Mohamed Elzohiery

Computational Fluid Dynamics Simulation of the Hydrogen Reduction of Magnetite Concentrate in a Laboratory Flash Reactor

A three-dimensional computational fluid dynamics (CFD) model was developed to study the hydrogen reduction of magnetite concentrate particles in a laboratory flash reactor representing a novel flash ironmaking process. The model was used to simulate the fluid flow, heat transfer, and chemical reactions involved. The governing equations for the gas phase were solved in the Eulerian frame of reference while the particles were tracked in the Lagrangian framework. The change in the particle mass was related to the chemical reaction and the particle temperature was calculated by taking into consideration the heat of reaction, convection, and radiation. The stochastic trajectory model was used to describe particle dispersion due to turbulence. Partial combustion of H2 by O2 injected through a non-premixed burner was also simulated in this study. The partial combustion mechanism used in this model consisted of seven chemical reactions involving six species. The temperature profiles and reduction degrees obtained from the simulations satisfactorily agreed with the experimental measurements.

Analysis of the Hydrogen Reduction Rate of Magnetite Concentrate Particles in a Drop Tube Reactor Through CFD Modeling

A computational fluid dynamics (CFD) approach, coupled with experimental results, was developed to accurately evaluate the kinetic parameters of iron oxide particle reduction. Hydrogen reduction of magnetite concentrate particles was used as a sample case. A detailed evaluation of the particle residence time and temperature profile inside the reactor is presented. This approach eliminates the errors associated with assumptions like constant particle temperature and velocity while the particles travel down a drop tube reactor. The gas phase was treated as a continuum in the Eulerian frame of reference, and the particles are tracked using a Lagrangian approach in which the trajectory and velocity are determined by integrating the equation of particle motion. In addition, a heat balance on the particle that relates the particle temperature to convection and radiation was also applied. An iterative algorithm that numerically solves the governing coupled ordinary differential equations was developed to determine the pre-exponential factor and activation energy that best fit the experimental data.

Determination of Total Iron Content in Iron Ore and DRI: Titrimetric Method Versus ICP-OES Analysis

The determination of reduction degree in a DR process is sensitive to the total iron in the ore and DRI. An accurate and high throughput analysis method for total iron has been developed. Titration of the solution after tin(II) chloride reduction of ferric ion is a widely used method foriron analysis. However, it is a multistep method that requires many chemical reagents and much time. In this work, an ICP-OES analysis method with higher or equivalent accuracy compared with the titrimetric method was developed. This method has much higher throughput and demands fewer chemical reagents compared with the titrimetric method. In this paper, a comparison of the two methods is presented.

Reduction Kinetics of Hematite Concentrate Particles by CO+H2 Mixture Relevant to a Novel Flash Ironmaking Process

The kinetics of hematite concentrate reduction by mixtures of hydrogen and CO of various compositions has been investigated as part of the development of a flash ironmaking process at the University of Utah. This process produces iron directly from iron oxides concentrates by the gas-solid flash reaction based on the partial oxidation of natural gas, resulting in a significant reduction in energy consumption and greenhouse gas emission. The reduction kinetics of hematite concentrate of an average particle size 21.3 µm by the above mentioned gases in the temperature range 1423 to 1623 K (1150 to 1350 °C) was investigated. Hematite concentrate particles can be reduced to > 90% by any of these reductants in several seconds of residence time typically available in a flash reactor. The activation energy ranged from 214 kJ/mol for hydrogen to 231 kJ/mol for CO.

Status of the Development of Flash Ironmaking Technology

The Flash Ironmaking Technology being developed at the University of Utah is aimed at producing iron directly from iron oxide concentrate. In this technology, the concentrate is reduced by H2 and CO gas mixtures formed from the partial oxidation of natural gas in a flash reactor. Natural gas represents an economically and environmentally superior reductant/fuel for the flash ironmaking. The rate equations for the reduction kinetics by H2, CO and H2 + CO gas mixtures were determined in the temperature range 1150–1600 °C. These rate equations were applied to experimental results from a laboratory flash reactor using Computational Fluid Dynamics CFD simulation. A new mini-pilot reactor, which is capable of operating at 1150–1550 °C with a concentrate feeding rate of 2–5 kg/h, has been installed. Commissioning of the reactor with an emphasis on preheating of the reactor, production of reducing gas mixtures and the feeding and collection of iron ore concentrate and product particles has been completed.

