JP7676849B2 - Reactor reaction calculation device and reactor reaction calculation method - Google Patents

Description

The present invention relates to a reactor reaction calculation device and a reactor reaction calculation method.

As a method for smelting laterite ores (nickel oxide ores) such as limonite ore and saprolite ore, which are types of oxide ores, a dry smelting method is known that uses a rotary kiln or a moving hearth furnace to produce ferronickel, an alloy whose main components are iron and nickel.

In the dry smelting method using a rotary kiln, the raw ore is dried in a rotary dryer to reduce the adhering moisture content to, for example, 15% to 25%, and the dried ore with reduced adhering moisture content is then charged into the charging end of the rotary kiln. The dried ore is then heated by the heat of combustion of coal supplied from the charging end of the rotary kiln, or by a pulverized coal-only burner or a pulverized coal and heavy oil mixed-fuel burner installed at the discharge end of the rotary kiln, to dry and fire the dried ore.

As a dry smelting method using such a rotary kiln, for example, in addition to the combustion heat of coal supplied from the charging end and the combustion heat generated by burning pulverized coal and heavy oil in a burner, there is a method in which the combustion heat generated by burning coal fed into the rotary kiln midway is used to provide the heat necessary for drying and partial reduction of the dried ore (see, for example, Patent Document 1).

Patent Document 1 discloses a method of operating a rotary kiln in which coal is fed into the rotary kiln from a scoop feeder installed midway through the rotary kiln, and the dried nickel oxide ore fed into the feeding end of the rotary kiln is burned with the heat of combustion generated by the combustion of fossil fuels in a burner and is also partially reduced. In this method of operating a rotary kiln, the coal fed into the rotary kiln from the scoop feeder is thermally decomposed into volatile matter and fixed carbon, and the volatile matter is discharged from the feeding end together with the combustion gas in the furnace, and the fixed carbon is discharged from the discharge end together with the burnt ore produced by drying and reducing the dried ore.

Patent No. 5967616

Here, it is known that in well-known operating methods such as the rotary kiln operating method described in Patent Document 1, dust is generated from the raw ore and discharged outside the furnace together with exhaust gas. When the dust generated from the raw ore is dispersed into the gas phase, the composition and temperature of the gas phase change, affecting the reaction in the bed layer. Therefore, when simulating the behavior of dried ore in a reaction furnace such as a rotary kiln, it is not possible to accurately calculate the reaction in the furnace unless the reaction behavior of the dust dispersed into the gas phase is taken into account.

One aspect of the present invention aims to provide a reactor reaction calculation device that can calculate the reactions in a reactor with high accuracy, taking into account the reactions in the gas region of dust generated from the bed layer in the reactor.

One aspect of the in-furnace reaction calculation device according to the present invention is a furnace reaction calculation device in which raw material ore is supplied from one end of a reactor, and while moving the raw material ore toward the other end, the raw material ore is brought into contact with combustion gas supplied from the other end, thereby drying and reducing the raw material ore,
A gas mixing amount calculation unit calculates a flow rate of an inflow gas moving from the gas region containing the combustion gas in the reactor to a bed layer containing the raw material ore, out of the gas phase containing the combustion gas flowing through the gas region in the reactor;
a bed layer material quantity correction unit for correcting the material quantity of the first bed layer by subtracting the amount of a second material, which is included in the first bed layer and includes the raw ore moving through the bed layer and includes at least one of a solid material and a liquid material, from the amount of the second material moving to the gas region, to calculate a corrected first bed layer;
a gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between a gas phase from which the inflow gas has been removed and a first substance that includes at least one of a solid substance and a liquid substance present in the gas region;
a bed layer equilibrium reaction calculation unit for calculating an equilibrium reaction between the modified first bed layer and the inflow gas;
Equipped with.

One aspect of the method for calculating a reaction in a furnace according to the present invention is a method for calculating a reaction in a furnace, in which a raw material ore is supplied from one end of a reactor, and while moving the raw material ore toward the other end, the raw material ore is brought into contact with a combustion gas supplied from the other end, thereby drying and reducing the raw material ore, the method comprising the steps of:
a gas mixing amount calculation step of calculating a flow rate of an inflow gas moving from the gas region containing the combustion gas in the reactor to a bed layer containing the raw material ore, among the gas phase containing the combustion gas flowing through the gas region in the reactor;
a bed layer material quantity correction step of correcting the material quantity of the first bed layer by subtracting the amount of a second material, which is included in the first bed layer and includes the raw ore moving through the bed layer, from the amount of the second material, which is included in the first bed layer and includes at least one of a solid material and a liquid material, moving to the gas region, to calculate a corrected first bed layer;
a gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the gas phase from which the inflow gas has been removed and a first substance including at least one of a solid substance and a liquid substance present in the gas region;
a bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the modified first bed layer and the inflow gas;
Includes.

One aspect of the reactor reaction calculation device of the present invention can calculate the reactions in the reactor with high accuracy by taking into account the reactions in the gas region of the dust generated from the bed layer in the reactor.

1 shows a schematic configuration of a rotary kiln to which a calculation device for a furnace reaction according to an embodiment of the present invention is applied. 1 is a block diagram showing the functions of a reactor reaction calculation device according to an embodiment of the present invention; 1 is a flowchart illustrating a method for calculating an in-furnace reaction according to an embodiment of the present invention. 4 is a flowchart showing the operation of a gas region equilibrium reaction implementation step (step S17) in FIG. 3. 4 is a flowchart showing the operation of the second equilibrium reaction implementation step (step S18) of FIG. 3. FIG. 2 is a hardware configuration diagram of a reactor reaction calculation device. FIG. 2 is a diagram showing the flow of combustion gas and raw ore in a rotary kiln. 1 is a flowchart showing a method for calculating furnace reactions according to an embodiment of the present invention when applied to the entire rotary kiln.

The following describes in detail an embodiment of the present invention. To facilitate understanding of the description, the same components in each drawing are given the same reference numerals, and duplicate descriptions are omitted. Also, the scale of each component in the drawings may differ from the actual scale.

Before explaining the furnace reaction calculation device according to the embodiment of the present invention, we will explain the configuration of a rotary kiln to which the furnace reaction calculation device according to this embodiment is applied.

<Rotary kiln>
Fig. 1 shows a schematic configuration of a rotary kiln to which the calculation device for furnace reactions according to the present embodiment is applied. As shown in Fig. 1, the rotary kiln 1 has a rotatable, substantially cylindrical kiln body 11 and a combustion material supply pipe 12 provided midway through the kiln body 11.

The kiln body 11 is a kiln consisting of a cylindrical hollow structure, and is made of carbon steel with a thickness of 15 to 30 mm. It is preferable that the kiln body 11 is provided with a refractory material on the inner wall surface to increase heat resistance.

The size of the kiln body 11 is preferably, for example, an inner diameter of 4.5 m to 5.5 m and a length in the longitudinal direction (total length) of 100 m to 110 m.

The kiln body 11 has an open end 11a at one end (left side in FIG. 1) inserted into the rotary kiln charging end (hereinafter also simply referred to as the "charging end") 14A and closed, and an open end 11b at the other end (right side in FIG. 1) inserted into the rotary kiln discharge end (hereinafter also referred to as the "discharge end") 14B and closed. The kiln body 11 is arranged at a slight incline from the charging end 14A toward the discharge end 14B, and is supported so as to be freely rotatable around its axis.

A raw material supply pipe 15 that introduces raw material ore into the kiln body 11 is installed through the charging end 14A. A burner 16 is installed at the discharge end 14B and is introduced into the kiln body 11 through the open end 11b.

