KnetMET — Kompetenznetzwerk für metallurgische und ... · It is based on mass and energy...
1
gPROMS Modelling The sub models and process flow sheet required for the blast furnace model were created in the environment of the gPROMS ModelBuilder. The model is based on the use of three parallel calculation layers which are implemented through gPROMS sub topologies. The material flows of the blast furnace process are depicted by the main sub topology layer. A black box model is used on this sub topology for the chemical and physical transformation of burden, coke, hot blast and injectants into blast furnace gas, slag and hot metal. It is based on mass and energy balances of involved components and elements. The second sub topology layer is used for the calculation of the RAFT. For this task, the material stream information of hot blast and injectants is used. The third sub topology layer is required to construct the Rist operating diagram in order to investigate the thermodynamic conditions of the blast furnace process. It incorporates all solid, liquid and gaseous input streams of the black box model. Blast Furnace Process The main system inputs of a blast furnace are iron oxides, coke, additives, hot blast and substitute reducing agents in order to produce liquid hot metal, slag and blast furnace gas. It can be described as a counter current, multi-phase heat and mass exchange reactor which combines three main process units: • Reduction reactor • Gasification reactor • Smelting oven The energy required to maintain stable operation is provided by gasification of coke and hydrocarbons within the raceway in front of the blast furnace tuyeres. Main parameter to describe this process is the raceway adiabatic flame temperature (RAFT).The Rist operating diagram provides a graphical representation of balances of carbon, oxygen and hydrogen. These elements contribute in formation and utilization of reducing gas during in the blast furnace process. Development of a Blast Furnace Model in gPROMS with Thermodynamic Process Depiction by Means of the Rist Operating Diagram Andreas Spanlang 1 , Bernd Weiss 2 , Walter Wukovits 3 1 K1 - MET GmbH Metallurgical Competence Center, Linz, Austria Contact: andreas.spanlang@k1 - met.com 2 Primetals Technologies Austria GmbH, Iron - and Steelmaking Technology and Innovation, Linz, Austria 3 TU Wien, Institute of Chemical Engineering, Vienna, Austria 1,5 1,0 1,0 2,0 ϑ BG H 2 /H 2 O CO/CO 2 Mixture Wuestite -1,0 -1,5 Metallic Iron Fe Wuestite FeO Magnetite Fe 3 O 4 0,0 Operation Line Equilibrium Line CO 2 + H 2 O CO + CO 2 + H 2 + H 2 O 1,0 0,0 Iron-Wuestite – Equilibrium Wuestite-Magnetite – Equilibrium Iron-Magnetite - Equilibrium Magnetite (O+H 2 )/(Fe) (O+H 2 )/(C+H 2 ) Indirect Reduction Direct Reduction References: • Geerdes M., Toxopeus H., van der Vliet C., 2009, Modern Blast Furnace Ironmaking - an introduction, IOS Press BV, Amsterdam • Ottow, M., 1975. Eisen. In: Ullmann's Encyklopädie der technischen Chemie, Band 10, 4th ed., Verlag Chemie, Weinheim • Peacey J.G., Davenport W.G., 1979, The Iron Blast Furnace - Theory and Practice, Pergamon Press, Oxford • Rist A., Meysson N., 1967, A Dual Graphic Representation of the Blast-Furnace Mass and Heat Balances, Journal of Metals, 19, 50-59 Coordinated by Financially supported by Since all calculation layers are assigned to the same hierarchical level, the interdependencies between the corresponding sub systems (blast furnace process, RAFT and Rist operating diagram) can be depicted through the use of a single mathematical model. Simulation Results The developed model was validated against well established calculation tools as well as plant data provided by Primetals Technologies. The main interest is focused on the calculated properties of the process outputs as well as on the corresponding Rist operating diagram. Introduction The traditional blast furnace route is the worlds most important process for the production of hot metal. A wide range of different mathematical models has been developed in the past. As an alternative an analogue representation of the blast furnace process is given by the Rist operating diagram. The