MATHEMATICAL MODELLING OF BLAST FURNACE

PROCESS AT SMELTING OF NON-TRADITIONAL RAW

MATERIALS
Yu.A. Chesnokov, A.N. Dmitriev
Institute of Metallurgy of Ural Branch of Russian Academy of Sciences
Ekaterinburg, Russia
ABSTRACT. The offered balance logic-statistical model of blast furnace rocess is
based on use of the material and thermal balances added !ith calculations of heat- and
mass e"change taking into account non-uniformity of gas and burden distribution on
radius of the furnace and characteristics of the basic metallurgical characteristics of
iron ore ra! materials and coke on indices of blast furnace oeration# $or check of
alicability of model the calculations on the most critical arameters of blast furnace
rocess % smelting of ferromanganese and iron nickel !ith grahic reresentation of
heat- and mass e"change rocesses, dynamics of o"ides reduction on height and
radius of blast furnace ha&e been carried out#
1. INTRODUCTION
The blast furnace rocess is characteri'ed by a substantial scale, o!er
consumtion and orientation to the e"ensi&e energy carriers# Thereuon !orks on its
mathematical modeling for the urose of maintenance of ossibilities of forecasting
of the furnace !ork indicators and otimi'ation of the technological arameters of the
blast furnace rocess are e"ecuted# Because of the comle"ity of hysical and
chemical rocesses the research in the gi&en direction de&eloed on a !ay of creation
of ri&ate models( balance, kinetic-mathematical, dynamic, e)uilibrium and others#
In articular, at Institute of metallurgy of Ural Brunch of Russian Academy of
Sciences last years is !idely used balance logic-statistical model of blast furnace
rocess *+, !hich is based on use of the material and thermal balances added !ith
statistical data and most significant regularities of heat e"change and balance
conditions of iron o"ides !ith a gas hase#
Recently the model ha&e added !ith the integral e)uations for calculation of the
distribution of the burden temeratures both gas on height and radius of the furnace
and differential e)uations % for calculation of kinetic cur&es of iron o"ides reduction
in blast furnace shaft#
2. REDUCTION OF IRON OXIDES IN THE BLAST FURNACE
$or calculation of the iron o"ides reduction rocesses in the dry art of a blast
furnace is offered to use the follo!ing modified e)uation *+,
( )
( )
( )
- . +
, , ,
, ,
- . /
, ,
- . +
, ,
/ , ,
- . +
, ,
- . /
, , , , 012
, ,
, ,
,
/ /
/
+ , 2
3
w m g O H
w m g
E
w m g w m g P
w m g
X
P
w m g w m g w m g
w m g
X w m g
H CO
D
B !

B A !

, 4+5
+-+++
!here
w , m , g
H , CO
/

% increment of degree of reduction of hematite 4g5, magnetite 4m5
and !ustite 4!5 at the e"ense of CO 676
/
H
agreeably# 8ther designations are
resulted in Section 3#
Balance constants 49:
/
.9:5 of reactions
/ -
/ ; - - /
CO O "e CO O "e + +
, 4/5
-
/ ; -
CO "eO CO O "e + +
, 4-5
CO "e CO "eO
/
+ +
4;5
are described by the e)uations */,
+;; # / . /</3 lg + # !
CO
g
, 415
+ # / . +=12 lg + # !
CO
m
, 435
0 # 2 . 3== lg # !
CO
w
# 4<5
Balance constants of iron o"ides reduction reactions by hydrogen 4
/ /
. H O H
5
>?@@A6BCD?EB@F GH I>?DJKJ6FL are calculated on the e)uations
wg w m g
H
w m g
! ! !
M8
, , , ,
/

, 4=5
!here wg
!
% balance @onstant of reaction of !ater gas
O H CO H CO
/ / /
+ +
# 405
Total degrees of reduction of iron o"ides are calculated in model according to
the e)uations
( )
w m g
H
w m g
CO
i
w m g
w m g , , , ,
+
, ,
, ,
/
+ +

, 4+25
( )
w
CO
m
CO
g
CO
i CO
CO
+ + +

</; # 2 +33 # 2 ++ # 2
+
, 4++5
( )
w
H
m
H
g
H
i
H
H
/ / /
/
/
</; # 2 +33 # 2 ++ # 2
+
+ + +