The raw ore may be nickel oxide ore (nickel oxide ore). For example, the raw ore may be dried ore obtained by pre-drying nickel oxide ore with a dryer (rotary dryer) to remove some of the adhering moisture. The moisture content in the dried ore is about 15% to 25% by mass.

The nickel oxide ore as the raw material ore is not particularly limited, but garnierite ore is preferably used in the smelting of ferronickel, which is an alloy mainly composed of iron and nickel. The typical composition of garnierite ore is, calculated on a dry ore basis, a Ni content of 2.1% to 2.5% by mass, a Fe content of 11% to 23% by mass, a MgO content of 20% to 28% by mass, _{a SiO2} content of 29% to 39% by mass, a CaO content of less than 0.5% by mass, and a loss on ignition of 10% to 15% by mass.

The burner 16 may be a pulverized coal burner or a mixed combustion burner of pulverized coal and heavy oil. The burner 16 burns a fuel containing pulverized coal or pulverized coal and heavy oil, etc., to generate combustion heat within the rotary kiln 1.

The combustion material supply pipe 12 is provided midway along the outer circumferential surface of the kiln body 11, and can supply the combustion material into the kiln body 11. The combustion material includes at least one of substances that mainly enter the gas phase, such as volatile matter, and solid substances that mainly enter the bed layer, such as fixed carbon, and can be, for example, carbonaceous materials such as coal.

Volatile matter includes volatile substances such as hydrocarbon compounds, sulfur, and halogens.

Fixed carbon is the combustion fraction of char particles (mainly fixed carbon and ash), which are the residue after pyrolysis after moisture and volatile matter have been removed from coal, and is composed mainly of carbon, excluding ash.

In FIG. 1, only one combustion material supply pipe 12 is provided on the outer peripheral surface of the kiln body 11, but multiple combustion material supply pipes 12 may be provided on the outer peripheral surface of the kiln body 11 along the axial direction or around the axis of the kiln body 11.

The combustion material is often not a single type of carbonaceous material, but a mixture of multiple different types of carbonaceous materials, and the particle size of the carbonaceous material to be added often has a distribution. Note that the particle size refers to the volume average particle size based on the effective diameter, and the particle size is measured, for example, by a laser diffraction/scattering method, a dynamic light scattering method, or a classification method. When the laser diffraction/scattering method is used, the particle size (D ₅₀ ) at which the cumulative particle size distribution from the small particle size side in the volume-based particle size distribution measured by the laser diffraction/scattering method is 50% can be used as the average particle size.

The raw ore is charged into the kiln body 11 through the raw material supply pipe 15 installed at the charging end 14A, and the combustion material is fed into the kiln body 11 through the combustion material supply pipe 12. From the discharge end 14B side, high-temperature combustion gas generated by burning pulverized coal, heavy oil, etc. with the burner 16 installed at the discharge end 14B is blown from the discharge end 14B side toward the charging end 14A side, i.e., in the opposite direction to the flow of the raw ore.

In the kiln body 11, the raw ore is charged from the charging end 14A, and the kiln body 11 rotates at a predetermined speed to transport the raw ore charged into the kiln body 11 from the charging end 14A through the raw material supply pipe 15 from the opening end 11a side, which is one end side, to the discharge end 14B, which is the other end side. At this time, while moving inside the kiln body 11, the raw ore comes into countercurrent contact with the combustion gas flowing from the discharge end 14B to the charging end 14A side, and is heated by the combustion heat and flame of the high-temperature combustion gas generated by burning fuel such as pulverized coal and heavy oil with the burner 16. In addition, the combustion material fed into the kiln body 11 from the combustion material supply pipe 12 is burned by the combustion gas in the kiln body 11. The raw ore is also heated by the combustion heat generated by the combustion of the combustion material fed from the combustion material supply pipe 12. Therefore, as the kiln body 11 rotates, the raw ore moves from the charging end 14A to the discharge end 14B of the kiln body 11, and is heated by the combustion heat and flame of the combustion gas generated by the combustion of the fuel in the burner 16 and the combustion heat generated by the combustion of the combustion material, gradually increasing its temperature.

In the kiln body 11, material transfer occurs between the raw ore and the combustion gas due to evaporation of moisture contained in the raw ore and the combustion materials, evaporation and condensation of volatile matter contained in the combustion materials, and scattering and falling of ash contained in the burner fuel and the combustion materials. Moisture and volatile matter generated by the thermal decomposition of the combustion materials supplied midway through the rotary kiln 1 move with the combustion gas to the charging end 14A side, and char particles move with the raw ore to the discharge end 14B.

By the time the raw ore in the kiln body 11 reaches the discharge end 14B, the moisture contained in the raw ore is almost completely removed, the raw ore is burned, and the ore is partially reduced to become burnt ore. The burnt ore is discharged from the discharge end 14B.

For example, the calcined ore has a temperature of 800 to 900°C and a particle size of about 10 mm to 100 mm.

At the discharge outlet of the discharge end 14B, a grate (sieving device) 17 is provided to separate the cinders with particle diameters of about 10 mm to 100 mm from the sintered lumps (particle diameters of about 100 mm to 500 mm) generated in the rotary kiln 1. The grate 17 is, for example, made of an iron grate with a mesh size of about 100 mm. The cinders discharged from the discharge end 14B pass through the grate 17 and then pass through the cinders discharge chute 18 to be transported to the next process.

<Calculation device for reactor reactions>
Next, the calculation device for furnace reactions according to this embodiment will be described. FIG. 2 is a block diagram showing the functions of the calculation device for furnace reactions according to this embodiment. In FIG. 2, the calculation device for furnace reactions will be described as a unit operation model in region A where combustion material is supplied from the combustion material supply pipe 12 when the rotary kiln 1 is divided into a plurality of regions. In FIG. 2, the adjacent region on the side where the combustion gas is blown in from region A is region (A+1), and the adjacent region on the side where the raw material ore is charged is region (A-1).

In the following description, the gas region refers to the region in the rotary kiln 1 where the gas phase containing gas and dust flows, and the bed layer refers to the region where the raw ore moves.

The gas phases in the region A are described as a first gas phase G1, a second gas phase G2, a third gas phase G3, or a third mixed gas phase G3'. Each gas phase in the region A is defined as follows.
The "first gas phase G1" refers to the combustion gas flowing into region A from one adjacent region (region (A+1)). The combustion gas includes gases that contribute to the equilibrium reaction, such as volatile matter, oxygen, carbon dioxide, carbon monoxide, and hydrogen, and may also include inert substances (e.g., nitrogen, etc.) that do not contribute to the reaction.
The "second gas phase G2" is a gas phase obtained by combining the added gas phase distributed from the combustion material and the first gas phase.
The "third gas phase G3" is a gas phase generated in the mixed gas phase calculation unit 209 described later.
The "third mixed gas phase G3'" is a gas phase generated in the gas mixer 213, which will be described later.

The bed layers in the region A are described as the first bed layer S1, the second bed layer S2, or the third bed layer S3. Each bed layer in the region A is defined as follows.
The "first bed layer S1" refers to raw ore flowing into the region A from the other adjacent region (region (A-1)). The raw ore includes solid substances including compounds in the ore such as nickel oxide, iron oxide, and magnesium oxide, and fixed carbon, and liquid substances, and may also include inactive substances that do not contribute to the reaction in the bed layer equilibrium reaction calculation unit 208-2 described later.
The "second bed layer S2" is a bed layer formed by combining the additive bed layer distributed from the combustion material and the first bed layer.
The "third bed layer S3" is a bed layer generated in the mixed bed layer calculation unit 211 described later.

