 0.5O2 → H2O A = 540 m3 kg−1 s−1; E = 15.1 kJ mol−1; [i] = [H2][O2]0.5
ε ⎛ [i] ⎞
H2O → H2 + 0.5O2 ri = CA min⎜ ⎟ CA = 4.0; [i] = [H2O]
κ ⎝ vt′ ⎠
2(ϕ − 1) ⎛ T⎞
ϕchar + O2 → 2(ϕ − 1)CO + (2 − ϕ)CO2 = AS exp⎜⎜− s ⎟⎟ Ac = 140 m s−1 K−1; Tc = 21580 K; As = 2500; Ts = 6240 K
C
2−ϕ ⎝ Tp ⎠
dmC 3ϕ MC ρ∞ −1
char + CO2 → 2CO =− (k1 + (k 2 + k 3)−1mC) Ac = 202300 m s−1 K−1; Tc = 39743 K; As = 0.0004; Ts = 6240 K
dt 1− e MO2 ρC
char + H2O → CO + H2 Ac = 6069 m s−1 K−1; Tc = 32406 K; As = 0.0004; T s = 6240 K
a 2 2 0.5
k1 = D/RP ; k2 = (1 − e)kc/RP; k3 = kcTp(β coth β − 1)/β α; kc = AcTp exp(−Tc/Tp); β = R(kc/Dpea) ; Dp = effic × D; D = Dref/ρfluid((Tp + Tg)/2Tref)α.
Article
DOI: 10.1021/acs.energyfuels.7b03150
Energy Fuels XXXX, XXX, XXX−XXX
Energy & Fuels Article
coal and charcoal into a BF. However, in these model studies, (ii) Devolatilization is modeled using two-competing reaction
the irregular shape of biomass particles that may greatly affect models30,35 rather than a one-step global model used in the past.25
the motion and conversion of fuel particles in combustors28,29 In the experimental study,10 it was found that the charcoal particles
was not considered. To date, the studies considering irregular used in the test do not swell much during the devolatilization. Thus, in
this numerical study based on the conditions of ref 10, the swelling
particle shape have not been conducted for biomass injection coefficient of charcoal particles is set to zero (Cs = 0). (iii) Gaseous
into BFs. combustion reactions of fuel gas are modeled by the three-fuel gas
In this study, a 3D CFD model is improved to describe the model and controlled by the combined eddy dissipation model and
flow and thermochemical behaviors related to biomass injec- finite rate chemistry. (iv) Char oxidation and gasification are modeled
tion in BFs and study the effects of non-spherical particle by Gibb’s model. The models are summarized in Table 2. The models
shapes. The model is applied to charcoal in a pilot-scale PCI are developed on the basis of the framework of software package
test rig. The comparisons against measurements show that the ANSYS-CFX, version 17.2.36
simulations using the cylindrical particle shape give the most
comparable burnouts to the measurements. Then, other key phe- 3. SIMULATION CONDITIONS
nomena of injecting charcoal in cylinder shape are described, 3.1. Properties of Charcoal. In this study, the model of
including gas−particle flow, temperature, and concentrations. biomass injection is applied to charcoal in the base cases for
model validation. Charcoal, derived by carbonizing biomass, is
2. MODEL DEVELOPMENT typically low in oxygen, VM, and ash contents compared to
2.1. Model Outline. The mathematical model of the biomass biomass/cellulosic materials, while they all tend to remain the
injection is based on our previous PCI models.30−32 The governing original shape. The proximate (ad) and ultimate (daf) analyses
equations for the gas−solid flow and associated heat transfer and the and mean particle size (de) of the pulverized charcoal are listed
reactions of charcoal are outlined below for completion. in Table 3. For the injectant, 50 particle size groups ranging
The gas phase is modeled using a 3D steady-state Reynolds-
averaged Navier−Strokes equation closed by a standard k−ε
Table 3. Proximate (ad) and Ultimate (daf) Analyses of the
turbulence model. The particle phase is modeled using the Lagrangian
method, where the trajectories of the discrete particles are determined Pulverized Charcoal Used in This Study25
by integrating Newton’s second law of motion, where drag force moisture ash VM fixed carbon calorific value density
and turbulence dispersion are included. The heat transfer of the (%) (%) (%) (%) (MJ/kg) (kg/m3)
gas−particle phase is modeled by considering three physical processes: 9.3 1.8 4.3 84.6 32.48 1150
convective heat transfer, latent heat transfer associated with mass
C (%) H (%) O (%) N (%) S (%)
transfer, and radiative heat transfer. Full coupling of continuity,
momentum, and energy are applied to the particle−gas phase inter- 95.0 0.99 3.7 0.33 0.03
action. The models are summarized in Table 1.
