Modeling as a Tool for Scale-Up of an Iron Smelt-Reduction Process

The HIsmelt Process is a smelt-reduction process involving the injection of iron ore and coal into a molten iron bath, and post-combustion of CO and H2 above the bath by means of a top jet of air to increase energy efficiency. Substantial fluid dynamic related challenges are involved in developing such a process: these include ensuring that the solids are injected down into the metal bath and that post-combustion heat is effectively transferred back to the bath while minimising oxidation back reaction. Reactive multi-phase Computational Fluid Dynamics (CFD) modelling can be used in conjunction with experimental modelling and plant trials to achieve reliable scale-up. The application of these modelling tools will be described.