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Analysis
Modeling of Combustion System Bed Combustion Modeling F l Characterization Fuel Ch t i ti Computational Fluid Dynamics Physical Model Tests Process Simulation Modeling g of Dioxin Emissions
C b i of Combustion f the h single i l particle i l +I Interaction i b between the h particles i l Material ate a flow: o Gas, So Solid, d, Multiple u t p e Co Componenets po e ets Reactions : Solid-gas reaction, Gaseous reaction Heat transfer : Conduction, Convection, Radiation Ph i l and Physical d geometrical t i l changes h
Generation of internal pore, Change of particle size Bed structural change : Porosity, height Melting, Sintering
Major phenomena
Iron-making process
Coke oven, Sintering bed, Blast furnace
Waste Incinerator
Stoker type
Rotary kiln
~90% 90% of fi inert : Ph Physical i l changes h of fi inert (i (iron ore) )i is i important Self-sustaining combustion (no external heat source) once ignited No py pyrolysis, y very y slow p progress g of coke combustion
PSEUDO-PARTICLES CHARGING REROLLING STACK HEARTH BED EP FAN RETURN FINE SCREENING BLAST FURNACE COLD CRUSHING COG BURNER SINTERING BED WIND BOXES SINTERED ORE HOT CRUSHING COOLING MIXING ORE BIN YARD +WATER +COKE, LIME etc
Sintering bed
Size
L Length th : 100 100m Height : 0.7m Width : 5m
Coke Oven
16.0m
6.7m 6m
Charging coal
. . . .
0.70m
0.45m
fuel air
Blast Furnace
Blast Furnace
<10 m
S k zone Stack
Alternate coke/ore layers Ore layer is heated up and partially reduced ( (wustite, tit FeO). F O)
Stack zone
Cohesive zone
Ore layer is softened and agglomerates. Low permeability of ore layer coke slit Wustite is transferred to Fe.
Dripping pp g zone
Ore starts to melt and fall down.
Raceway Reducing gas by coke combustion Deadman - Stagnant coke zone Deadman Raceway
Thermal Engineering Lab
Advanced Technology
FINEX Process
Modeling Approach
Reactors with bed of solid material : Solid flow: batch or continuous Common governing mechanism and physical/chemical phenomena but differ in the dimension, the boundary conditions and additional physical changes
Solid material
Oxidizer Fixed bed combustor Direct melting furnace Coke oven Co-current fixed bed gasifier
Solid Material
Gas Flow
Locally homogeneous & Porous Media Multiple components Assumed to be continuum Governing G i E Equations ti of f PDE
ACTUAL FUEL BED UNSTEADY 3-D 3 D MODEL
y time x
ACTUAL FUEL BED
y time x
UNSTEADY 3-D MODEL
y time x
UNSTEADY 2-D MODEL
y x (time)
Waste Incinerator Iron Ore Sintering Bed Fixed-bed Gasifier Coke Oven Blast Furnace
or
y time x
y time x
y time r
Solid S lid components and d gaseous species i Combustion/reaction types and their rates Boundary y conditions Physical and geometric properties Numerical Scheme
N P S E
Solid-gas reactions
Gas phase
Gas-gas Gas gas reactions
- combustion - water-gas shift reactions
Solid p phase J
gas conduction
Solid phase K
Solid-solid interaction (radiative and conductive heat transfer)
Governing equations
( fV ,s , I hs , I ) t
vs , I hs ,I y
( s ,I fV , I ms ,I ,k ) t
( s , I vs , I ms ,I ,k ) y
( hg ) t
t
( vg hg ) y
+
( g mg ,k )
