Tateo Usui

Abstract:

In reaction models for gaseous reduction of iron ore agglomerates, the formations of both unreacted-core shrinking (UCS) model for one interface and UCS model for three interfaces and the developments of multi-stage zone-reaction models without and with considering solid-state diffusion are summarized; these models are used mainly for pellets but sometimes used for sinter. UCS model for six interfaces in consideration of quaternary calcium ferrite reduction process is newly developed for sinter. Comparisons of these reaction models for pellets and sinter are carried out by using experimental data on gaseous reduction of these iron ore agglomerates. References: [1] T. Usui, M. Naito, T. Murayama and Z. Morita: Kinetic Analysis on Gaseous Reduction of Agglomerates, Part 1, Reaction Models for Gaseous Reduction of Agglomerates (in Japanese), Tetsu-to-Hagané, 80 (1994), 431-439. [2] T. Usui, M. Ohmi, M. Naito, H. Kamiya, Y. Oshima and Z. Morita: Kinetic Analyses on the Rate of Gaseous Reduction of Single Particles and Packed Beds of Iron Ore Agglomerates, Proceedings of The Julian Szekely Memorial Symposium on Materials Processing, ed. by H. Y. Sohn, J. W. Evans and D. Apelian, (October, 1997, Boston, Massachusetts, U.S.A.), 67-80, TMS. [3] M. Ohmi, T. Usui, M. Naito and Y. Minamide: Experimental Study of the Resistance Due to the Rate of Gas Flow on the Hydrogen Reduction of an Iron Oxide Pellet, Tetsu-to-Hagané (in Japanese), 67 (1981), 1943-1951; Trans. ISIJ (Transactions of the Iron and Steel Institute of Japan), 23 (1983), 81-89 [4] O. Levenspiel and K. B. Biscoff: Patterns of Flow in Chemical Process Vessels, Adv. Chem. Eng., 4 (1963), 95-198. [5] A. Moriyama, J. Yagi and I. Muchi: The Rate-Determining Steps of the Reduction Process of Iron Oxide Pellet (in Japanese), J. Japan Inst. Metals, 29 (1965), 528-534; Rate-Controlling Steps of the Reduction Process of Iron-Oxide Pellet, Trans. ISIJ, 7 (1967), 271-277. [6] R. H. Spitzer, F. S. Manning and W. O. Philbrook: Mixed-Control Reaction Kinetics in the Gaseous Reduction of Hematite, Trans. Metall. Soc. AIME, 236 (1966), 726-742. [7] R. H. Spitzer, F. S. Manning and W. O. Philbrook: Generalized Model for the Gaseous, Topochemical Reduction of Porous Hematite Spheres, Trans. Metall. Soc. AIME, 236 (1966), 1715-1724. [8] M. Ohmi and T. Usui: Study on the Rate of Reduction of Single Iron Oxide Pellet with Hydrogen (in Japanese), Tetsu-to-Hagané, 59 (1973), 1888-1901; On the Unreacted-core Shrinking Model for Reduction of a Single Hematite Pellet with Hydrogen, Trans. ISIJ, 16 (1976), 77-84. [9] M. Ohmi, M. Naito and T. Usui: Applicability of Three Interface Model to the Analysis of Reduction Rate of Iron Oxide Pellets with Hydrogen, Technology Reports of the Osaka University, 34 (1984), No.1743, 19-27. [10] H. W. St. Clair: Rate of Reduction of an Oxide Sphere in a Stream of Reducing Gas, Trans. Metall. Soc. AIME, 233 (1965), 1145-1152. [11] T. Usui, M. Ohmi and I. Miyatake: Gas Concentration Change in a Reactor in the Initial Stage of Hydrogen Reduction of Metallic Oxide Pellets, Technology Reports of the Osaka University, 38 (1988), No.1934, 229-236. [12] T. Usui, M. Ohmi and E. Yamamura: Analysis of Rate of Hydrogen Reduction of Porous Wustite Pellets Basing on Zone-reaction Models, Tetsu-to-Hagané (in Japanese), 72 (1986), 1263-1270; ISIJ International, 30 (1990), 347-355. [13] J. Szekely and J. W. Evans: Studies in Gas-Solid Reactions: Part I. A Structural Model for the Reaction of Porous Oxides with a Reducing Gas, Met. Trans., 2 (1971), 1691-1698. [14] Y. Hara: On the Reduction Model of Porous Iron-Oxide Pellet, Tetsu-to-Hagané (in Japanese), 57 (1971), 1441-1452; Trans. ISIJ, 12 (1972), 358-366. [15] H. Y. Sohn and J. Szekely: A Structural Model for Gas-Solid Reactions with a Moving Boundary －Ⅲ, Chem. Eng. Sci., 27 (1972), 763-778. [16] M. Ishida and C. Y. Wen: Comparison of Kinetic and Diffusional Models for Solid-Gas Reactions, AIChE J., 14 (1968), 311-317. [17] M. Ohmi, M. Naito and T. Usui: Multi-stage Zone-reaction Model for the Gaseous Reduction of Porous Hematite Pellets (in Japanese), Tetsu-to-Hagané, 68 (1982), 592- 601. [18] M. Ohmi and T. Usui: Improved Theory on the Rate of Reduction of Single Particles and Fixed Beds of Iron Oxide Pellets with Hydrogen, Trans. ISIJ, 22 (1982), 66-74. [19] M. Ohmi, M. Naito and T. Usui: Kinetic Analysis of Hydrogen Reduction of Various Hematite Pellets on the Basis of the Multi-stage Zone-reaction Models (in Japanese), Tetsu-to-Hagané, 69 (1983), 546-555. [20] M. Ohmi, M. Naito and T. Usui: Effects of Various Factors on the Reduction Rate of Hematite Pellets with Hydrogen (in Japanese), Tetsu-to-Hagané, 68 (1982), 1503-1512. [21] L. von Bogdandy and H.-J. Engell: Die Reduktion der Eisenerze, 1967, Springer-Verlag, Berlin/Heidelberg and Verlag Stahleisen m.b.H., Germany, 127. [22] M. Ohmi, M. Naito and T. Usui: Multi-stage Zone-reaction Model with Solid-state Diffusion for the Hydrogen Reduction of Porous Hematite Pellets (in Japanese), Tetsu-to-Hagané, 69 (1983), 363-370. [23] M. Ohmi, T. Usui, Y. Minamide and M. Naito: Reduction of Single Particles and Fixed Beds of Hematite Pellets with Hydrogen, Proceedings of The Third International Iron and Steel Congress, (April, 1978, Chicago, U.S.A.), 472-478, American Society for Metals. [24] A. Rist and G. Bonnivard: Reduction d’un Lit d’Oxydes de Fer par un Gas, Premiere Partie, Etude Theorique dans l’Hypothese de Vitesses Infinies de Reaction, Rev. Met., 60 (1963), 23-37. [25] T. Usui, M. Ohmi, S. Hirashima and Y. Oshima: Kinetic Analysis on the Rate of Reduction of Single Particles and Fixed Beds of Sinter with CO-CO2-N2 and H2-H2O-N2 Gas Mixtures, Proceedings of The Fifth International Iron and Steel Congress, (April, 1986, Washington, D.C., U.S.A.), Book 3 [ = Process Technology Proceedings, Vol.6], 545-553, The Iron and Steel Society of AIME (The American Institute of Mining, Metallurgical and Petroleum Engineers). [26] T. Usui, M. Ohmi, S. Hirashima and N. Kitagawa: Kinetic Analysis on the Rate of Stepwise Reduction of a Single Sinter with CO-CO2-N2 Gas Mixture (in Japanese), Tetsu-to-Hagané, 73 (1987), 1956-1963. [27] T. Usui, M. Ohmi, S. Kaneda, M. Ohmasa and Z. Morita: Re-examination of Method of Kinetic Analysis on the Rate of Stepwise Reduction of a Single Sinter Particle with CO-CO2-N2 Gas Mixture, ISIJ International, 31 (1991), 425-433. [28] T. Usui, M. Ohmi, N. Kitagawa, S. Kaneda, H. Kawabata and Z. Morita: Change of Sinter Minerals and Final Fractional Reduction in the Reduction Stage from Hematite to Magnetite with CO-CO2-N2 Gas Mixture, Proceedings of The Sixth International Iron and Steel Congress, (October, 1990, Nagoya, Japan), Vol.1, 99-107, ISIJ (The Iron and Steel Institute of Japan). [29] T. Usui, M. Ohmi, N. Kitagawa, S. Kaneda, H. Kawabata and Z. Morita: Change of Sinter Minerals and Final Fractional Reduction in the Reduction