2.2. Model Improvements. Some model improvements specific
to biomass combustion are also included in this part, including the from 1 to 250 μm are sampled and 500 representative particles
model of the non-spherical particle shape and the improved devolatil- are tracked in the simulations. In this model, de is the volume-
ization model. equivalent sphere diameter for different particle shapes,
2.2.1. Non-spherical Particle Shape. Unlike coal that will soften 27 μm in this study. In this study, charcoal is in the shape
and form a spherical particle shape during devolatilization, biomass of a cylinder, as shown in the scanning electron microscopy
particles will largely retain their initial irregularly shaped form.33 (SEM) characterization.10
This large aspect ratio may affect gas−particle drag force and heat and 3.2. Geometry and Boundary Conditions. The model is
mass transfer correlations. This necessitates the introduction of a non- applied to a pilot-scale PCI test rig (Figure 1a).17 The test
spherical shape factor. In this model, two shape factors, namely, cross-
rig was designed to simulate the flow and combustion in the
sectional area factor and surface area factor, are used to describe the
influence of the particle shape on the drag force and mass and heat region of lance−tuyere−raceway (along the coal plume)
transfer correlations, respectively. The former factor is multiplied by related to PCI operation under simulated BF conditions.
the calculated cross-sectional area when assuming spherical particles. The computational domain (Figure 1b) includes lance,
The latter factor is defined as the ratio of the surface area of the non- tuyere, and raceway centerline. The main duct is used for
spherical particle to the surface area of the spherical particle with the injecting the hot blast (i.e., oxygen-enriched air). The coaxial
equivalent diameter. With the cylindrical spherical particle taken for lance is installed at an inclination angle of 6° with respect
example, the two shape factors are defined as eqs 1 and 2. The particle to the centerline of the duct. The inner tube is used for injec-
shape factors are considered in the governing equations in the form of ting pulverized charcoal and the conveying gas (i.e., 100%
the volume-equivalent sphere diameter of particle, de. For consistency
nitrogen), and the outer tube is used for injecting cooling gas
and tidiness, their definitions (i.e., eqs 1 and 2) are not specified in the
governing equations in Table 1. (i.e., air). The geometry is plane-symmetric. The exit at the
end of the chamber is set as an outlet, and the wall of the
scross‐cylinder πr 2 chamber is assumed non-slippery and adiabatic. A boundary-
fcross‐sectional = = fitted, multi-block structured finite volume mesh is used, with
Scross‐sphere π(1/2de)2 (1)
a highly fine mesh around the lance and tuyere and along the
centerline of the chamber. Table 4 shows main parameters of
ssurface cylinder 2πr 2 + 2πrd operating conditions.
fsurface = =
Ssurface sphere 4π(1/2de)2 (2) 3.3. Model Validation. The charcoal injection model is
validated against the measured burnouts obtained from the
2.2.2. Improved Devolatilization Model. Similar to pulverized
coal combustion, biomass combustion is considered to be a four-stage pilot-scale test rig using two charcoal materials, as shown in
chemical reaction; however, the parameters of reactivity and inner Table 5.10,25 The burnout is calculated according to ash
particle structure are quite different, which gives highly different balance, as below. The ash data were collected at three positions,
reaction rates.34 They are modeled by means of the following: (i) The +50 mm, centerline, and −50 mm, at 925 mm downstream from
moisture evaporation process is controlled by finite rate chemistry. the injection point.