( g vg mg ,k ) y
Submodel - Reactions
solid
Solid-gas g reactions
Rio , g =
As vsWchar Cg ,i d p 1 1 1 + + kr km keff
Limestone decomposition
CaCO 3 CO 2 + CaO
Rl = 1 d p ( d p dl ) 2 K l 4.1868 d p + + km dl Ds kl RTs dl
Thermal Engineering Lab
* nl dl ( CCO CCO2 ) 2
R = gCO2 , g M CO2
Aface )
Ak s film,CO2
) + ( k )
1 5
T j Tmelt , j T j
inflow
( G
j
s , face
M j Volcell
Heat Transfer
Conduction C d i :I Included l d di in the h energy equations i Convections : Wakao and Kaguei(1982)s equation or Ranz-Marshall equation q Radiation : 2-flux model(Shin and Choi, 2000) Among solid phases
qss ,IJ = hIJ As ,I (Ts , J Ts ,I ) 2 where hIJ =
I
V ,I
ks ,I ( s C ps ) + k g g C pg I fV , J fV ,I ts + t g fV ,I I
Geometrical changes
3 3 dp = 1 F d + Fd ( ) u r
1/ 3
fV ,I ip ,I t
vs ip ,I y
= f ip ,i
i
& M comb ,i
& + ip ,loss , I
Bed type Feeding Solid material Mode of gas/air flow Heat source
Blowing air
Physical change
External Wall Heating, latent Heat of Pyrolysis Melting/sintering Swelling, Negligible change shrinkage of bed height
Coke combustion
Blowing of preheated blast air(or gas) Coke & PC(pulverized coal) combustion Melting of iron ore, coke diameter change(combustion)
Waste Incinerator
Ignition I ii b by radiation di i f from wall/hot ll/h gas Drying Pyrolysis Char combustion Combined closely y with the gas g flow in the incinerator
(1) Raw waste (2) Drying (3) Pyrolysis (4) Char reaction RADIATION ( ) Ash (5)
(5)
ASH HOPPER
Single solid phase Bed height : 0.68 m The particle size and porosity are not changed during the process
Bed height (m) # of f cells ll tmax (sec) t (sec) Size Moisture Solid mat. (i l di (including mass-base composition) Volatile Char Ash o LHVa n Shrinkage of grid
Ignition
Volatile+O2CO+ H2 CO+H2OCO2+H
2
Air
Time = tmax
H2+0.5O2H2O
RADIATION
0.6
13
0.3
O2 H 2O H2
H2O
CO2 CO CxHyOz
O2
3 .7
04 0.4
Mole Fractio on
COMBUSTION GAS
0.2
14
0.2
AIR
CO2
0.1
H2 CO
13 10
8 6
10
4
12
0.0 0 1000 2000 3000
0.0 0 2 4 6 8
4000
5000
6000
Ti ( Time(sec) )
FURNACE ENCLOSURE GAS FLOW FIELD : Mass, Energy, Momentum and Species Conservation Equations +Turbulence, Radiation, Reaction Models Temperature, Heat Transfer Velocity, Turbulent Mixing, Chemical Species and Reaction
CFD
QRAD
FUEL BED COMBUSTION MODEL FUEL BED: Combustion, Gas Reaction Heat Transfers x=0 (t=0) PRIMARY AIR(x) Fuel Components and Temperature Gas Species and Temperature Bed Height, etc. x = Grate Length (tmax: Fuel Residence Time)
Thermal Engineering Lab
TEMPERATURE [ UNIT : K ]
1200
1500
Tgas
1100
1100
CO2
0.2
1500
700
0.1
Tgas
Mole Fraction
1400
CxHyOz+CO+H2
300
0.0
1200
1100
CO2
0.2
700
CxHyOz+CO+H2
300
01 0.1
0.0
1300
0.35
0.00 0 4 8 12
500
Distance (m)
Bed Height ( (m) 0.70
1500
0.35
13 12 11 31 12
700
0.00 0
4 Distance (m)
AIR IGNITION
SINTERED ZONE
SINTERED ZONE
COOLING
RAW MIX
y x
COMBUSTION GAS
COMBUSTION GAS
Oxidi zer
Solid materiala
Time = 0
a
Combustion g gas
Shrinkage g of g grid
No
CO+0.5O2CO2
IRON ORE SINTERING BED COMPARISON WITH SINTERING POT TEST RESULTS
Bed Type: Fixed Bed of Mixed Materials without a Gas Plenum Extension of 1-D Unsteady Model to 2-D Steady Model
& Q air
