Thermodynamic Simulation of an Efficient Flash Ironmaking Technology for Chadormalu Mining and Industrial Company

The Flash Ironmaking Technology (FIT) utilizing methane (CH4) and air blast (containing 21% oxygen) has been exclusively simulated and calculated for the Chadormalu Mining and Industrial Company (CMIC). The obtained results based on thermodynamic simulation and heat and material balance calculations of the FIT have revealed that a total rate of 70.405 tons/h preheated CH4 is required for the annual production of one million tons of hot metal with 95% metallization. 47% of the methane acts as a reducing agent, and the rest burns with 764.489 tons/h preheated air blast (including 20% excess) to provide 1078 GJ/h energy for running the process at 1600 ˚C (1873 K). Accordingly, 193.134 tons/h carbon dioxide (CO2) is emitted through the process, equivalent to 1.550 tons for every ton of produced hot metal. It indicates that the simulated FIT is eco-friendlier than the blast furnace and coal-based direct reduction ironmaking processes while eliminating coke-making, pelletization or gas-reforming units.