The substances present in the region A are referred to as a first substance M1, a second substance M2, a first mixed substance M11, or a first modified mixed substance M12. In the following description, each substance in the region A is defined as follows.
The "first substance M1" includes at least one of a solid substance and a liquid substance that exists in a gas region.
The "second substance M2" includes at least one of a solid substance and a liquid substance present in the bed layer, and includes, for example, dust.
The "first mixed material M11" is a mixture of the first material M1 generated in the first mixed material calculation unit 210 described later.
The "first modified mixed material M12" is a mixture of the first material M1 produced in the first mixed material amount modifying unit 214 described below.

The reacted, unreacted and product portions calculated within region A are described as gas reacted portion GR1, gas unreacted portion Gr1, gas product portion GP1, first substance reacted portion MR1, first substance unreacted portion Mr1, first substance product portion MP1, inflow gas reacted portion GR11, inflow gas unreacted portion Gr11, inflow gas product portion GP11, bed layer reacted portion SR1, bed layer unreacted portion Sr1 or bed layer product portion SP1. These are calculated by any of the components constituting the furnace reaction calculation device shown in Figure 2.

As shown in FIG. 2, the furnace reaction calculation device 20 includes a combustion material distribution unit (distribution unit) 201, a gas mixture amount calculation unit 202, a bed layer material amount correction unit 203, a gas reaction amount calculation unit 204, a first material reaction amount calculation unit 205, a bed layer reaction amount calculation unit 206, an inflow gas reaction amount calculation unit 207, a gas region equilibrium reaction calculation unit 208-1, a bed layer equilibrium reaction calculation unit 208-2, a mixed gas phase calculation unit 209, a first mixed material calculation unit 210, a mixed bed layer calculation unit 211, a mixed inflow gas calculation unit 212, a gas summation unit 213, and a first mixed material amount correction unit 214.

The furnace reaction calculation device 20 performs a gas region equilibrium reaction calculation to calculate the reaction between the gas flowing in the gas region and the solid or liquid material present in the gas region, taking into account the mass transfer to the gas region of some of the solid or liquid material moving in the bed layer and the mixing of some of the gas flowing in the gas region into the bed layer, and a bed layer equilibrium reaction calculation to calculate the reaction between the solid or liquid material moving in the bed layer and the gas mixed into the bed layer. As a result, the furnace reaction calculation device 20 analyzes the furnace reaction with high accuracy and improves the calculation accuracy of the reaction in the rotary kiln 1. Therefore, the furnace reaction calculation device 20 can analyze the reaction in the reactor with high accuracy, taking into account the reaction in the gas region of the dust generated from the bed layer in the reactor, and can calculate the reaction in the rotary kiln 1 with high accuracy.

That is, when simulating the furnace reaction based on the Gibbs energy minimization method, the furnace reaction calculation device 20 calculates the reaction between the bed layer and the gas mixed in the bed layer, and the reaction between the gas flowing in the gas region and the solid or liquid substance present in the gas region, taking into account the movement amount of a substance (second substance M2) containing at least one of a solid substance and a liquid substance moving in the bed layer, such as dust. The furnace reaction calculation device 20 can calculate the reaction of the dust generated in the rotary kiln 1 in the gas region by treating the dust generated in the rotary kiln 1 as a substance (first substance M1) containing at least one of a solid substance and a liquid substance moving in the gas region. As a result, the furnace reaction calculation device 20 can consider the influence on the reaction in the bed layer due to changes in the gas composition, temperature, etc. in the gas region, and can improve the prediction accuracy of the furnace reaction.

As shown in FIG. 2, the reactor reaction calculation device 20 inputs the quantities, temperatures, pressures, etc. of the first bed layer S1 flowing into the bed layer of region A and the first gas phase G1 flowing into the gas region. The reactor reaction calculation device 20 uses these input values to perform mass transfer and reaction calculations within each divided region A.

When calculating the mass transfer and reactions in region A, the reactor reaction calculation device 20 defines the amount of gas (inlet gas G11) that is mixed into the bed layer from the first gas phase G1 flowing in the gas region. One method for defining this gas mixing amount is to give a fixed value as the proportion of the total amount of gas that is mixed into the bed layer.

The reactor reaction calculation device 20 also defines the amount of mass transfer to the gas region associated with scattering or volatilization of solid or liquid materials moving within the bed layer. The definition may also include the amount of mass transfer to the bed layer associated with falling (settling) or coagulation of solid or liquid materials moving within the gas region. One method for defining this amount of mass transfer is to define it for each calculation material based on, for example, the scattering velocity, settling velocity, etc., calculated from the specific gravity, particle size, etc., of the solid or liquid material.

As shown in FIG. 2, the distribution unit 201 has the function of distributing the combustion material to the gas phase and bed layer contained in the combustion material at a mass flow rate by setting the type and components of the combustion material in advance.

The distributed gas phase and bed layer are supplied into region A as additive gas phase AG11 and additive bed layer AS11.

The gas mixture calculation unit 202 calculates the mass flow rate of the inflow gas G11 moving from the gas region to the bed layer, out of the second gas phase G2, which includes the first gas phase G1, which is the combustion gas flowing from one adjacent region (region (A+1)) into the gas region of region A in the furnace, and the added gas phase AG11 of the combustion material distributed by the distribution unit 201.

The bed layer quantity correction unit 203 corrects the quantity of the second bed layer S2 by subtracting the amount of the second substance M2, which contains at least one of a solid substance and a liquid substance contained in the second bed layer S2, moving into the gas region, and calculates the corrected second bed layer S2A.

In this embodiment, the bed layer quantity correction unit 203 may calculate the amount of movement of the second substance M2 into the gas region and correct the quantity of the second bed layer S2 by taking into account not only the amount of movement of the second substance M2 into the gas region but also the amount of movement of the second substance M2 from the gas region to the second bed layer S2.

The gas reaction amount calculation unit 204 calculates the amount of gas reaction that contributes to the equilibrium state of the second gas phase G2 with the first substance M1. That is, the gas reaction amount calculation unit 204 calculates the amount of gas reaction that is expected to occur in equilibrium with the first substance reaction amount MR1 during the residence time of the second gas phase G2 present in the gas region in region A. The reaction amount during the residence time of the second gas phase G2 in region A is calculated using reaction rate parameters set for each individual substance and the residence time in region A. The gas reaction amount can be calculated by using a reaction rate equation to determine the amount that reacts during the residence time in region A. Then, the gas reaction amount calculation unit 204 calculates the gas reaction amount GR1 that contributes to the equilibrium state with the first substance reaction amount MR1 of the second gas phase G2 from the gas reaction amount.

In this specification, the reactive portion refers to the flow rate that contributes to the reaction by contact with the second gas phase G2 or the first substance M1 during the residence time during which the second gas phase G2 or the first substance M1 present in the gas region in region A passes through.

That is, the gas reaction portion GR1 is the reaction portion that contributes to the equilibrium reaction with the first substance M1 present in the gas region of the second gas phase G2. The first substance reaction portion MR1 is the reaction portion of the first substance M1 present in the gas region flowing in from one adjacent region (region (A+1)) that contributes to the equilibrium state with the second gas phase G2.

The gas reaction amount calculation unit 204 can determine the amount of the second gas phase G2 and the solid or liquid substance present in the first substance M1 that reaches an equilibrium state by employing, for example, a model that can calculate the amount from the reaction rate according to the Arrhenius reaction rate equation and the residence time of the second gas phase G2 in the region A. The gas reaction amount calculation unit 204 then divides the amount into a gas reaction amount GR1 that corresponds to the gas reaction amount and an unreacted gas amount Gr1 that corresponds to the mass flow rate of the remaining unreacted gas.

