Intensive carbon combustion in sintering packed bed via steam spraying: An experimental study on carbon monoxide emission reduction

Abstract

Improving the combustion efficiency of solid fuels is important for reducing carbon monoxide emissions in the iron ore sintering process. In this paper, the surface steam spraying technology is introduced in the sintering process based on the auxiliary combustion effect of steam on coke, and its potential to reduce carbon monoxide emissions is demonstrated. Thermogravimetric analysis experiments of coke breeze in air and air-steam mixed atmosphere are carried out, and the results show that the introduction of steam can reduce the concentration of carbon monoxide in the exhaust gas from 183×10⁻⁶ to 78×10⁻⁶. At the same time, the mechanisms of carbon monoxide emission reduction by surface steam spraying technology are analyzed from the thermodynamic and kinetic perspectives. Then, a series of laboratory-scale sintering pot tests are carried out under no spraying operation, interval spraying operation, and continuous spraying operation. The results indicate that both interval and continuous spraying operations can reduce carbon monoxide emissions. The optimal mode of steam spraying under the present experimental conditions is continuously spraying for 13 min at a volume rate of 0.053 m³/min. Compared with no spraying, the average carbon monoxide concentration in the exhaust gas is reduced from 7565×10⁻⁶ to 6231×10⁻⁶, and total carbon monoxide emissions for per ton sinter are reduced from 13.46 m³/t to 9.51 m³/t.

References

[1] WangY-q, ZhengH-r, XieZ-w, et al.. Exploitation of wild Chinese herbs leads to environmental degradation and possible loss of the resource [J]. Environmental Science & Technology, 2012, 46(3): 1307-1308

[2] ChenJ-l, HuangJ-y, HuangX-c, et al.. How does new environmental law affect public environmental protection activities in China? Evidence from structural equation model analysis on legal cognition [J]. Science of the Total Environment, 2020, 714: 136558

[3] RosselotK, AllenD T, KuA Y. Global warming breakeven times for infrastructure construction emissions are underestimated [J]. ACS Sustainable Chemistry & Engineering, 2022, 10(5): 1753-1758

[4] XiaW-w, WangY, ChenS-y, et al.. Double trouble of air pollution by anthropogenic dust [J]. Environmental Science & Technology, 2022, 56(2): 761-769

[5] RuggerioC A. Sustainability and sustainable development: A review of principles and definitions [J]. The Science of the Total Environment, 2021, 786: 147481

[6] LinJ-h, LinC-q, TaoM-h, et al.. Spatial disparity of meteorological impacts on carbon monoxide pollution in China during the COVID-19 lockdown period [J]. ACS Earth and Space Chemistry, 2021, 5(10): 2900-2909

[7] WuJ, TalA. From pollution charge to environmental protection tax: A comparative analysis of the potential and limitations of China’s new environmental policy initiative [J]. Journal of Comparative Policy Analysis: Research and Practice, 2018, 20(2): 223-236

[8] ShiJ-x, HuangW-p, HanH-j, et al.. Pollution control of wastewater from the coal chemical industry in China: Environmental management policy and technical standards [J]. Renewable and Sustainable Energy Reviews, 2021, 143: 110883

[9] LuY-l, WangY, ZhangW, et al.. Provincial air pollution responsibility and environmental tax of China based on interregional linkage indicators [J]. Journal of Cleaner Production, 2019, 235: 337-347

[10] AlmetwallyA A, Bin-JumahM, AllamA A. Ambient air pollution and its influence on human health and welfare: An overview [J]. Environmental Science and Pollution Research, 2020, 27(20): 24815-24830

[11] LinC-q, ZhangY-hua. Lofting and circumnavigation of biomass burning aerosols and carbon monoxide from a North American wildfire in October 2020 [J]. ACS Earth and Space Chemistry, 2021, 5(2): 331-339

[12] KumarP, KuttippurathJ, von der GathenP, et al.. The increasing surface ozone and tropospheric ozone in Antarctica and their possible drivers [J]. Environmental Science & Technology, 2021, 55(13): 8542-8553

[13] VinayagamN K, HoangA T, SolomonJ M, et al.. Smart control strategy for effective hydrocarbon and carbon monoxide emission reduction on a conventional diesel engine using the pooled impact of pre-and post-combustion techniques [J]. Journal of Cleaner Production, 2021, 306: 127310

