Minimization of Blast Furnace Fuel Rate by Optimizing Burden

and Gas Distributions

THE PROBLEM
The blast furnace (BF) process is a counter-current moving-
bed chemical reactor to reduce iron oxides to iron, which
involves complex transport phenomena and chemical
reactions. The fuel economy of the blast furnace process is
directly coupled to the gas and burden distributions. The
knowledge of gas distributions and its influential factors in a
blast furnace is essential for the process optimization. Due to
the difficulties in measurements, such knowledge can be most
readily obtained through the development of high fidelity
computational fluid dynamics (CFD) numerical simulations.
Schematic of the CFD model

THE PROJECT
The comprehensive CFD model consists of burden
distribution, gas distribution, heat transfer and chemical
reactions. The multiphase reacting CFD code has been
developed to simulate the BF shaft process and predicted
the cohesive zone shape under different conditions. The
simulation results are validated with industry
measurement. The effects of burden distribution, tuyere
operation and production rate are investigated.

Temperature & CO species in BF operation

THE RESULTS
The CFD results showed the influence of different
operating parameters and burden distributions on the
shape and position of the cohesive zone. So this model
is used as a tool to predict the furnace internal
conditions. Research work is going on to optimize the
Validation Top gas utilization burden and gas distribution for maximum efficiency of
the furnace operations.
Sponsor: Department of Energy (DOE)
Partner: ArcelorMittal-USA, SeverStal ArcelorMittal-
Dofasco, US Steel, US Steel - Stelco Inc., Union Gas
Students: Md. Taifur Rahman & Dong Fu
0461114 CENTER FOR INNOVATION THROUGH
VISUALIZATION AND SIMULATION
Purdue University Calumet
2200 169th Street, Hammond, IN 46323
219-989-2765
This research was partially supported by U.S. Department of Energy Grant DE-NA000741 under the administration of the National Nuclear Security Administration.

www.purduecal.edu/civs civs@purduecal.edu