In the rotary kiln 1, the second gas phase G2 and the first substance M1 present in the gas region flow in parallel. The flow rate of the second gas phase G2 is greater than the flow rate of the first substance M1 present in the gas region, and the second gas phase G2 and the first substance M1 present in the gas region have not reached equilibrium. In this embodiment, the gas reaction amount calculation unit 204 assumes that only a portion of the second gas phase G2 in a certain region (region A) in the rotary kiln 1 reaches equilibrium with the first substance M1 present in the gas region, and divides the second gas phase G2 into a gas reaction portion GR1 and the remaining gas unreacted portion Gr1 according to the corresponding gas reaction amount.

The first substance reaction amount calculation unit 205 calculates the amount of the first substance reaction that contributes to the equilibrium state of the first substance M1 with the second gas phase G2. That is, the first substance reaction amount calculation unit 205 calculates the amount of the first substance reaction that is expected to occur when the first substance M1 reacts in equilibrium with the second gas phase G2 during the residence time of the first substance M1 present in the gas region in region A. The amount of the first substance reaction can be calculated from the reaction rate equation. Then, the first substance reaction amount calculation unit 205 calculates the amount of the first substance reaction MR1 that contributes to the equilibrium state of the first substance M1 with the second gas phase G2 from the amount of the first substance reaction.

The first substance reaction amount calculation unit 205, like the gas reaction amount calculation unit 204, can determine the amount of the second gas phase G2 and the first substance M1 present in the gas region that reaches an equilibrium state by employing a model that can calculate the amount from, for example, a reaction rate according to an Arrhenius reaction rate equation and the residence time of the first substance M1 in the region A. The first substance reaction amount calculation unit 205 then divides the amount into a first substance reaction amount MR1 that corresponds to the first substance reaction amount and an unreacted first substance amount Mr1 that corresponds to the remaining unreacted mass flow rate.

As described above, in the rotary kiln 1, the second gas phase G2 and the first substance M1 flow in parallel, the flow rate of the second gas phase G2 is faster than that of the first substance M1, and the second gas phase G2 and the first substance M1 do not reach equilibrium. In this embodiment, the first substance reaction amount calculation unit 205 assumes that only a portion of the second gas phase G2 in a certain area (area A) in the rotary kiln 1 reaches equilibrium with the first substance M1, and divides the first substance M1 into a reacted portion of the first substance MR1 and an unreacted portion of the first substance Mr1 depending on the corresponding first substance reaction amount.

The bed layer reaction amount calculation unit 206 calculates the amount of bed layer reaction that contributes to the equilibrium state of the modified second bed layer S2A with the inflow gas G11. That is, the bed layer reaction amount calculation unit 206 calculates the amount of bed layer reaction that is expected to occur in equilibrium with the inflow gas during the movement time of the modified second bed layer S2A in region A. The reaction amount during the movement time of the modified second bed layer S2A in region A is calculated using the reaction rate parameters set for each substance contained in the modified second bed layer S2A and the residence time in region A. The bed layer reaction amount can be calculated by using the reaction rate formula to calculate the amount that reacts during the movement time in region A. Then, the bed layer reaction amount calculation unit 206 calculates the bed layer reaction amount SR1 that contributes to the equilibrium state with the inflow gas G11 from the bed layer reaction amount.

The bed layer reaction amount calculation unit 206, like the gas reaction amount calculation unit 204, can determine the amount of the modified second bed layer S2A and the inflow gas G11 present in the gas region that reach equilibrium by adopting a model that can calculate the amount from, for example, a reaction rate according to an Arrhenius reaction rate equation and the residence time of the modified second bed layer S2A in region A. The bed layer reaction amount calculation unit 206 calculates the bed layer reaction amount of the modified second bed layer S2A that contributes to the reaction with the inflow gas G11 only for the amount that is estimated to reach equilibrium between the modified second bed layer S2A and the inflow gas based on the residence time of the modified second bed layer S2A using the Arrhenius reaction rate equation. Then, the bed layer reaction amount calculation unit 206 divides the modified second bed layer S2A into a bed layer reaction amount SR1 corresponding to the bed layer reaction amount and a bed layer unreacted amount Sr1 corresponding to the remaining unreacted mass flow rate.

In other words, the bed layer reaction portion SR1 is the reaction portion that contributes to the equilibrium reaction with the inflow gas G11 in the modified second bed layer S2A.

In the rotary kiln 1, the flow of the modified second bed layer S2A and the inflow gas G11 are countercurrent. The flow rate of the inflow gas G11 is faster than the movement of the modified second bed layer S2AC, and the modified second bed layer S2A and the inflow gas G11 have not reached equilibrium. In this embodiment, the bed layer reaction amount calculation unit 206 assumes that only a portion of the modified second bed layer S2A in a certain area (area A) in the rotary kiln 1 reaches equilibrium with the inflow gas G11, and divides the modified second bed layer S2A into a bed layer reaction portion SR1 and the remaining bed layer unreacted portion Sr1 according to the corresponding bed layer reaction amount.

The inflow gas reaction amount calculation unit 207 calculates the inflow gas reaction amount that contributes to the equilibrium state of the inflow gas G11 present in the bed layer with the modified second bed layer S2A. That is, the inflow gas reaction amount calculation unit 207 calculates the inflow gas reaction amount that is expected to cause the inflow gas G11 to react in equilibrium with the modified second bed layer S2A during the residence time of the inflow gas present in the bed layer in region A. The reaction amount during the residence time of the inflow gas G11 in region A is calculated using the reaction rate parameters set for each individual substance and the residence time in region A. The inflow gas reaction amount can be calculated from the reaction rate equation. Then, the inflow gas reaction amount calculation unit 207 calculates the inflow gas reaction amount GR11 that contributes to the equilibrium reaction of the inflow gas G11.

That is, the inflow gas reaction portion GR11 is the reaction portion of the inflow gas G11 that contributes to the equilibrium state of the second modified bed layer S2A.

The inflow gas reaction amount calculation unit 207 determines the amount of the first inflow gas G111 and the modified second bed layer S2A that reaches an equilibrium state by adopting a model that can calculate the amount from, for example, a reaction rate according to an Arrhenius-type reaction rate equation and the residence time of the inflow gas G11 in region A. The inflow gas reaction amount calculation unit 207 then divides the inflow gas into an inflow gas reaction amount GR11 that corresponds to the inflow gas reaction amount and an inflow gas unreacted amount Gr11 that corresponds to the unreacted mass flow rate other than the remaining inflow gas reaction amount GR11.

As described above, in the rotary kiln 1, the inflow gas G11 and the modified second bed layer S2A flow in countercurrent, the flow rate of the inflow gas G11 is greater than the flow rate of the modified second bed layer S2A, and the inflow gas G11 and the modified second bed layer S2A do not reach equilibrium. In this embodiment, the inflow gas reaction amount calculation unit 207 assumes that only a portion of the inflow gas G11 in a certain area (area A) in the rotary kiln 1 reaches equilibrium with the modified second bed layer S2A, and divides the inflow gas G11 into the inflow gas reacted portion GR11 and the remaining inflow gas unreacted portion Gr11 according to the corresponding gas reaction amount.

The gas region equilibrium reaction calculation unit 208-1 calculates the equilibrium reaction between the second gas phase G2 flowing in the gas region in region A and the first substance M1 present in the gas region. That is, the gas region equilibrium reaction calculation unit 208-1 performs equilibrium reaction calculations for the gas region using the gas reaction portion GR1 that contributes to the equilibrium reaction with the first substance M1 present in the gas region of the second gas phase G2 and the first substance reaction portion MR1 that contributes to the equilibrium reaction with the gas reaction portion GR1 of the first substance reaction portion MR1, and calculates at least the composition, amount, etc. of the gas reactant GR1 and the first substance reactant MR1, and the change in the heat quantity and flow rate of each of the gas reactant GR1 and the first substance reactant MR1 when the gas reactant GR1 and the first substance reactant MR1 reach an equilibrium state.

