Evaluation of Australian PCI Coals Under Industry Scale Blast Furnace Conditions Using 3D Computer Modelling – Stage 3: Under Overseas Blast Furnace Conditions

This project evaluated the Australian PCI coals under industry scale blast furnace (BF) conditions using an improved 3D Computational Fluid Dynamics (CFD) model. In Stage 1 (C26041), the single coal injection of a range of Australian PCI coals was evaluated using a 3D PCI model under Australian BF conditions. In this project the Australian PCI coals are evaluated under two typical overseas BF conditions i.e., one Chinese BF and one Indian BF, aiming for promoting Australian PCI coals in Chinese and Indian markets.

BF ironmaking is the dominant technology by which iron is rapidly and efficiently reduced from ore+. PCI technology is widely operated in BFs worldwide, representing a significant amount of coal export. Considering the number and productivity of BFs worldwide and high PCI rate in most BF operations, the market of PCI coal is huge and increasing. Australian coals play a dominant role in the PCI coal market.

Notably, China has been a significant importer of Australian PCI coals and India on the other hand, represents one of the fastest developing importers. It is noted that the BF and PCI conditions in the overseas BFs are very different from the Australian BFs in terms of BF size, equipment geometry and operational features. Moreover, it is well received that the in-furnace performance of PCI coals will vary significantly in different BFs considering different BF scale/size, geometry and unique PCI operating conditions. Thus, the in-furnace phenomena related to PCI operations under Chinese BFs and Indian BFs can be very different from those in the Australian BF, considering their significant differences in BF scale/size and PCI conditions.

This project evaluated the combustion of a range of Australian High Volatile /Mid Volatile /Low Volatile (HV/MV/LV) PCI coals in the entire raceway (rather than along tuyere centreline only, like Drop Tube Furnace) under two real BF conditions (rather than lab or pilot-scale conditions) of one Chinese BF and one Indian BF using an improved 3D Computational Fluid Dynamics (CFD)-based PCI model.

The deliveries for this project include:

• The final report of the assessment of a range of Australian PCI coals under real BF conditions of one Chinese BF and one Indian BF, respectively, and
• Standalone PCI simulators for ACARP's HV/MV/LV PCI coals with one Chinese BF and one Indian BF. They can predict in-furnace phenomena of flow and thermochemical behaviours related to the injection of Australian coals under different BF conditions. They will act as research tools and also marketing tools for Australian PCI coal producers and/or distributors for promotion into the overseas market.  

The outcomes of this project include:

• Detailed and quantified understanding on in-furnace phenomena for a range of Australian PCI coals under real BF conditions at one Chinese BF and an Indian BF, respectively;
• General knowledge of effects of key operational parameters on PCI operation for Australian PCI coals under real BF conditions at one Chinese BF and an Indian BF, respectively;
• A database of burnout for different Australian PCI coals under different BF operational conditions at one Chinese BF and an Indian BF, respectively.