Air
y=490mm 600mm m
Sintering bed
ID=205mm
R-type T/C
y=300mm y=110mm
Tbed
P
& Q gas
Tgas
y t=0
Combustion zone
time tmax
Wind Box
IRON ORE SINTERING BED COMPARISON WITH SINTERING POT TEST RESULTS
2000 1800 1600 1400 1200 1000 800 600 400
25
y=0.30m
y=0.11m
20
Tempera ature(K)
15
10
0
0 200 400 600 800 1000 1200 1400
200
400
600
800
1000
1200
1400
Time (sec)
Time(sec)
Temperature profile Flame front speed (FFS) and Sintering time for various air velocities and particle diameters
Sintering time
Flam me Front Speed (cm m/min)
4
Extingushed
1600
1200 3
FFS
2
800
400
Flame Front Speed (FFS) Combustion Zone Thickness (CZT) Melting Zone Thickness (MZT) : for an Iron Ore Sintering Bed CZT : Combustion Zone Thickness Maximum Temperature (MaxT) MZT : Melting Zone Thickness
40 35 30
Thicknes ss (cm)
Sintered Zone
1600
25 20 15
CZT
Combustion Zone Melting Zone
1400
1200 10
MZT
Te emperature
MaxT
Raw Mix
1373K 1000K
Time (sec)
Quantified results : CZT, MZT, MaxT (for various air Thermal Engineering Lab supply)
Maximum Te emperature (K K)
CZT(AirV=0.26m/s) CZT(AirV=0.32m/s) CZT(AirV=0.45m/s) CZT(AirV=0.52m/s) MZT(AirV=0 26m/s) MZT(AirV=0.26m/s) MZT(AirV=0.32m/s) MZT(AirV=0.45m/s) MZT(AirV=0.52m/s)
2000
MaxT(AirV=0.26m/s) MaxT(AirV=0.32m/s) MaxT(AirV=0.45m/s) MaxT(AirV=0.52m/s) MaxT(AirV 0.52m/s)
1800
Coke Oven
Coke Oven
Plastic layer
Flue Flue
(1) Wet Coal (<100oC) (2) Dried Coal (100~400oC) (3) Semi-Coke (4) Coke
(4)
Coal
Air Fuel
Coke
Air Fuel
Thermal decomposition of bituminous coal with final temperatures of about 900 in the absence of air 0.45m width, 6m height and 16m length, Slot -type furnace Oven wall is heated by fuel gas combustion in the combustion chamber
Thermal Engineering Lab
Height (6m) is much longer than width(0.45m) 1D model Charging coal is assumed to be not a coal blend but a single coal Input data - Elemental/Proximate analysis data Homogeneous porous media
Shrinkage g of g grid
No
Coke oven (Batch type fixed bed) Gas Heat from hot wall Raw
coking coal
Coke
Time = 0
Time = t1
Time = tmax
Temperature e (oC)
0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Time (h)
Time
Temperature (K)
Tempera ature(K)
10
15
20
10
15
20
Time (hour)
Time (hour)
Blast Furnace
Modeling
[17]
coke
Solid flow
G Gas
a:
Simplification
Height(m)
30.5 30 29.5
Profilemeter
R di ( ) Radius(m)
30 29.5
7 6 5
Height t(m)
29 28.5 28 27.5 27 0 1 2
Lo/Lc
4
ORE COKE
3
4 3 2 1 0 0 1 2 3 4
Radius(m)
R a diu s(m )
7 6 5
Lo/L Lc
4 3 2 1 0 0 1 2 3 4 5
Radius(m)
Case A
Case B
Case C
Case A
Case B
Case C
Thermal Engineering Lab
Fe2O3
Fe3O4
FewO
Fe
Thermal Engineering Lab
1.0
0.40 0.35
CO2 CO
08 0.8
Fe2O3 FewO Fe
Mass Fr raction
Fe3O4
Mass fr raction
0.6
0.4
0.2
0.0 10 15 20 25
0.00 5 10 15 20 25 30
Height(m)
Height(m)
Chemical Reaction
F w O ( s ) + CO ( g ) wFe Fe F ( s ) + CO2 ( g )
1 3 Fe3O4 ( s ) + CO ( g ) Fe ( s ) + CO2 ( g ) (Ts < 848 K ) 4 4
6 f Rn = i i i d i g W CO , g CO2 , g a n ,m K m M M CO2 m =1,4 CO
a1,1 = A3 ( A2 + B2 + B3 + F ) + ( A2 + B2 ) ( B3 + F ) a 2,2 = ( A1 + B1 + B2 )( A3 + B3 + F ) + A3 ( B3 + F )
* a3,3 = ( A1 + B1 )( A2 + B2 + B3 + F ) + A2 ( B2 + B3 )
k n (1+11 K n )