The gas region equilibrium reaction calculation unit 208-1 has a function of performing equilibrium reaction calculations to determine the type, phase, flow rate, etc. of the product, which may be generated by the reaction between the gas reaction portion GR1 and the first substance reaction portion MR1, so that the free energy of the product is minimized, by setting in advance the type, phase, flow rate, etc. of the product. In other words, the gas region equilibrium reaction calculation unit 208-1 can perform equilibrium reaction calculations based on the Gibbs energy minimization method. The gas region equilibrium reaction calculation unit 208-1 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product, etc., when the gas reaction portion GR1 and the first substance reaction portion MR1 reach an equilibrium state.

The gas region equilibrium reaction calculation unit 208-1 calculates the product gas generated by the reaction between the gas reaction amount GR1 and the first substance reaction amount MR1, and the unused portion of the gas reaction amount GR1, as the gas product amount GP1. The gas region equilibrium reaction calculation unit 208-1 also calculates the product material generated by the reaction between the gas reaction amount GR1 and the first substance reaction amount MR1, and the unused portion of the first substance reaction amount MR1, as the first substance product amount MP1.

In other words, the gas product GP1 is a gas phase that is the sum of the gas phase that is generated by the reaction of the gas reaction GR1 with the first substance reaction MR1 and the unused portion of the gas reaction GR1. The first substance product MP1 is the sum of the product material that is generated by the reaction of the gas reaction GR1 with the first substance reaction MR1 and the unused portion of the first substance reaction MR1.

The bed layer equilibrium reaction calculation unit 208-2 calculates the equilibrium reaction between the modified second bed layer S2A moving through the bed layer in region A and the inflow gas present in the bed layer. That is, the bed layer equilibrium reaction calculation unit 208-2 performs equilibrium reaction calculations for the bed layer using the bed layer reaction portion SR1 that contributes to the equilibrium reaction with the inflow gas G11 in the modified second bed layer S2A and the inflow gas reaction portion GR1 that contributes to the equilibrium state with the modified second bed layer S2A in the inflow gas, and calculates at least the composition, amount, etc. of the bed layer reactant SR1 and the inflow gas reactant GR11, and the change in heat quantity and flow rate of each when the bed layer reactant SR1 and the inflow gas reactant GR11 reach an equilibrium state.

The bed layer equilibrium reaction calculation unit 208-2 has a function of performing equilibrium reaction calculations to determine the type, phase, flow rate, etc. of the product that may be generated by the reaction between the bed layer reaction portion SR1 and the inflow gas reaction portion GR11, so that the free energy of the product is minimized, by setting in advance the type, phase, flow rate, etc. of the product. That is, the bed layer equilibrium reaction calculation unit 208-2 can perform equilibrium reaction calculations based on the Gibbs energy minimization method, similar to the gas region equilibrium reaction calculation unit 208-1. The bed layer equilibrium reaction calculation unit 208-2 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product, etc., when the bed layer reaction portion SR1 and the inflow gas reaction portion GR11 reach an equilibrium state.

The bed layer equilibrium reaction calculation unit 208-2 calculates the product material produced by the reaction between the bed layer reaction portion SR1 and the inflow gas reaction portion GR11, and the unused portion of the bed layer reaction portion SR1, as the bed layer product portion SP1. The bed layer equilibrium reaction calculation unit 208-2 also calculates the product gas produced by the reaction between the bed layer reaction portion SR1 and the inflow gas reaction portion GR11, and the unused portion of the inflow gas reaction portion GR11, as the inflow gas product portion GP11.

In other words, the bed layer product SP1 is the sum of the product material generated by the reaction of the bed layer reaction SR1 with the inflow gas reaction GR11 and the unused portion of the bed layer reaction SR1. The inflow gas product GP11 is the sum of the product gas generated by the reaction of the bed layer reaction SR1 with the inflow gas reaction GR11 and the unused portion of the inflow gas reaction GR11.

The mixed gas phase calculation unit 209 has the function of mixing multiple flows, and calculates the flow rate, composition data, etc. of the third gas phase G3, which is a mixed gas phase obtained by mixing the unreacted gas portion Gr1 separated by the gas reaction amount calculation unit 204 and the gas product portion GP1 generated by the gas region equilibrium reaction calculation unit 208-1.

The first mixed substance calculation unit 210 has the function of mixing multiple flows, and calculates the flow rate, composition data, etc. of the first mixed substance M11, which is a mixture of the unreacted portion of the first substance Mr1 and the product portion of the first substance MP1 generated in the gas region equilibrium reaction calculation unit 208-1.

The mixed bed layer calculation unit 211 has the function of mixing multiple flows, and calculates the flow rate, composition data, etc. of the third bed layer S3, which is a mixed bed layer obtained by mixing the bed layer unreacted portion Sr1 separated by the bed layer reaction amount calculation unit 206 and the bed layer product portion SP1 generated by the bed layer equilibrium reaction calculation unit 208-2.

The mixed inflow gas calculation unit 212 has the function of mixing multiple flows, and calculates the flow rate and composition data of the mixed inflow gas G12, which is a mixture of the inflow gas unreacted portion Gr1 and the inflow gas product portion GP11 generated in the bed layer equilibrium reaction calculation unit 208-2.

The gas mixing unit 213 has the function of mixing multiple flows, and mixes the third gas phase G3 generated by the mixed gas phase calculation unit 209 with the mixed inflow gas G12 generated by the mixed inflow gas calculation unit 212.

The first mixed substance quantity correction unit 214 adds the movement amount of the second substance M2 generated in the bed layer quantity correction unit 203 to the first mixed substance M11 generated in the first mixed substance calculation unit 210 to correct the quantity of the first mixed substance M11 and calculate the first corrected mixed substance M12.

In this embodiment, the furnace reaction calculation device 20 does not need to include the distribution section 201 if the combustion material 230 is not dropped into the rotary kiln 1. In this case, the gas reaction portion GR1 is the reaction portion of the first gas phase G1 that contributes to the equilibrium reaction with the bed layer S1, and the bed layer reaction portion SR1 is the reaction portion of the bed layer S1 that contributes to the equilibrium state with the first gas phase G1.

In this embodiment, the reactor reaction calculation device 20 may calculate the heat conduction in the reactor using models such as radiation, conduction, and convection, as necessary.

<Calculation method for reactor reactions>
Next, a calculation method of a furnace reaction according to the present embodiment will be described using the calculation device of the furnace reaction according to the present embodiment. In the calculation method of the furnace reaction according to the present embodiment, in a rotary kiln 1 having a configuration as shown in Fig. 1, raw ore supplied from the charging end 14A side of the rotary kiln 1 is moved toward the discharge end 14B side, and a combustion material is charged from the middle of the movement, and the raw ore is brought into contact with combustion gas supplied from a burner 16 provided on the discharge end 14B side, thereby drying and reducing the raw ore.

Figure 3 is a flowchart explaining the method for calculating the furnace reaction according to this embodiment. As shown in Figure 3, the furnace reaction calculation device 20 checks whether the combustion material 230 has been dropped into the rotary kiln 1 (checking process: step S11).

If combustion material has been dropped into the rotary kiln 1 (step S11: Yes), the furnace reaction calculation device 20 provides materials such as volatile matter assumed to be in the gas phase and solid materials assumed to be in the bed layer as input materials. The furnace reaction calculation device 20 uses the distribution unit 201 to distribute the combustion material 230 added to the rotary kiln 1 at a mass flow rate between the added gas phase AG11, which is in the gas phase, and the added bed layer AS11, which is in the bed layer (distribution process: step S12).

