Development of an Industrial Iron-Making Melter Gasifier Model with Multiphase Equilibrium Calculations

Abstract

The Corex® and Finex® processes are the only industrially proven alternative options for hot metal production compared to the traditional blast furnace iron making route. Due to their more economical and ecological characteristics, their use has been gaining ground over the last two decades. The main unit operation of these processes is the melter gasifier device. The target of this work is to create a prototype multizone model of the melter gasifier and implement it in the platform of gPROMS ModelBuilder. For the calculation of the elemental distribution between the hot metal and the slag phases, the thermodynamic equilibrium routines of ChemApp are used. The simulation results showed a good fitting with plant data for most of the important components (Fe, C, CaO, MgO, CaO, Al₂O₃, S). Deviations were observed in the Mn and Si components. Through this work, predictive simulations of Corex® and Finex® iron-making processes can take place and a better understanding is gained in regard to the thermodynamic equilibrium. This knowledge can contribute in the direction of both process and design optimisation.