Numerical Analysis of the Effect of Reduction Gas Composition and Temperature on the Quality of Sponge Iron Product

Reduction zone of iron ore reactor have been simulated. This is a part of counter current gas-solid reactor for producing sponge iron. The aim of this research is to study the effect of reduction gas composition and temperature on quality and product capacity of sponge iron products through mathematical modeling arrangement and simulation. Simultaneous mass and energy balances along the reactor lead to a set of ordinary differential equation which includes kinetic equations. Kinetic equations of reduction of hematite to iron metal, methane reforming, and water gas shift reaction are taken into account in the model. Hydrogen and carbon monoxide are used as reduction gas. The equations were solved by finite element method. Simulation result shows an increase in H₂ composition while an attenuation of CO will produce higher metallization degree. Metallization degree is also increased with an increase in gas inlet temperature. Reduction gas temperature over than 973°C (1246 K) is not recommended because the formation of sticky iron will be initiated.