Stage from Hematite to Magnetite with CO-CO2-N2 Gas Mixture (in Japanese), Tetsu-to-Hagané, 77 (1991), 1251-1258. [30] T. Usui, H. Kawabata, T. Fujimori, I. Fukuda and Z. Morita: Influence of CO Ratio and Reduction Temperature upon the Reducibility of Calcium Ferrite in Sinter in the Initial Stage of Reduction with CO-CO2-N2 Gas Mixture (in Japanese), Tetsu-to-Hagané, 78 (1992), 982-989. [31] T. Usui and Z. Morita: Reducibility of Calcium Ferrite in Iron Ore Sinter in the Initial Stage of Reduction with CO-CO2-N2 Gas Mixture, Proceedings of The Sixth International Symposium on Agglomeration, (November, 1993, Nagoya, Japan), 344-349, The Society of Powder Technology, Japan, The Iron and Steel Institute of Japan, and The Society of Chemical Engineers, Japan. [32] T. Usui, M. Ohmi, T. Ohkata, Y. Kawaguchi, Y. Yamaoka and Z. Morita: Influence of H2O Partial Pressure upon the Retardation in the Final Stage of Reduction of Fluxed Pellets with H2-H2O Gas Mixture, Proceedings of The Sixth International Iron and Steel Congress, (October, 1990, Nagoya, Japan), Vol.1, 83-91, The Iron and Steel Institute of Japan. [33] R. Takahashi, M. Ishigaki, M. Ishii, Y. Takahashi and Y. Koyabu: Experimental Investigation on Iron Oxide Pellet Reduction with H2-CO-N2 Gas Mixture in a Laboratory Scale Moving Bed Reactor (in Japanese), Tetsu-to-Hagané, 66 (1980), No.11, S720. [34] K. Narita, D. Kaneko, Y. Kimura, Y. Takenaka and M. Onoda: Study on DRI Production Technology in a Shaft Furnace (in Japanese), Tetsu-to-Hagané, 65 (19879, No.8, A125-A128. [35] T. Usui, M. Ohmi, H. Kawabata, M. Naito, H. Ono, Y. Nakamuro, M. Nishi and Paulo S. Assis: Gaseous Reduction Behavior of Iron Ore Sinter and Kinetic Analysis in Consideration of Calcium Ferrite Reaction Process, Proceedings of SUSTAINABLE INDUSTRIAL PROCESSING SUMMIT, 2015, (October, 2015, Antalya, Turkey), CD-ROM, Flogen Technologies Inc. [36] K. Sugiyama, A. Monkawa and T. Sugiyama: Crystal Structure of the SFCAM Phase Ca2(Ca,Fe,Mg,Al)6(Fe,Al,Si)6O20, ISIJ International, 45 (2005), 560-568. [37] 37 H. Ono-Nakazato, Y. Tsubone, Y. Takaki and T. Usui: Measurement of Hydrogen Reduction Rates of FeO in 2FeO.SiO2 and CaO.FeO.SiO2 (in Japanese), Tetsu-to-Hagané, 87 (2001), 320-326. [38] Discussion Sessions of High Temperature Processes: “Control of reduction equilibrium for mitigation of CO2 emission of blast furnace (in Japanese)” {The final report of the Research Project on “Control of reduction equilibrium in blast furnace by close arrangement between ore and carbonaceous materials” (Chairman: M. Shimizu)}, CAMP-ISIJ (Current Advances in Materials and Processes - Iron and Steel Institute of Japan), 23 (2010), 560-610, CD-ROM. [39] M. Naito, A. Okamoto, K. Yamaguchi, T. Yamaguchi and Y. Inoue: Improvement of Blast Furnace Reaction Efficiency by Use of High Reactivity Coke (in Japanese), Tetsu-to-Hagané, 87 (2001), 357-364. [40] S. Nomura, H. Ayukawa, H. Kitaguchi, T. Tahara, S. Matsuzaki, M. Naito, S. Koizumi, Y. Ogata, T. Nakayama and T. Abe: Improvement in Blast Furnace Reaction Efficiency through the Use of Highly Reactivite Calcium Rich Coke, ISIJ International, 45 (2005), 316-324. [41] T. Usui, H. Konishi, K. Ichikawa, H. Ono, H. Kawabata, F. B. Pena, M. H. Souza and P. S. Assis: Various Factors Influencing upon Reduction Rate of Carbon Composite Iron Oxide Pellets, Proceedings of SUSTAINABLE INDUSTRIAL PROCESSING SUMMIT, 2015, (October, 2015, Antalya, Turkey), CD-ROM, FLOGEN Stars