[14] ValenteO S, daS M J, PasaV M D, et al.. Fuel consumption and emissions from a diesel power generator fuelled with castor oil and soybean biodiesel [J]. Fuel, 2010, 89(12): 3637-3642

[15] DeyS, DhalG C. A review of synthesis, structure and applications in hopcalite catalysts for carbon monoxide oxidation [J]. Aerosol Science and Engineering, 2019, 3(4): 97-131

[16] ZhangW, WangJ-n, ZhangB, et al.. Can China comply with its 12th five-year plan on industrial emissions control: A structural decomposition analysis [J]. Environmental Science & Technology, 2015, 49(8): 4816-4824

[17] ZhangQ, XuJ, WangY-j, et al.. Comprehensive assessment of energy conservation and CO₂ emissions mitigation in China’s iron and steel industry based on dynamic material flows [J]. Applied Energy, 2018, 209: 251-265

[18] TangL, XueX-d, JiaM, et al.. Iron and steel industry emissions and contribution to the air quality in China [J]. Atmospheric Environment, 2020, 237: 117668

[19] SuopajärviH, UmekiK, MousaE, et al.. Use of biomass in integrated steelmaking-Status quo, future needs and comparison to other low-CO₂ steel production technologies [J]. Applied Energy, 2018, 213: 384-407

[20] de CastroJ A, da SilvaL M, de MedeirosG A, et al.. Analysis of a compact iron ore sintering process based on agglomerated biochar and gaseous fuels using a 3D multiphase multicomponent mathematical model [J]. Journal of Materials Research and Technology, 2020, 9(3): 6001-6013

[21] de CastroJ A, de OliveiraE M, de CamposM F, et al.. Analyzing cleaner alternatives of solid and gaseous fuels for iron ore sintering in compacts machines [J]. Journal of Cleaner Production, 2018, 198: 654-661

[22] LilikG K, BoehmanA L. Advanced diesel combustion of a high cetane number fuel with low hydrocarbon and carbon monoxide emissions [J]. Energy & Fuels, 2011, 25(4): 1444-1456

[23] ZhengB, ChevallierF, CiaisP, et al.. Rapid decline in carbon monoxide emissions and export from East Asia between years 2005 and 2016 [J]. Environmental Research Letters, 2018, 13(4): 044007

[24] MirzajanzadehM, TabatabaeiM, ArdjmandM, et al.. A novel soluble nano-catalysts in diesel-biodiesel fuel blends to improve diesel engines performance and reduce exhaust emissions [J]. Fuel, 2015, 139: 374-382

[25] GanM, JiZ-y, FanX-h, et al.. Insight into the high proportion application of biomass fuel in iron ore sintering through CO-containing flue gas recirculation [J]. Journal of Cleaner Production, 2019, 232: 1335-1347

[26] JhaG, SorenS, MehtaK D. Life cycle assessment of sintering process for carbon footprint and cost reduction: A comparative study for coke and biomass-derived sintering process [J]. Journal of Cleaner Production, 2020, 259: 120889

[27] AbreuG C, de CarvalhoJ A, da SilvaB E C, et al.. Operational and environmental assessment on the use of charcoal iniron ore sinter production [J]. Journal of Cleaner Production, 2015, 101: 387-394

[28] ChengZ-l, TanZ-t, GuoZ-g, et al.. Recent progress in sustainable and energy-efficient technologies for sinter production in the iron and steel industry [J]. Renewable and Sustainable Energy Reviews, 2020, 131: 110034

[29] HanJ, HuangZ-h, QinL-b, et al.. Refused derived fuel from municipal solid waste used as an alternative fuel during the iron ore sinter process [J]. Journal of Cleaner Production, 2021, 278: 123594

[30] ChengZ-l, FuP, GuoZ-g, et al.. CFD prediction of heat/mass transfer in multi-layer sintering process assisted with gaseous fuel injection [J]. International Communications in Heat and Mass Transfer, 2021, 128(12): 105654

[31] FanX, YuZ, GanM, et al.. Flue gas recirculation in iron ore sintering process [J]. Ironmaking & Steelmaking, 2016, 43(6): 403-410

[32] ShresthaS, XuJ, YuA-b, et al.. Numerical simulation of fuel layered distribution iron ore sintering technology [J]. Ironmaking & Steelmaking, 2022, 49(1): 83-100

[33] LiuZ-j, NiuL-l, ZhangS-j, et al.. Comprehensive technologies for iron ore sintering with a bed height of 1000 mm to improve sinter quality, enhance productivity and reduce fuel consumption [J]. ISIJ International, 2020, 60(11): 2400-2407

