铁矿石烧结过程的数值模拟与试验验证
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摘要
铁矿石烧结过程是钢铁工业中关系到高炉生产的产量、质量及能耗的重要环节。近年来,随着我国钢铁工业的迅猛发展以及铁矿石烧结矿用量的大幅增长,烧结设备大型化已成为必然趋势。同时,烧结床的床料高度越来越高,铁矿石种类波动也越来越大,铁矿石烧结的能耗高、污染物排放多以及铁矿石资源问题也日益严峻。这些问题的出现,使得人们对铁矿石烧结过程机理的研究愈发重视,从机理的研究中寻求能耗低、污染物排放少以及效率高的烧结方法。本文的研究就是在这样的大背景下提出的。本文对铁矿石烧结过程开展了系统的数值模拟工作。
铁矿石烧结是涉及相变、传热与传质、流动、燃烧、矿物生成与转化等现象的复杂过程。同时考虑上述因素,对其进行数值模拟具有很大难度。本文对烧结过程开展了系统的数值模拟工作。本文主要进行了烧结中物理化学变化的分析、模型基本假设的提出、模型控制方程的构建、关键子模型的建立、模型数值求解、模型的试验验证、模型结果分析等内容的研究。具体地,本文的内容描述如下。
本文首先介绍了全文的研究背景并开展了文献综述。该部分详细分析了我国钢铁工业的发展现状及存在的问题,指出我国钢铁工业目前处于高速发展时期,但存在着能耗高、污染重等突出问题。随后介绍了我国铁矿石烧结的发展现状及存在的问题,指出我国烧结工艺技术取得了很大的改善,但同时存在着能耗、环保、铁矿石资源缺乏等问题。而后介绍了铁矿石烧结过程的工艺流程和特点,以及烧结床结构的特点。随后,本文对数学模型的研究现状进行了文献综述,对文献中烧结模型的优缺点进行了评述。最后,提出了本文的研究目的。
第二章详细介绍了铁矿石烧结过程的数学描述。首先分析了烧结床内物理化学过程的特点。针对烧结杯和烧结机中的烧结床的共同点,详细阐述了烧结床不同区域内颗粒(或物料)形态变化及可能发生的物理化学过程,列出了床内可能发生的14个物理化学过程。分析结果得出了铁矿石烧结过程的四个鲜明特点,即1涉及的物理化学过程众多(包括相变、传热与传质、流动、燃烧、矿物生成与转化等)、2床层结构和床料颗粒形态发生很大变化、3各种物理化学过程之间强烈耦合、4过程显示出一维特征。之后,给出了烧结模型的九条基本假设。本模型共考虑13种组分,包括8种固相组分和5种气相组分,以及8个化学反应。描述烧结过程的8个控制方程、以及相应的边界条件和初始条件也同时给出,并作了详细阐述。
第三章详细介绍了铁矿石烧结模型的关键子模型和模型的数值求解方法。这些关键子模型包括焦炭燃烧、烧结床石灰石分解、白云石分解、烧结床水分干燥和凝结、磁铁矿氧化、矿物熔化和凝固、烧结床传热传质模型。
第四章首先介绍了澳大利亚必和必拓公司纽卡斯尔技术中心的中试规模烧结杯试验,本文试验数据均来自该技术中心。烧结杯试验结果进行了详细介绍。对试验过程的分析表明试验结果可以用于本文的模型验证。
第四章随后对本文模型的预测性能进行了全面验证,本文选取25组不同工况范围的烧结杯试验数据,将模型计算结果和试验结果进行了详细对比,证明了本文的烧结模型的合理性。
第五章利用模型计算结果对铁矿石烧结过程进行了详细剖析,分析了气体固体温度曲线、床内熔体份额分布、二维温度和熔体份额分布、烧结床内压力分布特点、料层结构分析、重要参数的敏感性。本文模型的良好预测效果得到了验证。
最后,第六章为全文总结部分,该部分对全文结论、创新点和展望进行了总结。本文的主要研究内容为铁矿石烧结床内物理化学过程的机理性研究、铁矿石烧结过程数学模型控制方程建立、铁矿石烧结过程数学模型关键子模型的建立与求解方法、铁矿石烧结数学模型的验证、利用模型结果剖析铁矿石烧结过程。本文的创新点以及工作展望也这里作了详细阐述。
Iron ore sintering is a critical process influencing the productivity, quality and energy consumption of the integrated iron and steel industry. With the rapid development of the iron and steel industry and the increasing consumption of iron ore sinter in China, larger-scale iron ore sintering equipments have appeared in China in recent years. At the same time, the bed height is getting higher and higher and the received iron ore types are varying greatly in sinter plants. The issues of high energy consumption and high pollutant emission and lack of iron ore resources have also getting more and more serious. Therefore, increasing attention has been paid to the investigation of the iron ore sintering mechanisms to explore environmentally-friendly and more efficient sintering technologies. The present work is proposed under this background. Numerical modelling of the iron ore sintering process is carried out in the present study.