OUTREACH. [42] T. Usui and K. Higaki: A Consideration on Inapplicability of Rate Parameter Values for Gaseous Reduction of Iron Ore Sinter to the Analysis of In-furnace Phenomena (in Japanese), CAMP-ISIJ, 7 (1994), 1027. [43] Y. Shimomura and T. Sugiyama: Private communication (1982.7). [44] 44 T. Sugiyama and M. Sugata: Development of Two-Dimensional Mathematical Model of Blast Furnace “BRIGHT” (in Japanese), Seitetu Kenkyu, 325 (1987), 34-43. [45] T. Maeda and Y. Ono: Reduction Equilibria at the Final Stage of Reduction of Quaternary Calcium Ferrite with CO-CO2 Gas Mixtures (in Japanese), Tetsu-to-Hagané, 75 (1989), 416-423. [46] T. Maeda: Fundamental study on gaseous reduction of calcium ferrite in iron ore sinter, Doctor Thesis at Kyushu University, (1992), 65-81. [47] T. Usui, Y. Nakamuro, M. Nishi, M. Naito, H. Ono and P. S. Assis: Development of Gaseous Reduction Model for Sinter in Consideration of Calcium Ferrite Reaction Process (in Japanese), CAMP-ISIJ, 25 (2012), 603-606, CD-ROM. [48] T. Usui, Y. Nakamuro, M. Nishi, M. Naito, H. Ono and P. S. Assis: Gaseous Reduction Model for Sinter in Consideration of Calcium Ferrite Reaction Process (Unreacted-core Shrinking Model for Six Interfaces), Tetsu-to-Hagané (in Japanese), 100 (2014), 294-301; ISIJ International, 55 (2015), 1617-1624. [49] H. Hayashi, K. Inoue, K. Yoshioka and T. Takahashi: Investigation of Mineral Structure and its Formation Process of Low FeO Sinter (Effect of FeO on Microstructure and Properties of Lime-Fluxed Sinter – II), Tetsu-to-Hagané (in Japanese), 68 (1982), S738. [50] T. Nakazawa and M. Sasaki: The Change of Properties of the Charge Materials in a Blast Furnace Shaft (in Japanese), Tetsu-to-Hagané, 55 (1969), 112-122. [51] L. H. Hsieh and J. A. Whiteman: Effect of Oxygen Potential on Mineral Formation in Lime-fluxed lron Ore Sinter, ISIJ International, 29 (1989), 625-634. [52] M. Sasaki and T. Nakazawa: On the Formation of Calcium Ferrite in Sintered Ore (in Japanese), Tetsu-to-Hagané, 54 (1968), 1217-1225. [53] Y. Hara, M. Tuchiya and S. Kondo: Intraparticle Temperature of Iron-Oxide Pellet during the Reduction (in Japanese), Tetsu-to-Hagané, 60 (1974), 1261-1270. [54] T. Yagi and Y. Ono: A Method of Analysis for Reduction of Iron Oxide in Mixed-Control Kinetics, Trans. ISIJ, 8 (1968), 377-381. [55] N. Oyama, Y. Iwami, T. Yamamoto, S. Machida, T. Higuchi, H. Sato, M. Sato, K. Takeda, Y. Watanabe, M. Shimizu and K. Nishioka: Development of Secondary-fuel Injection Technology for Energy Reduction in the Iron Ore Sintering Process, Tetsu-to-Hagané (in Japanese), 97 (2011), 510-518; ISIJ International, 51 (2011), 913-921. [56] T. Murayama, T. Usui, M. Naito and Y. Ono: Kinetic Analysis on Gaseous Reduction of Agglomerates, Part 2, Rate Parameters Included in the Mathematical Model for Gaseous Reduction of Agglomerates (in Japanese), Tetsu-to-Hagané, 80 (1994), 493-500. [57] M. Naito, T. Murayama and T. Usui: Kinetic Analysis on Gaseous Reduction of Agglomerates, Part 3, Application of Gaseous Reduction Models for Agglomerates to Blast Furnace Analysis (in Japanese), Tetsu-to-Hagané, 80 (1994), 581-586. [58] Discussion Sessions of High Temperature Processes: “Improvement of the iron ore sintering process aiming at lowering its environmental load and energy saving (in Japanese)” {the final report of the Research Project on “Technological Principle for Low-Carbon Sintering” (Chairman: E. Kasai)}, CAMP-ISIJ, 25 (2012), 599 – 642, CD-ROM.