# 4+/5
$or check of ade)uacy of the acceted scheme of reduction of iron o"ides
e"eriments on reduction of agglomerate and ellets by hydrogen in an inter&al 022-
++22
H
9 ha&e been made#
In $ig#+ the e"erimental and settlement kinetic cur&es constructed !ith use of
the e)uations 4+5, 4+2-+/5 are resulted#
3. DISTRIBUTION OF TEMPERATURES ON BLAST FURNACE HEIGHT
The basic e)uations for heat e"change calculation in the differential form look
like
$ i i % t w t w
g & m m g g
+ +
, 4+-5
m m g g
t w t w
, 4+;5
t t v i t w
'
5 4
m g m h m m
+
, 4+15
m
m g m
m
h m g m
m
5 4 5 4
w
t t v
w
i t t v

t
' '

, 4+35
+-++/
Fig. 1. The e"erimental 4continuous5 and calculating 4stroke-dotted5 kinetic
cur&es of ellets reduction 4?5 and agglomerate 4b5 of Nachkanarsky O8N
g
m g m g
5 4
w
t t v

t
'

, 4+<5
!here
m
w
% !ater e)ui&alent of burden, e)uals

,
_

+

t
w
i
w w
m
m
h
m m
+
, 4+=5
g
w
% !ater e)ui&alent of gas,

,
_

t
w
i
w w
g
g
&
g g
+
# 4+05
+-++-
Sol&ing in common the e)uations 4+;5 and 4+35, at an assumtion
g
(
w
w
m

P const !e recei&e the e)uations
[ ]
m
t t t m t
t
H
m
)
g
H
m
)
g
m

,
_

+
5 4 e"
, 4/25
( ) [ ]
m
t t m t m t
t
H
m
)
m
H
m g
g
)

+
5 4 e"
, 4/+5

5 + 4 5 4 m
w
v
m
m '

, 4//5
!here %
!
g
t
and
H
m
t % temeratures of gas and material on to 4the final temerature
of gas, the reference temerature of material5Q
*
g
t
and
+
m
t
% the same in the end of a
'one of heat e"change 4reference temerature of gas, final temerature of material5#
$or the calculation of deendence of the !ater e)ui&alent and !ater number of
the burden from temerature !e shall be limited to linear functions
m m m m
t , - w + # 4/-5
Integrating 4+-5 and 4+;5 in &ie! of 4/-5 !e shall recei&e
( ) ( ) [ ]
g
! & H
m m
g
m H
m m
g
m !
g g
w
. .
t t
w
,
t t
w
/
t t
+
+ + +
/
/
/
, 4/;5
!here ! &
. . +
% losses of heat and thermal effects of reactions at height of the
furnace limited in temeratures g
t
and t
+
g
, kR.t of ig-iron#
These e)uations recisely enough describe rocesses of heat e"change in the
blast furnace at small &alues of a ste on temerature or time#
4. CALCULATION OF NON-UNIFORMITY OF DISTRIBUTION OF GAS ON
TOP RADIUS
As the rimary information allo!ing to analy'e the !ork of gas in the furnace
use usually ractical data about distributions
/
CO
and temeratures of gas on radius
of to# Sistinguish t!o basic tyes of the distribution influencing on arameters of
!ork of the furnace % a eriheral and a"ial course# In the mathematical model the
oortunity of the task of any tyes of distributions as on ractical data, and by e"ert
is stiulated# The cur&e
$ r % 0
/
!ill be transformed to non-uniformity of
distribution of streams of burden and gas, thus the blast furnace is broken into ten
e)ual rings# Also follo!ing assumtions are acceted( ore
$ O %
and flu"
$ " %
are
distributed on section of the furnace in regular inter&als unlike coke ( ) r 0 +
r
and
gas#
Thus these &alues should be distributed on to radius so that to comensate the
acceted assumtions and to reflect such henomena, as inching-out of layers of
comonents of burden, an ad&ancing, segregation, etc#
As a result by means of calculation heat- and mass e"change on model the set
cur&e is reroduced ( ) r 0
1
# $or this urose used the e)uations !ith hel !hich
the ore loading
$ OB %
and the coke consumtion
%!$
are ut accordingly in direct
+-++;
and in&ersely roortional deendence on
$ CO %
/
and )uantity of gas in deendence
on the coke consumtion
( )
( )
/
/
M8
M8 8B
8B
r
r