Iron ore sintering is a complex process involving the phenomena of phase change, heat and mass transfer, gas flow, combustion, mineral formation and conversion, etc. Considering its complexity, modelling the sintering process is very difficult. The present work has conducted systematic modelling of the iron ore sintering process. The major contents of the present work include the analyses of the physico-chemical changes during sintering, proposal of the basic model assumptions, construction of the governing equations, building of the key sub-models, numerical solution of the model, model validation as well as the analyses of the model results. The specific contents are introduced as follows.
At the beginning of chapter one, the research background was introduced and relevant literature review was carried out. In this section, the current development status and the existing problems of the iron and steel industry in China were analyzed. The analyses results indicated that the iron and steel industry in China is developing rapidly, but still has some unsolved problems such as high energy consumption and high pollutant emission. Then the development of iron ore sintering technologies in China was also introduced. The results suggest that the iron ore sintering technologies have developed greatly but still have some significant problems. After that, the flow chart of the iron ore sintering process and its characteristics were introduced. The structure of the iron ore sintering bed was also discussed. Then the review of the iron ore sintering models reported in literature was carried out, in which the strengths and weaknesses of the models were discussed. The objective of the present work was given at the end of chapter one.
In chapter two, the detailed mathematical description of the iron ore sintering process was given. Based on the common characteristics of the sintering process in the commercial sinter machine and the sinter pot, this section firstly showed the great changes of granule shape (or raw materials) in different zones and the possible physico-chemical changes during the sintering process. Fourteen different physico-chemical changes were indentified. The analyses results indicated the four distinctive features of the sintering process, i.e.1. involvement of a number of physico-chemical changes (including phase change, heat and mass transfer, fluid flow, combustion, melting and solidification),2. great structure changes of the sintering bed and granules during sintering.3. the strong coupling of the physico-chemical changes,4. one-dimensional characteristic. Then, the nine basic model assumptions were shown and analyzed in detail. The present iron ore sintering model takes into account thirteen species including eight solid species and five gas species, as well as eight chemical reactions. Eight governing equations of the sintering process and relevant boundary and initial conditions were given and discussed.
In chapter three, the key sub-models and the numerical solution method of the iron ore sintering model were introduced in detail. The key sub-models are the models of coke combustion, limestone decomposition, dolomite decomposition, drying and condensation, magnetite oxidation, melting and solidification, heat and mass transfer.
In the first part of chapter four, the pilot-scale sinter pot test in the Newcastle technology center of BHP Billiton in Australia was carefully introduced. The introduction of the sinter pot testing process indicates that the testing results can be used to validate the iron ore sintering model developed in the present work. Some testing results were introduced. All the experimental data used in the present work were from the Newcastle technology center.
Latter in chapter four, the iron ore sintering model in the present work was fully validated against the sinter pot test results from the Newcastle technology center. Twenty five cases covering a wide range of experimental conditions were used for model validation. The validation results demonstrated that the present iron ore sintering model is reasonable.
The iron ore sintering process was further analyzed using the model results in the chapter five. The gas and solid temperature profiles, the distribution of liquid fraction inside the bed, the two-dimensional distributions of temperature and liquid fraction, the gas pressure distribution, the bed structure and the sensitivity of some important parameters were discussed in this section. The results suggested that the model can predict the sintering process reasonably.
