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研究生： 葉承朋
Yeh, Cheng-Peng
論文名稱： 高爐風徑區流場與燃燒之數值模擬研究
NUMERICAL STUDY ON FLOW AND COMBUSTION IN BLAST FURNACE RACEWAY
指導教授： 楊瑞珍
Yang, Ruey-Jen
學位類別： 博士
Doctor
系所名稱： 工學院 - 工程科學系
Department of Engineering Science
論文出版年： 2012
畢業學年度： 101
語文別： 英文
論文頁數： 115
中文關鍵詞： 高爐 、風徑區 、粉煤噴吹 、爐頂氣循環過程 、燃燒
外文關鍵詞： Blast furnace, Raceway, Pulverized coal injection, Top gas recycling process, Combustion
相關次數： 點閱：73  下載：3 
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    • 高爐於煉鐵鋼廠中是扮演著鐵水供應的重要角色。為降低煉鐵成本、增加企業的競爭力，現今高爐皆採用煤粉噴吹之技術來煉鐵以取代高價之焦炭。實務經驗表明，在高噴吹量的情況下，容易造成高爐的不穩定。為確保高爐的操作效率，研究中以數值模擬的方法來探討高爐風徑區內複雜的物理與化學現象，以瞭解造成爐況不穩定的因素。
    論文的第一部分中，建立（二維）全焦燃燒數學模型來探討鼓風量與爐內條件對風徑區變化的影響；然後將該模型擴展至三維全比例（高爐）模型來預測中鋼三號高爐的風徑區結構。
    論文的第二部分則建構一噴吹燃料燃燒之數學模式，以探討高爐雙輔助燃料（粉煤、爐頂氣）混合噴吹時，其不同的燃料特性對粉煤的燃燒效率與流場特性的影響。所探討參數包括噴槍型式、冷卻氣體種類與噴吹率。結果表明，高爐爐頂氣循環噴吹時，由於爐頂氣易燃的特性在鼓風嘴內立即著火燃燒，造成鼓風管–鼓風嘴內的阻力明顯增加；然而爐頂氣中的還原氣體燃燒會消耗粉煤周圍的氧氣濃度，所以粉煤的燃燒率隨著爐頂氣噴吹量的增加而明顯的降低。此外，較大槍口管徑的噴槍所導致的二次流旋渦效應明顯較小者強。
    本論文的最後一部分，結合了焦炭與粉煤燃燒的數學模型，來澄清風徑區內焦炭的燃燒效應對粉煤燃燒率的影響。結果顯示，當沒有考慮焦炭燃燒時，粉煤的燃燒效率至少高估10％；尤其是在探討小粉煤粒徑與低噴吹率的高揮發煤時，焦炭的燃燒效應最為顯著。此外，結果指出煤的性質（如燃料比，膨脹係數等）對其燃燒性能有很大的影響；混合煤之燃燒效率與混合重量之比例幾成線性相依關係。
    本論文之研究成果對於未來的煉鐵過程中，提供在高爐操作時對其工作效率與成本效益一個有用的調整之參考。

    Blast furnaces (BFs) play a crucial role in the ironmaking industry as a means of producing hot metal. However, to ensure the competitiveness of the final steel products, the cost of the BF process must be significantly reduced. In the modern ironmaking industry, this is most commonly achieved by using pulverized coal injection (PCI) as a way of reducing the consumption of higher cost prime coking coals. However, operational experience shows that the BF may become unstable at higher injection rates. To understand the origins of this instability, and to ensure an efficient BF operation, it is necessary to clarify the complex physical and chemical phenomena which take place within the combustion region of the furnace. In practice, this is most conveniently achieved using some form of numerical model.
    Accordingly, in the first part of this thesis, a two–dimensional coke combustion model is developed to investigate the dependency of the raceway dynamics on the blast volume and in–furnace conditions. The model is then extended to a three–dimensional full–scale model for predicting the combustion zone in a real–world blast furnace (BF No. 3 of China Steel Corporation in Taiwan).
    The second part of the thesis develops a PCI model to investigate the flow behavior and combustion characteristics of a pulverized coal and CO2–stripped blast furnace top gas (BFG) mixture within the blowpipe–tuyere–raceway region of a BF. The simulations focus specifically on the effects of the lance configuration, the cooling gas type and the cooling gas flow rate. The results show that a significant flow–induced pressure drop occurs in the blowpipe–tuyere region of the furnace due to the gaseous combustion of the oxygen within the blast and the BFG injected via the lance. Moreover, it is shown that the burnout of the injected coal reduces significantly with an increasing BFG cooling flow rate due to the greater amount of oxygen consumed in the BFG combustion process. Finally, it is shown that a stronger swirling flow is formed when the lance configuration with bigger diameter is employed.
    The final part of the thesis constructs an integrated model of the coke / coal combustion process in order to clarify the coke–burning effect on the burnout behavior of pulverized coal within the semi–void raceway region of a BF. The results show that the combustion efficiency of the injected fuel is reduced by a minimum of 10% when coke–burning occurs. The decrease in combustion efficiency is particularly apparent for high volatile fuels with a small particle size and a low injection rate. Moreover, the results show that the combustion performance of coal is highly dependent on the coal properties (e.g. the fuel ratio, the swelling coefficient, and so on). Finally, it is shown that the ratio of PCI coal blends should be set in accordance with the burnout propensities of the individual coals rather than the fuel ratio.
    Overall, the numerical results presented in this thesis provide a useful insight of lower zone of BF for improving the efficiency and cost–effectiveness of the blast furnace process in the future.