, 4/15
( )
( )
r
r
r
OB
" O
!
+

, 4/35
( ) ( ) ( )
n
r
g i
r
i i i i
r
' B A ' A '

,
_

+
1
]
1

,
_

+ + +
N
N
+
N
N
ln +
g g
, 4/<5
!here OB and ! % the a&erage ore loading and the a&erage coke consumtionQ T
i
,
A
i
, B
i
, n
i
% factors !hich steal u on a condition of maintenance of the greatest
ossible coincidence set cur&e and ( ) r 0
/
9: recei&ed as a result of calculations of
heat- and mass e"change in +2 rings#
5. EXAMPLES OF PROBLEMS PRACTICAL SOLUTION OF BLAST
FURNACE SMELTING
Model ossibilities are illustrated by the analysis of blast furnace rocess at
fusion of silikate-nickel and manganous ores#
5.1. S!"# $%"$&"%#i'( ') i*'( (i$+!"
The analysis of de&eloment of rocesses of heat e"change carried out on
change of temeratures of gas and burden in hori'ontal sections and on furnace height
4on erihery, on an ore crest and at a furnace !all5# As initial data are set - furnace
characteristics, comosition and roerties iron ore ra! materials, limestone, coke,
blasting arameters, factors of non-uniformity of the gas stream, coordinated !ith the
loading systems rofile 4a site of an ore crest, its height5# As a result of calculation
recei&ed ig-iron and slag comosition, the arametres characterising thermal and
reducing !ork of gas, and also technical and economic indicators of blast furnace
smelting# The basic indicators of smelting and the analysis of blast furnace rocess for
conditions of melt of ig-iron about 3 U Vi in a blast furnace in &olume /21 L
-
are
resulted in tab# + and in fig# /# $rom character of the temerature cur&es it is &isible,
that in an ore crest heat e"change is carried out at other relation of !ater e)ui&alents
of and gas, unlike the centre and erihery# Therefore this area romotes formation of
lo! a&erage temerature of to gas % -1
H
9#
T%,"! 1. The basic arameters of smelting of ferronickel in a blast furnace
Indices Walue
Xroducti&ity, t.day 1-
The sinter consumtion, kg.t ig-iron 3;-2
+-++1
Oeneral contents $e in burden, U +-,03
Moke consumtion, kg.t ig-iron +1-/
$lu", kg.t ig-iron =/
Blast(
natural gas consumtion, m
-
.minute +11=
temerature,
H
9 ++22
o"ygen contents, U /+,2
Xig-iron, comosition, U(
*Si, +#12
*Vi, 3#-0
*Mr, +#-=
Slag( )uantity, kg.t ig-iron 1+-=
comosition, U( 4Ma85 /=#=
4Mg85 +;#0
4Al
/
8
-
5 /=#=
basic caacity 4Ma8.Si8
/
5 2#32
Reduction rocesses of iron o"ides in all cuts are de&eloed acti&ely enough
because of tall reductibility of sinter# The greatest acti&ity of reduction rocesses of
iron o"ides is obser&ed at furnace centre# At the centre of furnace and on the rim the
reduction of iron o"ides is terminated comletely in the YdryZ 'one of the board, i#e#
to temeratures 012
o
9# In the ridge ore the rereduction rocesses are de&eloed less
acti&ely and to the emolliating 'one the material is enters in !hich !ustite it is
reduced only on 12 U# Therefore early slags in this cut !ill differ from slags of
central and eriheral cuts both on consumtion and on roerties#
5.2. S!"# $%"$&"%#i'( ') )!**'%(g%(!-!
The smelting of manganous ferroalloys in the blast furnace is characterised by
the raised coke consumtion bundled first of all !ith high heat consumtion of the
reduction rocesses of the manganese o"ides in the bottom of a blast furnace# In these
conditions for smelting of )ualitati&e ferromanganese are necessary high blast
arameters( ma"imum heat, its dee o"ygen enrichment# $or the analysis it is offered
to use the combined diagramme Y2 3 t 3 4Z allo!ing oerati&ely to estimate the
thermal state of furnace together !ith reduction rocesses of iron o"ides deending on
the stay time of materials in the furnace# In fig# - the cur&es of heat interchange and
reduction of iron o"ides at smelting of </ U of ferromanganese are resented# The
analysis sho!s, that in comarison !ith ordinary conditions of smelting the altitude of
the reser&e 'one on a time is much more more stretched 4+-+#1 hours against -#1-;#2
hours, accordingly5, that redetermines the conclusion about usage for a
ferromanganese smelting of lo!-shaft furnaces#
Mentre of furnace
+-++3
8re crest
Xerihery of furnace
Temerature,
H
9 Reduction degree, share of units
Fig. 2. Sistribution of temeratures of the burden and gas 4at the left5 and reduction
rocesses 4on the right5 in &ertical sections 4rings +, =, +25 of the blast furnace at
ferronickel smelting
+-++<
Fig. 3. The analysis of reduction rocesses and heat interchange for
ferromanganese smelting conditions
As a result of the fulfilled e"lorations the e"isting mathematical model of the
blast furnace smelting is added by a method of the taking into account kinetic
singularities of reduction rocess of iron o"ides until temeratures of 022-012
H
9# The
measure of the registration of irregularity of allocation of gas on shaft to radius is
de&eloed# The calculated analysis of the critical conditions and arameters of the
combined blast has sho!n essential sreading of functionality and a raise of ade)uacy
of the model#
.. SYMBOLS
w m g
H CO
, ,
,
/