The present work was finally summarized in the chapter six, in which the conclusions and the innovations and the future work were shown. The summarization results suggested that the present work mainly focus on the mechanisms of the physico-chemical changes in the iron ore sintering bed, the development of a new iron ore sintering numerical model, model validation and sensitivity analyses and the understanding of the sintering process using the model results. The innovations of the present work and the perspectives of the future work were also discussed at the end of this chapter.
铁矿石烧结是涉及相变、传热与传质、流动、燃烧、矿物生成与转化等现象的复杂过程。同时考虑上述因素,对其进行数值模拟具有很大难度。本文对烧结过程开展了系统的数值模拟工作。本文主要进行了烧结中物理化学变化的分析、模型基本假设的提出、模型控制方程的构建、关键子模型的建立、模型数值求解、模型的试验验证、模型结果分析等内容的研究。具体地,本文的内容描述如下。
本文首先介绍了全文的研究背景并开展了文献综述。该部分详细分析了我国钢铁工业的发展现状及存在的问题,指出我国钢铁工业目前处于高速发展时期,但存在着能耗高、污染重等突出问题。随后介绍了我国铁矿石烧结的发展现状及存在的问题,指出我国烧结工艺技术取得了很大的改善,但同时存在着能耗、环保、铁矿石资源缺乏等问题。而后介绍了铁矿石烧结过程的工艺流程和特点,以及烧结床结构的特点。随后,本文对数学模型的研究现状进行了文献综述,对文献中烧结模型的优缺点进行了评述。最后,提出了本文的研究目的。
第二章详细介绍了铁矿石烧结过程的数学描述。首先分析了烧结床内物理化学过程的特点。针对烧结杯和烧结机中的烧结床的共同点,详细阐述了烧结床不同区域内颗粒(或物料)形态变化及可能发生的物理化学过程,列出了床内可能发生的14个物理化学过程。分析结果得出了铁矿石烧结过程的四个鲜明特点,即1涉及的物理化学过程众多(包括相变、传热与传质、流动、燃烧、矿物生成与转化等)、2床层结构和床料颗粒形态发生很大变化、3各种物理化学过程之间强烈耦合、4过程显示出一维特征。之后,给出了烧结模型的九条基本假设。本模型共考虑13种组分,包括8种固相组分和5种气相组分,以及8个化学反应。描述烧结过程的8个控制方程、以及相应的边界条件和初始条件也同时给出,并作了详细阐述。
第三章详细介绍了铁矿石烧结模型的关键子模型和模型的数值求解方法。这些关键子模型包括焦炭燃烧、烧结床石灰石分解、白云石分解、烧结床水分干燥和凝结、磁铁矿氧化、矿物熔化和凝固、烧结床传热传质模型。
第四章首先介绍了澳大利亚必和必拓公司纽卡斯尔技术中心的中试规模烧结杯试验,本文试验数据均来自该技术中心。烧结杯试验结果进行了详细介绍。对试验过程的分析表明试验结果可以用于本文的模型验证。
第四章随后对本文模型的预测性能进行了全面验证,本文选取25组不同工况范围的烧结杯试验数据,将模型计算结果和试验结果进行了详细对比,证明了本文的烧结模型的合理性。
第五章利用模型计算结果对铁矿石烧结过程进行了详细剖析,分析了气体固体温度曲线、床内熔体份额分布、二维温度和熔体份额分布、烧结床内压力分布特点、料层结构分析、重要参数的敏感性。本文模型的良好预测效果得到了验证。
最后,第六章为全文总结部分,该部分对全文结论、创新点和展望进行了总结。本文的主要研究内容为铁矿石烧结床内物理化学过程的机理性研究、铁矿石烧结过程数学模型控制方程建立、铁矿石烧结过程数学模型关键子模型的建立与求解方法、铁矿石烧结数学模型的验证、利用模型结果剖析铁矿石烧结过程。本文的创新点以及工作展望也这里作了详细阐述。
Iron ore sintering is a critical process influencing the productivity, quality and energy consumption of the integrated iron and steel industry. With the rapid development of the iron and steel industry and the increasing consumption of iron ore sinter in China, larger-scale iron ore sintering equipments have appeared in China in recent years. At the same time, the bed height is getting higher and higher and the received iron ore types are varying greatly in sinter plants. The issues of high energy consumption and high pollutant emission and lack of iron ore resources have also getting more and more serious. Therefore, increasing attention has been paid to the investigation of the iron ore sintering mechanisms to explore environmentally-friendly and more efficient sintering technologies. The present work is proposed under this background. Numerical modelling of the iron ore sintering process is carried out in the present study.