Next, the furnace reaction calculation device 20 receives as input materials the first gas phase G1, which is the combustion gas flowing into region A from one adjacent region (region (A+1)), and the added gas phase AG11 of the combustion material 230 distributed by the distribution section 201. The furnace reaction calculation device 20 mixes the first gas phase G1 and the added gas phase AG11 to calculate the second gas phase G2 including the first gas phase G1 and the added gas phase AG11 (gas phase mixing process of the first gas phase and the added gas phase: step S13).

Next, the reactor reaction calculation device 20 uses the gas mixing amount calculation unit 202 to calculate the flow rate of the inflow gas G11 moving from the second gas phase G2, which includes the first gas phase G1 and the added gas phase AG11, to the bed layer (gas mixing amount calculation process: step S14).

Next, the reactor reaction calculation device 20 receives as input materials the bed layer S1 flowing into region A from the other adjacent region (region (A-1)) and the additive bed layer AS11, which is a bed layer of combustion material distributed by the distribution unit 201. The reactor reaction calculation device 20 mixes the bed layer S1 and the additive bed layer AS11 to calculate the second bed layer S2 (bed layer mixing process of the first bed layer and the additive bed layer: step S15).

Next, the reactor reaction calculation device 20 provides the second bed layer S2 and the amount of the second substance M2 contained in the second bed layer S2 moving into the gas region as input materials. The reactor reaction calculation device 20 corrects the amount of the second bed layer S2 by subtracting the amount of the second substance M2 contained in the second bed layer S2 moving into the gas region using the bed layer amount correction unit 203, and calculates the corrected second bed layer S2A (second bed layer amount correction process: step S16).

Next, the reactor reaction calculation device 20 performs a gas region equilibrium reaction (gas region equilibrium reaction execution process: step S17).

Next, the reactor reaction calculation device 20 performs a bed layer equilibrium reaction (bed layer equilibrium reaction implementation process: step S18).

Next, the reactor reaction calculation device 20 uses the gas mixing unit 213 to mix the third gas phase G3 generated in the gas region equilibrium reaction implementation process (step S17) with the mixed inflow gas G12 generated in the bed layer equilibrium reaction implementation process (step S18) to obtain a third combined gas phase G3' (gas mixing process: step S19).

The furnace reaction calculation device 20 moves the third combined gas phase G3' to a region (region (A-1)) closer to the charging end 14A than region A.

Next, the reactor reaction calculation device 20 uses the first mixed substance quantity correction unit 214 to add the movement amount of the second substance M2 generated in the second bed layer quantity correction process (step S16) to the first mixed substance M11 generated in the gas region equilibrium reaction implementation process (step S17), correcting the quantity of the first mixed substance M11 and calculating the first corrected mixed substance M12 (first mixed substance quantity correction process: step S20).

The furnace reaction calculation device 20 moves the first modified mixed material M12 to a region (region (A-1)) closer to the charging end 14A than region A.

Next, the gas region equilibrium reaction implementation process (step S17) will be described. FIG. 4 is a flowchart showing the operation of the gas region equilibrium reaction implementation process (step S17) of FIG. 3. As shown in FIG. 4, in the gas region equilibrium reaction implementation process (step S17), the reactor reaction calculation device 20 uses the gas reaction amount calculation unit 204 to calculate the gas reaction amount that contributes to the equilibrium state with the first substance reaction amount MR1 in the second gas phase G2 (gas reaction amount calculation process: step S171).

In other words, the furnace reaction calculation device 20 calculates the amount of gas reaction that contributes to the reaction when the second gas phase G2 reacts with the first substance M1 present in the gas region to reach an equilibrium state, assuming that the second gas phase G2 reacts with the first substance M1 present in the gas region to reach an equilibrium state.

Then, the reactor reaction calculation device 20 divides the gas reaction amount into a gas reaction amount GR1 corresponding to the gas reaction amount and an unreacted gas amount Gr1 corresponding to the remaining unreacted amount based on the gas reaction amount calculation result.

Next, the reactor reaction calculation device 20 uses the first substance reaction amount calculation unit 205 to calculate the amount of the first substance reaction that contributes to the equilibrium state with the second gas phase G2 from the first substance M1 present in the gas region (first substance reaction amount calculation process: step S172).

In other words, the reactor reaction calculation device 20 calculates the amount of reaction of the first substance that contributes to the reaction when the first substance M1 present in the gas region reacts with the second gas phase G2 to reach an equilibrium state, assuming that the first substance M1 present in the gas region reacts with the second gas phase G2 to reach an equilibrium state.

Then, based on the calculation result of the first substance reaction amount, the reactor reaction calculation device 20 divides it into a first substance reaction amount MR1 corresponding to the first substance reaction amount and an unreacted amount of the first substance Mr1 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 provides the gas reaction amount GR1 obtained in the gas reaction amount calculation process (step S171) and the first substance reaction amount MR1 obtained in the first substance reaction amount calculation process (step S172) as input materials. The reactor reaction calculation device 20 uses the gas region equilibrium reaction calculation unit 208-1 to calculate the equilibrium reaction between the gas reaction amount GR1 and the first substance reaction amount MR1, and calculates at least the change in heat quantity and flow rate of each of the gas reaction amount GR1 and the first substance reaction amount MR1 when they reach equilibrium (step S173).

For example, the Gibbs energy minimization method can be used to calculate equilibrium reactions.

The furnace reaction calculation device 20 calculates the product gas produced by the reaction between the gas reaction portion GR1 and the first substance reaction portion MR1 and the unused portion of the gas reaction portion GR1 as the gas product portion GP1, and calculates the product material produced by the reaction between the gas reaction portion GR1 and the first substance reaction portion MR1 and the unused portion of the first substance reaction portion MR1 as the first substance product portion MP1.

Next, the reactor reaction calculation device 20 provides the unreacted gas Gr1 obtained in the gas reaction amount calculation process (step S171) and the gas generated GP1 obtained in the gas region equilibrium reaction calculation process (step S17) as input materials. The reactor reaction calculation device 20 uses the mixed gas phase calculation unit 209 to calculate the flow rate, composition data, etc. of the third gas phase G3 containing the unreacted gas Gr1 and the gas generated GP1 (mixed gas phase calculation process: step S174).

The gas reaction amount GR1 calculated in the gas reaction amount calculation process (step S171) is the reaction amount when it is assumed that the second gas phase G2 and the first substance M1 have reached equilibrium, and therefore is normally all used. However, the gas reaction amount GR1, which is the gas phase, may contain substances that exist in amounts greater than the stoichiometric ratio of the reaction or inactive substances that do not contribute to the reaction. Examples of inactive substances include nitrogen. In the mixed gas phase calculation process (step S174), there are substances that exist in amounts greater than the stoichiometric ratio of the reaction and, as a result, remain after the equilibrium reaction or inactive substances. The unused portion that remains unused in the gas region equilibrium reaction calculation unit 208-1 is calculated as the gas production amount GP1.

Next, the reactor reaction calculation device 20 provides the first substance unreacted portion Mr1 obtained in the first substance reaction amount calculation process (step S172) and the first substance product portion MP1 obtained in the gas region equilibrium reaction calculation process (step S173) as input materials. The reactor reaction calculation device 20 uses the first mixed substance calculation unit 210 to calculate the flow rate, composition data, etc. of the first mixed substance M11 obtained by mixing the first substance unreacted portion Mr1 and the first substance product portion MP1 (first mixed substance calculation process: step S175).

Next, the second equilibrium reaction implementation step (step S18) will be described. FIG. 5 is a flowchart showing the operation of the second equilibrium reaction implementation step (step S18) in FIG. 3. As shown in FIG. 5, in the second equilibrium reaction implementation step (step S18), the reactor reaction calculation device 20 uses the bed layer reaction amount calculation unit 206 to calculate the bed layer reaction amount that contributes to the equilibrium state with the inflow gas reaction amount GR11 in the modified second bed layer S2A (bed layer reaction amount calculation step: step S181).

