CFD simulation of coupled multiphysics-multiscale non-catalytic gas-solid reaction systems: application to the direct reduction of iron ore

• Grant number: 21/09343-4
• Support Opportunities: Scholarships abroad - Research Internship - Doctorate
• Start date: July 15, 2022
• End date: July 14, 2023
• Field of knowledge: Engineering - Chemical Engineering - Chemical Process Industries
• Principal Investigator: Roberto Guardani
• Grantee: Patrícia Metolina
• Supervisor: Anthony G. Dixon
• Host Institution: Escola Politécnica (EP). Universidade de São Paulo (USP). São Paulo , SP, Brazil
• Institution abroad: Worcester Polytechnic Institute (WPI), United States
• Associated to the scholarship: 19/05840-3 - Mathematical modeling and computational simulation of gas-solid reactions in moving bed: application to the direct reduction process of iron ore, BP.DR

Abstract

Global warming is one of the main concerns of the humanity. Consequently, the need for reduction of CO2 emissions in ironmaking processes through the direct reduction of iron ore using only hydrogen as reducing gas has gained increasing prominence. Thus, knowledge about the process needs to be better explored in order to optimize and disseminate the technology. Such systems are complex due to their conceptually transient nature, involving mass and heat transport phenomena associated with multiple chemical reactions and structural changes in the solid over time. Most mathematical models reported in the literature adopt different levels of simplification, presenting a variety of results and dissimilarities in the estimated values of kinetic parameters. The present study proposes the development of a detailed mathematical model based on computational fluid dynamic simulation to describe non-catalytic gas-solid reactions in a multi-scale approach (single pellet and reactor scale) for the application in the direct reduction of iron ore (DR) using hydrogen. The models for pellet scale developed in this study will be extended to the multi-particle reactor to investigate how the transport mechanisms affect the performance of the DR. The multiscale study, therefore, aims to predict the heterogeneity effects of the system and evaluate structural configurations of the porous iron ore pellet and the operating conditions of the system, such as temperature, flow rate, gas composition, among others, on the reduction process. The models for both scales will be validated with data from laboratory-scale experiments and industrial plants. The planned collaboration with the research group in the Department of Chemical Engineering, Worcester Polytechnic Institute, is extremely important to advance this investigation, due to the large modeling experience of the research team coordinated by Prof. Anthony G. Dixon. (AU)