Iron ore sintering is a complex process involving the phenomena of phase change, heat and mass transfer, gas flow, combustion, mineral formation and conversion, etc. Considering its complexity, modelling the sintering process is very difficult. The present work has conducted systematic modelling of the iron ore sintering process. The major contents of the present work include the analyses of the physico-chemical changes during sintering, proposal of the basic model assumptions, construction of the governing equations, building of the key sub-models, numerical solution of the model, model validation as well as the analyses of the model results. The specific contents are introduced as follows.
At the beginning of chapter one, the research background was introduced and relevant literature review was carried out. In this section, the current development status and the existing problems of the iron and steel industry in China were analyzed. The analyses results indicated that the iron and steel industry in China is developing rapidly, but still has some unsolved problems such as high energy consumption and high pollutant emission. Then the development of iron ore sintering technologies in China was also introduced. The results suggest that the iron ore sintering technologies have developed greatly but still have some significant problems. After that, the flow chart of the iron ore sintering process and its characteristics were introduced. The structure of the iron ore sintering bed was also discussed. Then the review of the iron ore sintering models reported in literature was carried out, in which the strengths and weaknesses of the models were discussed. The objective of the present work was given at the end of chapter one.
In chapter two, the detailed mathematical description of the iron ore sintering process was given. Based on the common characteristics of the sintering process in the commercial sinter machine and the sinter pot, this section firstly showed the great changes of granule shape (or raw materials) in different zones and the possible physico-chemical changes during the sintering process. Fourteen different physico-chemical changes were indentified. The analyses results indicated the four distinctive features of the sintering process, i.e.1. involvement of a number of physico-chemical changes (including phase change, heat and mass transfer, fluid flow, combustion, melting and solidification),2. great structure changes of the sintering bed and granules during sintering.3. the strong coupling of the physico-chemical changes,4. one-dimensional characteristic. Then, the nine basic model assumptions were shown and analyzed in detail. The present iron ore sintering model takes into account thirteen species including eight solid species and five gas species, as well as eight chemical reactions. Eight governing equations of the sintering process and relevant boundary and initial conditions were given and discussed.
In chapter three, the key sub-models and the numerical solution method of the iron ore sintering model were introduced in detail. The key sub-models are the models of coke combustion, limestone decomposition, dolomite decomposition, drying and condensation, magnetite oxidation, melting and solidification, heat and mass transfer.
In the first part of chapter four, the pilot-scale sinter pot test in the Newcastle technology center of BHP Billiton in Australia was carefully introduced. The introduction of the sinter pot testing process indicates that the testing results can be used to validate the iron ore sintering model developed in the present work. Some testing results were introduced. All the experimental data used in the present work were from the Newcastle technology center.
Latter in chapter four, the iron ore sintering model in the present work was fully validated against the sinter pot test results from the Newcastle technology center. Twenty five cases covering a wide range of experimental conditions were used for model validation. The validation results demonstrated that the present iron ore sintering model is reasonable.
The iron ore sintering process was further analyzed using the model results in the chapter five. The gas and solid temperature profiles, the distribution of liquid fraction inside the bed, the two-dimensional distributions of temperature and liquid fraction, the gas pressure distribution, the bed structure and the sensitivity of some important parameters were discussed in this section. The results suggested that the model can predict the sintering process reasonably.
The present work was finally summarized in the chapter six, in which the conclusions and the innovations and the future work were shown. The summarization results suggested that the present work mainly focus on the mechanisms of the physico-chemical changes in the iron ore sintering bed, the development of a new iron ore sintering numerical model, model validation and sensitivity analyses and the understanding of the sintering process using the model results. The innovations of the present work and the perspectives of the future work were also discussed at the end of this chapter.
引文
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