D DOI: 10.1021/acs.energyfuels.7b03150
Energy Fuels XXXX, XXX, XXX−XXX
Energy & Fuels Article
Table 4. Operating Conditions in the PCI Test Rig Used in (case 2), and flat chip (case 3), where the cylindrical shape is
This Study26 common for charcoal particles and the flat chip is common for
wood chip particles: case 1, spherical charcoal injection; case 2,
temperature
flow rate (Nm3/h) (K) O2 (%) cylindrical charcoal injection; and case 3, flat-chip-shaped
charcoal injection.
blast gas 300 1473 20.9
cooling gas 3.2 600 20.9 eat‐upCO = mfCO /(mfCO + mfCO ) (4)
2 2
conveying gas 2 323 0 (i.e., 100% N2)
coal/charcoal 38 kg/h 320 Figure 2 compares the burnout evolutions along the centerline
of the raceway between the three cases. They are discussed in
Table 5. Experimental Conditions for Model Validation
blast
charcoal blast rate temperature blast O2 charcoal rate
case materiala (Nm3/h) (K) (%) (kg/h)
1 charcoal 1 301 1474 22.4 33.5
2 charcoal 1 304 1475 22.5 25.2
3 charcoal 2 302 1478 22.4 29.4
4 charcoal 2 301 1477 22.3 48.4
a
The injectants: charcoal 1, referenced in Table 3; charcoal 2, 9.5%
moisture, 2.9% ash, 10.2% VM, 77.4% fixed carbon, and de of 25 μm.
⎛ ma,0 ⎞
burnout = ⎜1 − ⎟ /(1 − ma,0)
⎝ ma ⎠ (3)
Table 6 compares the measured burnouts with the predicted
burnouts of particles in different shapes, i.e., sphere and cylinder.
Figure 2. Comparison of burnout evolutions along the centerline
Table 6. Model Validation in Terms of Burnout for Different among spherical (case 1), cylindrical (case 2), and flat-chip-shaped
Particle Shapes (case 3) charcoals.
Figure 4. Comparison of gas composition along the centerline among Figure 7. (a) Gas velocity vector and (b) charcoal particle trajectories
sphere (case 1), cylinder (case 2), and flat chip (case 3). colored by the particle size in the case of cylindrical charcoal injection.
F DOI: 10.1021/acs.energyfuels.7b03150
Energy Fuels XXXX, XXX, XXX−XXX
Energy & Fuels Article
Figure 10. Contours of gas concentrations of cylindrical charcoal injection, in terms of (a) H2O, (b) H2, (c) CO, and (d) O2.
G DOI: 10.1021/acs.energyfuels.7b03150
Energy Fuels XXXX, XXX, XXX−XXX
Energy & Fuels Article
smaller particles starts earlier and achieves a higher value than d = particle diameter (μm)
that of larger particles. de = volume-equivalent sphere diameter (μm)
e = void fraction of char particles
5. CONCLUSION E1 and E2 = activation energy of devolatilization reactions
A 3D CFD model is developed for describing the injection of (kJ/mol)
irregularly shaped charcoal particles and applied to a pilot-scale fD = drag force from a particle (N)
PCI test rig to simulate the charcoal injection under simulated fcross‑sectional = cross-sectional area factor
BF conditions. The model is validated against the measure- fsurface = surface area factor
ments in terms of burnout. The model is then used to H = enthalpy (J kg−1)
investigate the effects of particle shapes on irregularly shaped Hreac = reaction heat (J kg−1)
charcoal particles and the significance of the improved I = radiation intensity on the particle surface (W m−2)
devolatilization model and illustrate other flow and thermo- [i] = molar concentration of component i
chemical behaviors of charcoal particles in a cylindrical par- K = turbulent kinetic energy (m2 s−2)
ticle shape. The following is found: (1) This model with the kv1 and kv2 = devolatilization rate constants (s−1)
introduced shape factors can better describe the evolutions k1 = rate of external diffusion in the Gibb model (s−1)
of irregularly shaped charcoal particles in terms of burnout. k2 = rate of surface reaction in the Gibb model (s−1)
For the charcoal injection, the burnouts using a cylindrical k3 = rate of internal diffusion and surface reaction in the