Flash Ironmaking from Magnetite Concentrate in a Laboratory Reactor: Experimental and CFD Work

A flash ironmaking process is being developed at the University of Utah in which iron is produced directly from magnetite concentrate. The kinetics of magnetite reduction by a mixture of H2 and CO gases was determined in the temperature range 1150–1600 °C. Over 90% reduction degree was achieved at a temperature as low as 1250 °C within 4–6 s which is the typical residence time available in a flash reactor. The kinetics results were applied to experimental data obtained in a laboratory flash reactor in which H2 and CO gas mixtures were produced from in situ partial oxidation of natural gas with oxygen. CFD was used to simulate the laboratory reactor, and the results were in good agreement with the experimental data.

Analysis of the Reduction Rate of Hematite Concentrate Particles in the Solid State by H 2 or CO in a Drop-Tube Reactor Through CFD Modeling

The kinetic analysis of the reduction of hematite concentrate particles by individual reducing gas H2 or CO was performed using a computational fluid dynamics (CFD)-based approach in this paper. The particle residence time was calculated through the integration of the equation of particle motion. Non-uniform particle temperature profiles inside the reactor were obtained, and were taken into consideration for the kinetic analysis. The calculated reduction degrees based on this approach are in good agreement with the experimental values.

Reduction Kinetics of Magnetite Concentrate Particles with H2 + CO AT 1200 TO 1600 °C Relevant to a Novel Ironmaking Process

The kinetics of magnetite reduction with mixtures of hydrogen and CO of various compositions has been investigated as part of the development of a flash ironmaking process at the University of Utah. This new process bypasses the cokemaking and pelletization or sintering steps required for the blast furnace. The particle kinetics were studied using magnetite concentrate particles of different sizes. Reduction degree of 60% was achieved in a few seconds in at 1350 °C using CO reductant alone and over 90% when H2 + CO gas mixture was used. The effects of reductant partial pressures, temperature, and particle size on the reduction kinetics were studied.

Flash Reduction of Magnetite and Hematite Concentrates with Hydrogen in a Lab-Scale Reactor for a Novel Ironmaking Process

As part of the development of a novel flash ironmaking process at the University of Utah, a labscale flash reactor was used to produce iron directly from iron oxide concentrate. This work tested the feasibility of the novel flash ironmaking process using the partial combustion of hydrogen as fuel and reductant. In this flash reactor, the energy required to reduce concentrate particles was obtained from the internal combustion of hydrogen and oxygen with complementary energy from electrical resistance heating to compensate for the heat loss. After the reaction shaft was electrically pre-heated, hydrogen and oxygen streams produced a non-premixed flame inside the reaction shaft. Various conditions such as flame configuration, flame power, positions of concentrate feeding ports, excess hydrogen amount and residence time were tested. More than 90% reduction of magnetite or hematite was achieved at temperatures as low as 1175 °C with < 100% excess hydrogen in <10 s of residence time.

Reduction Kinetics of Magnetite Concentrate Particles with Hydrogen at 1150–1600 °C Relevant to a Novel Flash Ironmaking Process

A novel ironmaking process is under development at the University of Utah aimed at producing iron directly from iron oxide concentrate in a flash reactor. This process will reduce hazardous emissions and save energy. The kinetics of magnetite reduction with hydrogen was previously investigated in our laboratory in the temperature range 1150 to 1400 °C at large temperature increments (~100 °C increments). Due to the significant melting that occurs above 1350 °C, the reduction kinetics was measured and analyzed in two distinct temperature ranges of 1150 to 1350 °C and 1350 to 1600 °C (~50 °C increments). Experiments were performed using magnetite concentrate particles of different sizes under various hydrogen partial pressures and residence times. Reduction degrees of more than 90 % were achieved in a few seconds at temperatures as low as 1250 °G Different rate expressions were needed to obtain reliable agreement with experimental data.