[34] WangD-j, WuS-l, LiC-x, et al.. Efficient and clean production practice of large-scale sintering machine [J]. ISIJ International, 2013, 53(9): 1665-1672

[35] ZhangY P, ZhangJ L, ZhangC, et al.. Modelling and visual verification of combustion zone transfer in ultra-thick bed sintering process [J]. Ironmaking & Steelmaking, 2017, 44(4): 304-310

[36] ZhaoJ-p, LooC E, EllisB G. Improving energy efficiency in iron ore sintering through segregation: A theoretical investigation [J]. ISIJ International, 2016, 56(7): 1148-1156

[37] LuL, IshiyamaO. Recent advances in iron ore sintering [J]. Mineral Processing and Extractive Metallurgy, 2016, 125(3): 132-139

[38] SunC-f, YangY-z, XuY, et al.. A visualization method of quantifying carbon combustion energy in the sintering packed bed [J]. ISIJ International, 2021, 61(6): 1801-1807

[39] JhaG, SorenS. Study on applicability of biomass in iron ore sintering process [J]. Renewable and Sustainable Energy Reviews, 2017, 80: 399-407

[40] JhaG, SorenS, DeoM K. Partial substitution of coke breeze with biomass and charcoal in metallurgical sintering [J]. Fuel, 2020, 278: 118350

[41] MatsumuraM, YamaguchiY, HaraM, et al.. Improvement of sinter productivity by adding return fine on raw materials after granulation stage [J]. ISIJ International, 2013, 53(1): 34-40

[42] LiG-h, LiuC, YuZ-w, et al.. Energy saving of composite agglomeration process (CAP) by optimized distribution of pelletized feed [J]. Energies, 2018, 11(9): 2382

[43] PalJ, GhoraiS, GoswamiM C, et al.. Development of pellet-sinter composite agglomerate for blast furnace [J]. ISIJ International, 2014, 54(3): 620-627

[44] WangY-z, ZhangJ-l, LiuZ-j, et al.. Recent advances and research status in energy conservation of iron ore sintering in China [J]. JOM, 2017, 69(11): 2404-2411

[45] ZhouM-x, ZhouHao. Flame front propagation and sinter strength properties of permeable sintering bed prepared via enhanced granulation with hydrated lime [J]. Asia-Pacific Journal of Chemical Engineering, 2021, 16(2): 2592

[46] LuL-m, ManuelJ. Sintering characteristics of iron ore blends containing high proportions of goethitic ores [J]. JOM, 2021, 73(1): 306-315

[47] JiZ-y, FanX-h, GanM, et al.. Assessment on the application of commercial medium-grade charcoal as a substitute for coke breeze in iron ore sintering [J]. Energy & Fuels, 2016, 30(12): 10448-10457

[48] KawaguchiT, HaraM. Utilization of biomass for iron ore sintering [J]. ISIJ International, 2013, 53(9): 1599-1606

[49] LegemzaJ, FindorakR, FrohlichovaM. Utilization of charcoal in the iron-ore sintering process [J]. Scientia Iranica, 2016, 23(3): 990-997

[50] GanM, LvW, FanX-h, et al.. Gasification reaction characteristics between biochar and CO₂ as well as the influence on sintering process [J]. Advances in Materials Science and Engineering, 2017, 2017: 1-8

[51] SunC-f, MaP-s, DengJ-y, et al.. Intensive reduction of fuel consumption in the sintering process of double-layered fuel segregation with return fines embedding [J]. Fuel, 2023, 332: 125955

[52] FanX-h, YuZ-y, GanM, et al.. Combustion behavior and influence mechanism of CO on iron ore sintering with flue gas recirculation [J]. Journal of Central South University, 2014, 21(6): 2391-2396

[53] FanX-h, WongG, GanM, et al.. Establishment of refined sintering flue gas recirculation patterns for gas pollutant reduction and waste heat recycling [J]. Journal of Cleaner Production, 2019, 235: 1549-1558

[54] WangG, WenZ, LouG-f, et al.. Mathematical modeling of and parametric studies on flue gas recirculation iron ore sintering [J]. Applied Thermal Engineering, 2016, 102: 648-660

[55] ZhangX-h, FengP, XuJ-r, et al.. Numerical research on combining flue gas recirculation sintering and fuel layered distribution sintering in the iron ore sintering process [J]. Energy, 2020, 192: 116660