shape are more comparable to the measurements, consistent Gibb model (s−1)
with the practice. (2) The present model using the two-competing kc = carbon oxidation rate in the Gibb model (m s−1)
reaction model with a suitable Q factor is more suitable to ṁ = mass transfer rate from a particle (kg s−1)
illustrate the impacts of particle shape on charcoal combustion ma = ash mass fraction
than that using the one-step global model. (3) In comparison to ma,0 = original ash mass fraction
spherical charcoal cases, the two cases of irregularly shaped mc = mass of char (kg)
charcoal particles have a slower combustion process and lower mfCO = mass fraction of carbon monoxide
burnouts. (4) The significant moisture content of charcoal mfCO2 = mass fraction of carbon dioxide
makes the evaporation process obvious at the upstream and Mc = molecular weight of carbon
may delay the ignition process for the charcoal injection. MO2 = molecular weight of the oxygen molecule
(5) Different from PCI simulations, the charcoal injection does np = particle number per unit volume (m−3)
not show a flame-front high temperature over the coal plume Nu = Nusselt number
surface in front of tuyere. Pk = turbulence production by viscous force
■
p = pressure (Pa)
AUTHOR INFORMATION q = heat transfer from a particle (W)
Corresponding Author Q = Q factor for the devolatilization model
*E-mail: ys.shen@unsw.edu.au. rp = particle radius (m)
ri = reaction rate of gas species i (mol m−3 s−1)
ORCID
Re = Reynolds number
Yansong Shen: 0000-0001-8472-8805 T = temperature (K)
Notes Tblast = blast temperature (K)
The authors declare no competing financial interest. Tc = activation temperature (E/R) in the Gibb model (K)
■ ACKNOWLEDGMENTS
The authors acknowledge the financial support from the
Tg = gas temperature (K)
Tp = particle temperature (K)
Tref = reference temperature in the Gibb model (293 K)
Australian Research Council and Baosteel (LP150100112) and Ts = constant in the Gibb model (6240 K)
the first author wishes to acknowledge the financial support U = mean velocity of gas (m s−1)
from China Scholarship Council. Up = mean velocity of the particle (m s−1)
■ NOMENCLATURE
A1 and A2 = pre-exponential factors of devolatilization
u, v, and w = gas velocity components (m s−1)
VM = volatile matter
vi = stoichiometric coefficient of species i.
reactions (s−1) Wi = reaction rate of species i (per unit volume) (kg m−3 s−1)
Ac = pre-exponential factors in the Gibb model (m s−1 K−1) Yi = mass fraction of species i
Ap = particle area (m2) Greek Letters
As = constant in the Gibb model (0.0004) α = volume/internal surface area ratio in the Gibb model
a = exponent in the Gibb model (0.75) α1 and α2 = volatile yields
C0 = mass of raw charcoal (kg) ε = turbulent dissipation rate (m2 s−3)
C1 and C2 = turbulent model constants εp = particle emissivity
CD = drag coefficient λ = thermal conductivity (W m−1 K−1)
Cp = particle heat capacity (J kg−1 K−1) σB = Stefan−Boltzmann constant (5.67 × 10−8 W m−2 K−4)
D = external diffusion coefficient of oxygen in the Gibb σk and σε = turbulence model constants
model (m2 s−1) σH = turbulent Ptandtl number for enthalpy
Dref = reference dynamic diffusivity in the Gibb model (1.8 × ϕ = mechanism factor in the Gibb model
10−5 kg m−1 s−1) ρ = density (kg m−3)
Dp = pore diffusivity μ = dynamic viscosity (Pa s)
daf = dry and ash free μt = turbulent viscosity (Pa s)
I DOI: 10.1021/acs.energyfuels.7b03150
Energy Fuels XXXX, XXX, XXX−XXX
Energy & Fuels Article
Γi = molecular diffusivity of species i (kg m−1 s−1) (27) de Castro, J. A.; Araújo, G. M.; da Mota, I. O.; Sasaki, Y.; Yagi, J.
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■
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J DOI: 10.1021/acs.energyfuels.7b03150
Energy Fuels XXXX, XXX, XXX−XXX