    ABSTRACT I 摘要 III 致謝 IV TABLE OF CONTENTS V LIST OF TABLES IX LIST OF FIGURES X ABBREVIATION XV NOMENCLATURE XVI CHAPTER 1 INTRODUCTION 1 1.1 GENERAL BACKGROUND 1 1.2 BLAST FURNACE 3 1.2.1 Process description 3 1.2.2 Raceway structure 5 1.2.3 Auxiliary fuel injection 7 1.3 CHARACTERISTICS OF COAL COMBUSTION 8 1.4 SCOPE AND OBJECTIVES OF THESIS 9 1.5 STRUCTURE OF THESIS 11 CHAPTER 2 MATHEMATICAL MODELING 13 2.1 EULERIAN–EULERIAN (E–E) MODEL 13 2.1.1 Gas phase 14 2.1.2 Granular flow of solid phase 16 2.1.3 Gas–solid interphase exchange coefficient 17 2.1.4 Constitutive equations 17 2.1.5 k–ε dispersed turbulence model 19 2.1.6 Gaseous combustion in turbulent flowfield 21 2.2 EULERIAN–LAGRANGIAN (E–L) MODEL 22 2.2.1 Gas phase 22 2.2.2 Single particle in particulate phase 24 2.2.3 Standard k–ε turbulence model 25 2.2.4 Probability density function (PDF) of turbulence chemistry 26 2.3 COAL REACTION SUBMODELS 27 2.3.1 Devolatilization model 27 2.3.2 Coal swelling during devolatilization 28 2.3.3 Char combustion 29 2.4 COKE REACTIONS 29 CHAPTER 3 PREDICTION OF RACEWAY SHAPE AND SIZE IN BLAST FURNACE 33 3.1 INTRODUCTION 33 3.2 PYSICAL SYSTEM 35 3.3 MODEL DESCRIPTION 36 3.3.1 Outline of mathematical model 36 3.3.2 Boundary conditions 38 3.3.3 Numerical solution method 38 3.4 VALIDATION OF MATHEMATICAL MODEL 39 3.5 RESULTS AND DISCUSSION 41 3.5.1 Typical in–furnace phenomena in all–coke operation 41 3.5.2 Effect of blast velocity 43 3.5.3 Effect of coke particle size 46 3.5.4 Effect of initial coke–bed porosity 48 3.5.5 Prediction of raceway shape in No. 3 BF at China Steel Corporation 50 CHAPTER 4 FLOW AND COMBUSTION BEHAVIOR IN TUYERE AND RACEWAY OF BLAST FURNACE FUELED WITH COAL AND RECYCLED TOP GAS 53 4.1 INTRODUCTION 53 4.2 PHYSICAL GEOMETRY 55 4.3 MATHEMATICAL MODEL 57 4.3.1 Outline of mathematical model 57 4.3.2 Boundary conditions 59 4.3.3 PC and BFG properties 60 4.3.4 Numerical procedure 60 4.4 RESULTS AND DISCUSSION 62 4.4.1 Model validation 62 4.4.2 Type of cooling gas 64 4.4.3 Mass flow rate of cooling gas 69 CHAPTER 5 COKE–BURNING EFFECT ON COAL BURNOUT WITHIN RACEWAY REGION OF BLAST FURNACE 73 5.1 INTRODUCTION 73 5.2 PHYSICAL DOMAIN 76 5.3 MODELING 77 5.3.1 Model overview 77 5.3.2 Simulation conditions 79 5.3.3 Numerical method 80 5.4 RESULTS AND DISCUSSION 82 5.4.1 Coal particle size 83 5.4.2 Pulverized coal injection rate 87 5.4.3 Coal blending 91 CHAPTER 6 CONCLUSIONS AND RECOMMENDATIONS 95 6.1 SUMMARY OF ACCOMPLISHMENTS 95 6.2 RECOMMENDATIONS FOR FUTURE WORK 98 REFERENCES 101 APPENDIX A SUPPLEMENTARY INFORMATION FOR MATHEMATICAL MODELING 111 CURRICULUM VITAE 115

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