target of this work is the development and validation of a comprehensive blast furnace model in gPROMS. Blast Furnace Model Black Box Sub Model Adiabatic Flame Temperature Sub Model Rist Sub Model Solid Inputs Coke Iron Ore Sinter Pellets Scrap Additives Gaseous Inputs Hot Blast Injectants Carrier Gas Purge Gas Process Outputs Hot Metal Slag Blast Furnace Gas Process Type Multi-phase, counter current heat and mass exchange -2.00 -1.50 -1.00 -0.50 0.00 0.50 1.00 1.50 0.00 0.50 1.00 1.50 2.00 (O+H2)/Fe (O+H2)/(C+H2) Rist Operating Diagram Operation line gPROMS Operation line Base Case Baur-Glaessner gPROMS Baur-Glaessner Base Case 0.95 1.00 1.05 1.10 1.15 1.28 1.33 1.38 (O+H2)/Fe (O+H2)/(C+H2) 1 10 100 1000 10000 100000 1 10 100 1000 10000 100000 Blast furnace gas Hot metal Slag Mass flow in kg/h Volume flow in Nm3/h Calculated System Outputs Base Case gPROMS model Base Case gPROMS model 1 10 100 H2 H2O CO CO2 N2 Composition in % vol. Calculated Blast Furnace Gas Composition Base Case gPROMS model 1 10 100 1000 Blast furnace gas RAFT Temperature in °C Calculated Temperatures Base Case gPROMS model Conclusions and Outlook • The achieved simulation results are in good accordance with their corresponding target values. • Potential applications of the blast furnace model include verification of existing metallurgical plants as well as investigation of new process variants. • In the future, a multizonal implementation as well as an extension of the covered set of elements with respect to trace elements and alcalines are envisaged. Rist Operating Diagram Blast Furnace Process Overview Acknowledgements The authors gratefully acknowledge the funding support of K1-MET GmbH, metallurgical competence center. The research program of the competence center K1-MET is supported by COMET (Competence Center for Excellent Technologies), the Austrian program for competence centers. COMET is funded by the Federal Ministry for Transport, Innovation and Technology, the Federal Ministry for Science, Research and Economy, the province of Upper Austria, Tyrol, and Styria, the Styrian Business Promotion Agency. Advanced Process Modelling Forum 2016 – London, United Kingdom, 20 – 21 April 2016
Transcript of KnetMET — Kompetenznetzwerk für metallurgische und ... · It is based on mass and energy...
gPROMS Modelling
The sub models and process flow sheet required for the blast furnace model were
created in the environment of the gPROMS ModelBuilder. The model is based on the use
of three parallel calculation layers which are implemented through gPROMS sub
topologies. The material flows of the blast furnace process are depicted by the main sub
topology layer. A black box model is used on this sub topology for the chemical and
physical transformation of burden, coke, hot blast and injectants into blast furnace gas,
slag and hot metal. It is based on mass and energy balances of involved components
and elements. The second sub topology layer is used for the calculation of the RAFT. For
this task, the material stream information of hot blast and injectants is used. The third sub
topology layer is required to construct the Rist operating diagram in order to investigate
the thermodynamic conditions of the blast furnace process. It incorporates all solid, liquid
and gaseous input streams of the black box model.
Blast Furnace ProcessThe main system inputs of a blast furnace are iron oxides, coke, additives, hot blast and
substitute reducing agents in order to produce liquid hot metal, slag and blast furnace
gas. It can be described as a counter current, multi-phase heat and mass exchange
reactor which combines three main process units:
• Reduction reactor
• Gasification reactor
• Smelting oven
The energy required to maintain stable operation is provided by gasification of coke and
hydrocarbons within the raceway in front of the blast furnace tuyeres. Main parameter to
describe this process is the raceway adiabatic flame temperature (RAFT).The Rist
operating diagram provides a graphical representation of balances of carbon, oxygen and
hydrogen. These elements contribute in formation and utilization of reducing gas during
in the blast furnace process.
