Mathematical Modelling of Shaft based direct Reduction processes of Iron manufacture with Recirculation of Moisture free flue Gases

Shaft furnaces account for over 80 percent of the world
production of the directly reduced iron that is fed' to an
electric arc- furnace as an alternative to the blast furn-ace basic oxygen steelmaking route. The process is charac-terised by high rates of production as well as high deg-rees of metallisation of the product for its economic melting in the electric arc furnace for its survival in the present day competitive world. This is best done by keeping the amount of hot reducirig gases such as CO and H2 well above the theoretical minimum as the same would tend to ensure rapid preheating of the incoming uniformly
sized burdan materials and the accompanying high rates of Iron ore reduction . The unutilised portions of CO and H, in the flue gates are partly recycled back to the furnace through a reformer where CO2 in flue gases is used to conve, the natural gas into CO and H2 at around 10000, and partly used as fuel tc. meet. the energy requirements of the reformer. As the flue gases are to be cooled to get rid of the dust particles, most of the water vapours, present in the gases a5 a result of reduction of iron
ore by hydrogen in the shaft, are removed by condensation