1. Institute of Chemical Engineering page 1 Achema 2012 Thermal Process Engineering K1-MET Competence Center for Excellent Technologies in Advanced Metallurgical and Environmental Process Development Area 4 – Valuation and Optimization of Metallurgical Raw Materials CFD Simulation of Co-Injection of Plastic Particles and Oil into a Blast Furnace Raceway Christian JORDAN, Christian MAIER, Michael HARASEK Christoph FEILMAYR, Stefan SCHUSTER (voestalpine Stahl, Linz) michael.harasek@tuwien.ac.at Plastic Particle Injection into Blast Furnace Raceway

2. Institute of Chemical Engineering page 2 Achema 2012 Thermal Process Engineering nOptimization of the operation conditions and maximization of plastics injection rate lDetailed CFD-modeling of the blast furnace raceway lDetermination of fluid dynamic properties lInvestigations of the reaction kinetics of different auxiliary reductants nMaximum plastic injection capacity 220.000 t/a nStartup in June 2007 (test operation since 2006) nInput material processed waste plastics lPellets, agglomerates from mixed plastics fractions (municipal and industrial waste) lGranulate from shredder residue treatment process nFlexibility in injection Plastic Particle Injection into Blast Furnace Raceway Blast Furnace HO A (voestalpine Stahl GmbH, Linz) Region observed Pellets, agglomerates and granulate

3. Institute of Chemical Engineering page 3 Achema 2012 Thermal Process Engineering nTurbulence lSST-kω-Model by Menter or realizable k  -Model nRadiation lDiscrete Ordinates Model (DOM) lAbsorption coefficients estimated with the „Weighted Sum of Grey Gases“ (WSGG)-approach nReaction lGlobal and heterogeneous reactions (9 gas-phase species, coke) lEddy Dissipation Concept (Magnussen) nDPM – Discrete Particle Model lLagrangian particle tracking, coupled to fluid phase via source terms lPlastic particles – radiation interaction + decomposition lHeavy fuel oil multicomponent droplets - pyrolysis nUDF – User Defined Functions to extend CFD code lRaceway formation and coke bed porosity lExtended radiation model lParticle treatment (reaction, impact on raceway) Plastic Particle Injection into Blast Furnace Raceway

4. Institute of Chemical Engineering page 4 Achema 2012 Thermal Process Engineering  Measurements lConstruction of a small scale model of the oil lance and the tuyere based on Reynolds analogy lDroplet velocity (PIV) lGas velocity (LDA with seeding or PIV with fluorescent tracer) lDroplet size distribution using high speed photographs Plastic Particle Injection into Blast Furnace Raceway PIV image of the jet (velocity vectors with geometry in background) detailed view of the outlet

5. Institute of Chemical Engineering page 5 Achema 2012 Thermal Process Engineering  Results of CFD Modeling Plastic Particle Injection into Blast Furnace Raceway Raceway shape (50% porosity, blue) and hot blast pathlines entering from bustle pipe (colored according to velocity magnitude in m/s) Radial species distribution with and without particle injection Surface in tuyére level – mass fraction of carbon dioxide Mole fraction CO in the symmetry plane Flow direction

6. Institute of Chemical Engineering page 6 Achema 2012 Thermal Process Engineering  CFD Model Development lHeat transfer due to convection, thermal conductivity and radiation lEffects of material properties of fluid phase lSolid phase material properties & porosity lCoupling without using Eulerian model lImplementation of heterogenous reactions (coke bed – surrounding gas phase) lValidation of the new method using systems of various complexity Plastic Particle Injection into Blast Furnace Raceway 0 2.5 2.0 1.5 1.0 [mm/s] 0.5 0 20 16 12 8 [m/s] 4 coke bed gas flow velocity magnitude with path lines

7. Institute of Chemical Engineering page 7 Achema 2012 Thermal Process Engineering Summary nMeasurement (PIV) and modeling of fuel oil droplet size distribution nCharacterization of the pyrolysis of waste plastic particles nImplementation of new modeling approach: Dual Grid nSuccessful validation of CFD-model by comparison with experimental data nImplementation of UDF in full-scale blast furnace Further Work nFurther development of the Dual Grid Method - CFD-Calculations for different operating conditions nCo-injection of particles and fuel oil nAdditional high speed imaging for validation of spray modeling Plastic Particle Injection into Blast Furnace Raceway