[56] ZuoH-b, ZhangJ-l, HuZ-w, et al.. Load reduction sintering for increasing productivity and decreasing fuel consumption [J]. International Journal of Minerals, Metallurgy, and Materials, 2013, 20(2): 131-137

[57] WangY-z, LiuZ-j, ZhangJ-l, et al.. Study of stand-support sintering to achieve high oxygen potential in iron ore sintering to enhance productivity and reduce CO content in exhaust gas [J]. Journal of Cleaner Production, 2020, 252: 119855

[58] HuangX-x, FanX-h, JiZ-y, et al.. Investigation into the characteristics of H₂-rich gas injection over iron ore sintering process: Experiment and modelling [J]. Applied Thermal Engineering, 2019, 157: 113709

[59] GaoQ-j, XieJ-f, ZhangY-y, et al.. Mathematical modeling of natural gas injection in iron ore sintering process and corresponding environmental assessment of CO₂ mitigation [J]. Journal of Cleaner Production, 2022, 332: 130009

[60] ChengZ-l, WangJ-y, WeiS-s, et al.. Optimization of gaseous fuel injection for saving energy consumption and improving imbalance of heat distribution in iron ore sintering [J]. Applied Energy, 2017, 207: 230-242

[61] ChengZ L, WeiS S, GuoZ G, et al.. Visualization study on the methane segregation injection technology in iron ore sintering process [J]. Energy Procedia, 2017, 105: 1461-1466

[62] ZhongQ, LiuH-b, XuL-p, et al.. An efficient method for iron ore sintering with high-bed layer: Double-layer sintering [J]. Journal of Iron and Steel Research International, 2021, 28(11): 1366-1374

[63] FanX-h, YuZ-y, GanM, et al.. Appropriate technology parameters of iron ore sintering process with flue gas recirculation [J]. ISIJ International, 2014, 54(11): 2541-2550

[64] ConklinJ C, SzybistJ P. A highly efficient six-stroke internal combustion engine cycle with water injection for in-cylinder exhaust heat recovery [J]. Energy, 2010, 35(4): 1658-1664

[65] GlushkovD O, LyrshchikovS Y, ShevyrevS A, et al.. Burning properties of slurry based on coal and oil processing waste [J]. Energy & Fuels, 2016, 30(4): 3441-3450

[66] PrationoW, ZhangJ, CuiJ-f, et al.. Influence of inherent moisture on the ignition and combustion of wet Victorian brown coal in air-firing and oxy-fuel modes: Part 1: The volatile ignition and flame propagation [J]. Fuel Processing Technology, 2015, 138: 670-679

[67] XuJ, QiaoLi. Mathematical modeling of coal gasification processes in a well-stirred reactor: Effects of devolatilization and moisture content [J]. Energy & Fuels, 2012, 26(9): 5759-5768

[68] de PaepeW, SayadP, BramS, et al.. Experimental investigation of the effect of steam dilution on the combustion of methane for humidified micro gas turbine applications [J]. Combustion Science and Technology, 2016, 188(8): 1199-1219

[69] WangL, LiuZ-h, ChenS, et al.. Physical and chemical effects of CO₂ and H₂O additives on counterflow diffusion flame burning methane [J]. Energy & Fuels, 2013, 27(12): 7602-7611

[70] ChenX-l, HuangY-s, GanM, et al.. Effect of H₂O_(g) content in circulating flue gas on iron ore sintering with flue gas recirculation [J]. Journal of Iron and Steel Research, International, 2015, 22(12): 1107-1112

[71] PeiY-d, XiongJ, WuS-l, et al.Research and application of sintering surface steam spraying technology for energy saving and quality improvement [C], 2018, Cham, Springer: 785-796

[72] ChengZ-l, YangJ, ZhouL, et al.. Experimental study of commercial charcoal as alternative fuel for coke breeze in iron ore sintering process [J]. Energy Conversion and Management, 2016, 125: 254-263

[73] ZhouH, LiuZ-h, ChengM, et al.. Influence of coke combustion on NO_x emission during iron ore sintering [J]. Energy & Fuels, 2015, 29(2): 974-984

[74] ZhouM-x, ZhouH, ChengY, et al.. Investigation on the combustion behaviors of coke and biomass char in quasi-granule with CuO–CeO₂ catalysts in iron ore sintering [J]. Journal of the Energy Institute, 2020, 93(5): 1934-1941

RIGHTS & PERMISSIONS

Central South University