3 gain of the reduction degree of the hematite, magnetite and !ustite at the
e"ense of COor
/
H
accordinglyQ
w m g
5
!
, ,
3 constants of the reduction &elocities for the hematite, magnetite and
!ustiteQ
012
CO
3 M8 content at 012
H
9, UQ
6

3 diameter of the ore iece, mmQ

O H CO
w m g
E
D
/ /
,
, ,
5 4
3 the effecti&e diffusi&ity defining the diffusi&e resistance of the
reduced layer for hematite, magnetite and !ustite accordinglyQ
w m g
A
, , , w m g
B
, , , w m g
C
, , , w m g
D
, , 3 au"iliary coefficientsQ
g m
t
, % temerature of materials or gas, accordingly,
H
9Q
+-++=
'

% &olume heat-transfer factorQ

h
i
% heat effect of the reaction, kR.4h [ t5Q

i
% !armth losses, kR.4h [ t5Q
m % the ration of !ater e)ui&alents of the burden and gasQ
%$, %+$, %"$ % consumtion of ore, coke and limestone, accordingly, kg.t ig-ironQ
OB % ore burdenQ
( )
g
'
% to gas amount, kg.t ig-ironQ
%CO
1
$ % contents of the carbon dio"ide in the to gas, U#
/. CONCLUSION
Thus, the short descrition of a balance logic-statistical model of the blast-
furnace smelting and results of the solution of ractical roblems of the blast-furnace
smelting are resented#
A0NOWLEDGEMENTS
This !ork !as e"ecuted !ith suort from Mouncil under Orants for \eading
Scientific Schools of Russia 4School ] ;-1=#/22=#-5#
REFERENCES1
+# Mhentso& A#W#, Mhesnoko& ^u#A# and Sha&rin S#W#( The \ogic-Statistic Balance
Model of Blast $urnace Smelting# Ural Branch of Russian Academy of Sciences,
Ekaterinburg, /22-#
/# Xoel S#I#, Sotniko& A#I# and Boronenko& W#V#( The theory of metallurgical
rocesses# Mosco!, Metallurgy, +0=3#
-# Mhentso& A#W#, Mhesnoko& ^u#A# and Sha&rin S#W#( _Montrollable arameters of
system of loading and elements of modelling of domain rocess_# I'&estia Wu'o&,
Mhernaya Mettalurgia /223 < //-/;#
;# Belyae& I#\, Mhentso& A#W#, Mhesnoko& ^u#A# and Sha&rin S#W#( _Use of t!o-
dimensional model of blast furnace rocess at ig-iron melt about 3 U Vi_#
I'&estia Wu'o&, Mhernaya Mettalurgia /223 0 +=-/2#
1# Nudino& S#`#, Mhesnoko& ^u#A# and Sha&rin S#W#( $eatures of blast furace rocess
at melt of manganous alloys in the form of diagrams 2 3 t 3 4. I'&estia Wu'o&,
Mhernaya Mettalurgia /22/ - <3-<<#
+-++0