Development of a Blast Furnace Model in gPROMS with
Thermodynamic Process Depiction by Means of
the Rist Operating Diagram
Andreas Spanlang1, Bernd Weiss2, Walter Wukovits3
1K1-MET GmbH Metallurgical Competence Center, Linz, Austria Contact: [email protected] Technologies Austria GmbH, Iron- and Steelmaking Technology and Innovation, Linz, Austria3TU Wien, Institute of Chemical Engineering, Vienna, Austria
1,5
1,0
1,0 2,0
ϑBG
H2/H2OCO/CO2
Mixture
Wuestite
-1,0
-1,5
Metallic
Iron
Fe
Wuestite
FeO
Magnetite
Fe3O4
0,0
Operation
Line
Equilibrium
Line
CO2 + H2O
CO + CO2 + H2 + H2O
1,00,0
Iron-Wuestite
– Equilibrium
Wuestite-Magnetite
– Equilibrium
Iron-Magnetite
- Equilibrium
Magnetite
(O+
H2)/
(Fe
)
(O+H2)/(C+H2)
Indirect
Reduction
Direct
Reduction
References:• Geerdes M., Toxopeus H., van der Vliet C., 2009, Modern Blast Furnace Ironmaking - an introduction, IOS Press BV, Amsterdam
• Ottow, M., 1975. Eisen. In: Ullmann's Encyklopädie der technischen Chemie, Band 10, 4th ed., Verlag Chemie, Weinheim
• Peacey J.G., Davenport W.G., 1979, The Iron Blast Furnace - Theory and Practice, Pergamon Press, Oxford
• Rist A., Meysson N., 1967, A Dual Graphic Representation of the Blast-Furnace Mass and Heat Balances, Journal of Metals, 19, 50-59
Coordinated by Financially supported by
Since all calculation layers are assigned to the same hierarchical level, the
interdependencies between the corresponding sub systems (blast furnace process,
RAFT and Rist operating diagram) can be depicted through the use of a single
mathematical model.
Simulation ResultsThe developed model was validated against well established calculation tools as well
as plant data provided by Primetals Technologies. The main interest is focused on the
calculated properties of the process outputs as well as on the corresponding Rist
operating diagram.
IntroductionThe traditional blast furnace route is the worlds most important
process for the production of hot metal. A wide range of different
mathematical models has been developed in the past. As an
alternative an analogue representation of the blast furnace
process is given by the Rist operating diagram. The target of this
work is the development and validation of a comprehensive blast
furnace model in gPROMS.
Blast Furnace Model
Black Box Sub Model
Adiabatic Flame Temperature Sub
Model
RistSub Model
Solid InputsCoke
Iron Ore
Sinter
Pellets
Scrap
Additives
Gaseous InputsHot Blast
Injectants
Carrier Gas
Purge Gas
Process
OutputsHot Metal
Slag
Blast Furnace Gas
Process TypeMulti-phase, counter
current heat and mass
exchange
-2.00
-1.50
-1.00
-0.50
0.00
0.50
1.00
1.50
0.00 0.50 1.00 1.50 2.00
(O+
H2)/
Fe
(O+H2)/(C+H2)
Rist Operating Diagram
Operation line gPROMS
Operation line Base Case
Baur-Glaessner gPROMS
Baur-Glaessner Base Case
0.95
1.00
1.05
1.10
1.15
1.28 1.33 1.38
(O+
H2
)/F
e
(O+H2)/(C+H2)
1
10
100
1000
10000
100000
1
10
100
1000
10000
100000
Blast furnacegas
Hot metal Slag
Mas
s fl
ow
in k
g/h
Vo
lum
e f
low
in N
m3
/h
Calculated System Outputs
Base Case gPROMS model Base Case gPROMS model
1
10
100
H2 H2O CO CO2 N2
Co
mp
osi
tio
n in
% v
ol.
Calculated Blast Furnace Gas Composition
Base Case gPROMS model
1
10
100
1000
Blast furnacegas
RAFT
Tem
pe
ratu
re in
°C
Calculated Temperatures
Base Case gPROMS model
Conclusions and Outlook• The achieved simulation results are in good accordance with their corresponding
target values.
• Potential applications of the blast furnace model include verification of existing
metallurgical plants as well as investigation of new process variants.
• In the future, a multizonal implementation as well as an extension of the covered set
of elements with respect to trace elements and alcalines are envisaged.
Rist Operating DiagramBlast Furnace Process Overview
AcknowledgementsThe authors gratefully acknowledge the funding support of K1-MET GmbH, metallurgical
competence center. The research program of the competence center K1-MET is
supported by COMET (Competence Center for Excellent Technologies), the Austrian
program for competence centers. COMET is funded by the Federal Ministry for
Transport, Innovation and Technology, the Federal Ministry for Science, Research and
Economy, the province of Upper Austria, Tyrol, and Styria, the Styrian Business
Promotion Agency.
Advanced Process Modelling Forum 2016 – London, United Kingdom, 20 – 21 April 2016