Bn = F=
2
X n +1 X n X n +1 X n 1 k film,CO2
i 2d Dn
X1 = X2 =
50.2
d Fe2O3 ds d Fe3O4 ds
X3 =
d FewO ds
W = ( A1 + B1 ) a1,1 A2 a1,2
K 1 = exp 7.255 +
3720 Ts 1
X4 =1
K2 K3
K3
( ) k = 10 exp (3.16 = exp ( 5.289 ) k = 10 exp ( 2.09 = exp ( 3.127 3 127 + 5 42 ) k = 10 exp (5.42 = exp ( 1.032 + ) k =k D =D
4711 Ts 2 2 2879 Ts 2 3
981.5 Ts 4 1 4 2 Tave DCO g 1 2 ,N2 2 + 0.39 Re ig2 = Tave g DCO ds 2 ,N2
1
8.314610 3 Ts
40
8.314610 3 Ts 61 4 61.4
) )
8.314610 3 Ts
k film,CO2
Tave =
Ts + Tg 2
3 Fe w Fe 1 2 Fe F 2 O3 F 3 O4 F wO = + + M Fe2 O3 M Fe3O4 M Few O
1
d Fe F 2 O3 ds
1 2 Fe F 2 O3 = M Fe2 O3
d Fe F 3 O4 ds
3 Fe 1 2 Fe F 2 O3 F 3 O4 = + M Fe2 O3 M Fe3O4
d Fe F wO ds
3 =
2 Fe2O3 M Fe2 O3
3 Fe3O4 M Fe3O4
w Few O M Few O
Fe
M Fe
Solution loss
C ( s ) + CO2 ( g ) 2CO ( g )
R5 = g CO2 , g M CO2 As k film,CO2
1 + ( k 5 )
As =
6(1 ) d s s
k5 =
k 5,1 51
1 + k 5,2 PCO + k 5,3 PCO2
s (1 ) 82.056 82 056 10 3 Tg
Tave = 0.5 (Tg + Ts )
21421 k 5,2 = exp 6.688 + 1.987 Ts
( d s s )
k 5,1 =
1 60
)
k 5 s Tave s DCO 2 ,N2
Pj =
82.056 10 M
j
g Tg
j,g
ds 6
Sh s = 1.5 Re 0.55 sg
1 1 tanh ( 3 ) 3
CONCLUSIONS
Reacting R i fl flow of f solid, lid liquid li id and d gas phase h of f multiple l i l component Discretization of the solid flow in the same manner as the usual discretization of gas phase Common governing equations for gas and solid phases Easy to accommodate various configurations of gas and solid flow by treating them as boundary y conditions User can define the dimension, phenomena, boundary conditions, etc.
Moving bed in waste incinerator I Iron ore sintering i t i b bed d Coke oven Blast furnace
Physicsbased Computational Model: Critically beneficial for design and operation A li bl t Applicable to very i important t t engineering i i processes Validity shown for application in incinerators, sintering, coking and blast furnace Maybe applicable to food and bio processing
Sub-processes are not comprehensively modeled Difficult to validate: measurable quantities are limited
THANK YOU
Temperature in Raceway
Obtained from the heat and mass balance in the raceway Boundary condition of the energy equation of gas phase
Temperature Distribution
Measured Results
Base
High PCR
Position of CZ
18
16
16
14
14
12
12
10
10
6 1 2 3 4 5
6 1 2 3 4 5
Radius(m)
Radius(m)
Measured result
Simulated result
Thermal Engineering Lab
Pressure Drop
Measurement
Press sure(MPa)
0.25
0.28
0 5 10 15 20
2.1
3.2
4.4
5.6
6.7
7.9
--
Calculated data
Measurement data
Simulation Condition
<Operation condition>
Top gas pressure (MPa) Blast volume (Nm3/min) Blast pressure (MPa) Blast temperature (oC) Production rate of pig iron(t/d) PCR (kg/t) O2 rate t (Nm (N 3/hr) /h ) Blast moisture(g/Nm3) R.R (kg/t) Ore ratio (-) 0.277 6150 0 4192 0.4192 1191 9284 147.6 20000 22.3 489.2 1.683
<Calculation cases>
Case A : Case B : (0.5m) Case C : (1.0m)
<Layer property>
Layer Ore layer Coke layer Cohesive layer Raceway Deadman zone for gas Particle diameter (m) 0.0214 0.0477 0.0214 0 0477 0.0477 0.0477 Shape factor ( (-) ) 0.84 0.90 0.84 0 90 0.90 0.90 Voidage (-) () 0.36 0.45 0.10 0 80 0.80 0.10 Thermal Engineering Lab