The inflow gas reaction portion GR11 is the reaction portion of the inflow gas that moves from the gas region to the bed layer and contributes to the equilibrium state with the modified second bed layer S2A.

In other words, the reactor reaction calculation device 20 calculates the amount of bed layer reaction that contributes to the reaction when the modified second bed layer S2A reacts with the inflow gas to reach an equilibrium state, assuming that the modified second bed layer S2A reacts with the inflow gas to reach an equilibrium state.

Then, based on the calculation result of the bed layer reaction amount, the reactor reaction calculation device 20 divides it into a bed layer reaction amount SR1 corresponding to the bed layer reaction amount and a bed layer unreacted amount Sr1 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 uses the inflow gas reaction amount calculation unit 207 to calculate the inflow gas reaction amount that contributes to the equilibrium state with the modified second bed layer S2A (bed layer reaction amount calculation process: step S18).

In other words, the reactor reaction calculation device 20 calculates the amount of inflow gas reaction that contributes to the reaction when the inflow gas, which is a gas component present in the gas region, reacts with the modified second bed layer S2A to reach an equilibrium state, assuming that the inflow gas reacts with the modified second bed layer S2A to reach an equilibrium state.

Then, based on the result of the calculation of the inflow gas reaction amount, the reactor reaction calculation device 20 divides the inflow gas reaction amount GR11, which corresponds to the inflow gas reaction amount, and the inflow gas unreacted amount Gr11, which corresponds to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 provides the bed layer reaction amount SR1 obtained in the bed layer reaction amount calculation step (step S18) and the inflow gas reaction amount GR11 obtained in the inflow gas reaction amount calculation step (step S182) as input materials. The reactor reaction calculation device 20 uses the bed layer equilibrium reaction calculation unit 208-2 to calculate the equilibrium reaction between the bed layer reaction amount SR1 and the inflow gas reaction amount GR11, and calculates at least the change in heat quantity and flow rate of each of the bed layer reaction amount SR1 and the inflow gas reaction amount GR11 when they reach equilibrium (step S183).

The furnace reaction calculation device 20 calculates the product material produced by the reaction between the bed layer reaction portion SR1 and the inflow gas reaction portion GR11 and the unused portion of the bed layer reaction portion SR1 as the bed layer product portion SP1, and calculates the product gas produced by the reaction between the bed layer reaction portion SR1 and the inflow gas reaction portion GR11 and the unused portion of the inflow gas reaction portion GR11 as the inflow gas product portion GP11.

Next, the reactor reaction calculation device 20 receives as input materials the bed layer unreacted portion Sr1 obtained in the bed layer reaction amount calculation step (step S181) and the bed layer product portion SP1 obtained in the bed layer equilibrium reaction calculation step (step S183). The reactor reaction calculation device 20 uses the mixed bed layer calculation unit 211 to calculate the flow rate, composition data, etc. of the third bed layer S3 containing the bed layer unreacted portion Sr1 and the bed layer product portion SP1 (mixed bed layer calculation step: step S184).

The bed layer reaction portion SR1, which is the bed layer calculated in the bed layer reaction amount calculation process (step S181), may contain substances that exist in amounts greater than the stoichiometric ratio of the reaction and inactive substances that do not contribute to the reaction. In the mixed bed layer calculation process (step S184), the bed layer reaction portion SR1 contains a portion that exists in amounts greater than the stoichiometric ratio of the reaction and is not used in the reaction as a result, and an inactive portion. The unused portion that remains unused in the bed layer equilibrium reaction calculation process (step S183) is calculated as the bed layer product portion SP1.

The reactor reaction calculation device 20 moves the third bed layer S3 to a region (region (A+1)) closer to the discharge end 14B than region A.

Next, the reactor reaction calculation device 20 provides the inflow gas unreacted portion Gr11 obtained in the inflow gas reaction amount calculation step (step S182) and the inflow gas product portion GP11 obtained in the bed layer equilibrium reaction calculation step (step S183) as input materials. The reactor reaction calculation device 20 uses the mixed inflow gas calculation unit 212 to calculate the flow rate, composition data, etc. of the mixed inflow gas G12 containing the inflow gas unreacted portion Gr11 and the inflow gas product portion GP11 (mixed inflow gas calculation step: step S185).

In addition, in the method for calculating the furnace reactions according to this embodiment, the calculation process for the gas region equilibrium reaction (step S17) and the calculation process for the bed layer equilibrium reaction (step S18) may be performed in parallel.

In the method for calculating the furnace reaction according to this embodiment, the gas summing process (step S19) and the first mixed substance amount correction process (step S20) may be performed in parallel, or the gas summing process (step S19) may be performed after the first mixed substance amount correction process (step S20).

In the method for calculating the furnace reaction according to this embodiment, the gas reaction amount calculation step (step S171) and the first substance reaction amount calculation step (step S172) may be performed in parallel, or the gas reaction amount calculation step (step S171) may be performed after the first substance reaction amount calculation step (step S172).

In the method for calculating the reaction in the furnace according to this embodiment, the first mixing calculation step (step S174) and the mixing step (step S17) of the unreacted portion of the first substance Mr1 and the product of the first substance MP1 may be performed in parallel, or the first mixing calculation step (step S174) may be performed after the mixing step (step S175) of the unreacted portion of the first substance Mr1 and the product of the first substance MP1.

In the method for calculating the reactor reaction according to this embodiment, the bed layer reaction amount calculation step (step S181) and the bed layer reaction amount calculation step (step S182) may be performed in parallel, or the bed layer reaction amount calculation step (step S181) may be performed after the bed layer reaction amount calculation step (step S182).

In the method for calculating the furnace reaction according to this embodiment, the mixed bed layer calculation process (step S184) and the mixing process (step S18) of the bed layer unreacted portion Sr1 and the inflow gas generation portion GP11 may be performed in parallel, or the mixed bed layer calculation process (step S184) may be performed after the mixing process (step S185) of the bed layer unreacted portion Sr1 and the inflow gas generation portion GP11.

The method for calculating the furnace reaction according to this embodiment may calculate the heat conduction inside the furnace using models such as radiation, conduction, and convection, if necessary.

<Hardware configuration of reactor reaction calculation device>
Next, an example of the hardware configuration of the reactor reaction calculation device will be described. FIG. 4 is a hardware configuration diagram of the reactor reaction calculation device. As shown in FIG. 4, the reactor reaction calculation device 20 is, for example, configured as an information processing device (computer), and can be physically configured as a computer system including a CPU (Central Processing Unit: processor) 21, which is an arithmetic processing unit, a RAM (Random Access Memory) 22 and a ROM (Read Only Memory) 23, which are main storage devices, an auxiliary storage device 24, an input/output interface 25, and a display device 26, which is an output device. These are connected to each other by a bus 27. The auxiliary storage device 24 and the display device 26 may be provided externally.

The CPU 21 controls the overall operation of the furnace reaction calculation device 20 and performs various information processing. The CPU 21 executes the raw material ore reaction calculation program stored in the ROM 23 or auxiliary storage device 24, and controls the display operation of the measurement recording screen and the analysis screen.

RAM 22 is used as a work area for CPU 21 and may include non-volatile RAM for storing main control parameters and information.

The ROM 23 stores basic input/output programs, etc. The raw ore reaction calculation program may be stored in the ROM 23.

The auxiliary storage device 24 is a storage device such as an SSD (Solid State Drive) or an HDD (Hard Disk Drive), and stores, for example, a raw ore reaction calculation program and various data, files, etc. required for the operation of the furnace reaction calculation device 20.

The input/output interface 25 includes both a user interface such as a touch panel, keyboard, display screen, and operation buttons, and a communication interface that imports information from an external data recording server, etc., and outputs analysis information to other electronic devices.

