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: andreas.spanlang@k1-met.com2Primetals 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