Title

INDUSTRIAL FLOW DISTRIBUTION IMPROVEMENT BASED ON CFD ANALYSIS IN A PELLETIZING FURNACE AT SAMARCO

INDUSTRIAL FLOW DISTRIBUTION IMPROVEMENT BASED ON CFD ANALYSIS IN A PELLETIZING FURNACE AT SAMARCO

Authorship

Maycon Athayde; Roberto Parreiras Tavares; Sergio Fernando Nunes; Mauricio Cota Fonseca; Moises da Cruz Costa; Luiz Claudio Von Sperling Cotta

Maycon Athayde

I am this author

Roberto Parreiras Tavares

I am this author

Sergio Fernando Nunes

I am this author

Mauricio Cota Fonseca

I am this author

Moises da Cruz Costa

I am this author

Luiz Claudio Von Sperling Cotta

I am this author

DOI

10.5151/2594-357X-25633

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Abstract

Samarco produces high quality iron ore pellets processed in straight grate furnaces. This process is essential in order to obtain adequate mechanical strength to the pellet transportation and operation in the reduction reactors. All mechanical properties of the agglomerates are obtained during the stage of firing where the slag and sintering bond happens, thus it is a decisive step to improve the pellet quality. Therefore, the velocity distribution of gas flow within this zone must have homogeneous and even velocity distribution. Hence, it was developed a mathematical CFD model to characterize the gas flow in the burning zone, applying the equations of conservation of momentum, mass and energy and an uneven flow distribution was identified and the gas velocity analyzed and validated through experimental data. On the other hand, on the present paper, an improved firing zone burner were developed and industrially implemented in a way to mitigate the uneven flow pattern detected aided by CFD. Different burner designs, based on CFD analysis, were experimented in order to succeed on the aggressive condition. The combustion was investigated and burner efficiency evaluated and compared with the simulation purposed.

Samarco produces high quality iron ore pellets processed in straight grate furnaces. This process is essential in order to obtain adequate mechanical strength to the pellet transportation and operation in the reduction reactors. All mechanical properties of the agglomerates are obtained during the stage of firing where the slag and sintering bond happens, thus it is a decisive step to improve the pellet quality. Therefore, the velocity distribution of gas flow within this zone must have homogeneous and even velocity distribution. Hence, it was developed a mathematical CFD model to characterize the gas flow in the burning zone, applying the equations of conservation of momentum, mass and energy and an uneven flow distribution was identified and the gas velocity analyzed and validated through experimental data. On the other hand, on the present paper, an improved firing zone burner were developed and industrially implemented in a way to mitigate the uneven flow pattern detected aided by CFD. Different burner designs, based on CFD analysis, were experimented in order to succeed on the aggressive condition. The combustion was investigated and burner efficiency evaluated and compared with the simulation purposed.

Keywords

Modeling; CFD; Pelletizing; Packed beds

Modeling; CFD; Pelletizing; Packed beds