The display device 26 is a monitor display or the like. The display device 26 displays a measurement recording screen and an analysis screen, and the screen is updated in response to input/output operations via the input/output interface 25.

The functions of the reactor reaction calculation device 20 shown in FIG. 4 are realized by loading simulation software (including a reactor reaction calculation program) into a main memory device such as a RAM 22 or a ROM 23 or an auxiliary memory device 24, and executing a raw ore reaction calculation program stored in the RAM 22, ROM 23 or auxiliary memory device 24 by the CPU 21, thereby reading and writing data in the RAM 22, etc., and operating the input/output interface 25 and the display device 26.

The calculation program for the reactor reaction can be a program having the following configuration.
That is, the calculation program for the reaction in the furnace is a program that causes at least a computer to execute a calculation of a reaction in the furnace in which raw material ore supplied from one end of a reactor is brought into contact with a combustion gas supplied from the other end while moving the raw material ore toward the other end, thereby drying and reducing the raw material ore,
A gas mixing amount calculation step of calculating a flow rate of an inflow gas moving from a gas region containing the combustion gas in the reactor to a bed layer containing the raw material ore, among a first gas phase containing the combustion gas flowing through a gas region in the reactor;
a gas region equilibrium reaction calculation step of calculating an equilibrium reaction between a gas phase including the combustion gas flowing through the gas region and a first substance including at least one of a solid substance and a liquid substance present in the gas region;
A bed layer material quantity correction step of correcting the material quantity of the bed layer by subtracting the amount of a second material, including at least one of a solid material and a liquid material, contained in the bed layer including the raw ore moving through the bed layer from the amount of the second material, including at least one of a solid material and a liquid material, moving to the gas region, to calculate a corrected bed layer;
A program can be used that causes a computer to execute at least a bed layer equilibrium reaction calculation step for calculating the equilibrium reaction between the modified bed layer and the inflow gas.

The calculation program for the reaction in the furnace is stored in a storage device provided in the computer, such as the main storage device of the RAM 22 or ROM 23, or the auxiliary storage device 24. The raw ore reaction calculation program may be configured so that a part or all of it is transmitted via a transmission medium such as a communication line, and is received and recorded (including installed) by a communication module or the like provided in the computer. The raw ore reaction calculation program may be configured so that a part or all of it is recorded (including installed) in the computer from a state where it is stored in a portable storage medium such as a CD-ROM, DVD-ROM, or flash memory.

As described above, the reactor reaction calculation device 20 according to this embodiment includes a gas mixture amount calculation unit 202, a gas region equilibrium reaction calculation unit 208-1, and a bed layer equilibrium reaction calculation unit 208-2. In the gas mixture amount calculation unit 202, the reactor reaction calculation device 20 calculates the flow rate of the inflow gas that moves from the gas region to the bed layer in the second gas phase G2. In the gas region equilibrium reaction calculation unit 208-1, the reactor reaction calculation device 20 calculates the equilibrium reaction using the gas reaction amount GR1 and the first substance reaction amount MR1 obtained in the gas reaction amount calculation unit 204 and the first substance reaction amount calculation unit 205. This allows the reactor reaction calculation device 20 to calculate the equilibrium reaction between the second gas phase G2 and the first substance M1. In addition, the reactor reaction calculation device 20 calculates the equilibrium reaction in the bed layer equilibrium reaction calculation unit 208-2 using the bed layer reaction amount SR1 and the inflow gas reaction amount GR11 obtained in the bed layer reaction amount calculation unit 206 and the inflow gas reaction amount calculation unit 207. This allows the reactor reaction calculation device 20 to calculate the equilibrium reaction between the second modified solid phase S2' and the inflow gas G11 that has partially moved from the gas region to the bed layer.

The first material M1 in the gas region contains the second material M2 that has moved from the bed layer to the gas region in the adjacent region (A+1). The inflow gas G11 of the bed layer is gas that has mixed into the bed layer from the gas region. Therefore, the calculation device 20 of the reaction in the furnace can calculate the equilibrium reaction in each of the gas region and the bed layer based on the Gibbs energy minimization method, taking into account the mass transfer of the second material M2 moving in the bed layer to the gas region and the mixing of the gas flowing in the gas region into the bed layer. Therefore, the calculation device 20 of the reaction in the furnace can calculate the reaction in the gas region of the dust generated in the bed layer. Therefore, the calculation device 20 of the reaction in the furnace can calculate the reaction in the rotary kiln 1 with high accuracy, taking into account the reaction in the gas region of the dust generated from the bed layer in the rotary kiln 1.

The reactor reaction calculation device 20 can therefore take into account the effects of changes in gas composition and temperature on bed layer reactions, improving the accuracy of predictions of reactor reactions.

Because the dust contains about the same amount of nickel as the ore, it is collected in exhaust gas treatment equipment and repeatedly charged into the rotary kiln. The dust contains unburned ore, re-scattered dust from repeated use, as well as ash from coal fed into the kiln and unburned carbon. In the gas region, this dust rides the gas flow and moves through the kiln in a short time, and the residence time of dust in the gas region is very short compared to when it moves through the bed layer, but it is thought that some of the dust in the gas region undergoes thermal decomposition and reacts with the surrounding gas.

For example, unburned carbon contained in the dust may be gasified by the surrounding _CO2 or _H2O gas, resulting in reactions such as those shown in the following formulas (1) and (2). In addition, in areas where oxygen supplied from the burner remains, combustion reactions such as those shown in the following formulas (3) and (4) are thought to occur. These reactions cause changes in the gas composition and temperature in the gas region, which also affect the reactions in the bed layer, and it is important to have a detailed understanding of the reaction behavior of the dust scattered in the gas region.
C+CO ₂ →2CO...(1)
C+ _H2O →CO+ _H2 ...(2)
C+0.5O ₂ →CO...(3)
C+O ₂ →CO ₂ ...(4)

When simulating reactions inside the rotary kiln 1, if the dust generated from this bed layer is treated in the same way as gas in other gas regions, it is difficult to grasp the details. The furnace reaction calculation device 20 according to this embodiment can calculate reactions with high accuracy while taking into account the reactions in the gas region of the dust generated from the bed layer.

The reactor reaction calculation device 20 can include a gas reaction amount calculation unit 204 and a first substance reaction amount calculation unit 205. As a result, the reactor reaction calculation device 20 can determine the gas reaction amount GR1 that contributes to the equilibrium reaction from the second gas phase G2 in the gas reaction amount calculation unit 204, and can determine the first substance reaction amount MR1 that contributes to the equilibrium reaction from the first substance M1 in the first substance reaction amount calculation unit 205. Therefore, the reactor reaction calculation device 20 can determine the reaction amount of the second gas phase G2 and the first substance M1 to be used in the gas region equilibrium reaction calculation unit 208-1, and can reliably perform equilibrium reaction calculation in the gas region using the necessary reaction amount.

The furnace reaction calculation device 20 can include a mixed gas phase calculation unit 209 and a first mixed substance calculation unit 210. The mixed gas phase calculation unit 209 can at least calculate the flow rate of the third gas phase G3 obtained by mixing the unreacted gas portion Gr1 and the gas product portion GP1 generated in the gas region equilibrium reaction calculation unit 208-1. The first mixed substance calculation unit 210 can at least calculate the flow rate of the first substance M1 obtained by mixing the unreacted first substance portion Mr1 and the first substance product portion MP1 generated in the gas region equilibrium reaction calculation unit 208-1. Therefore, the furnace reaction calculation device 20 can more accurately calculate the amount of movement of the first gas phase G and the first substance M1 to the charging end 14A.

The furnace reaction calculation device 20 can include a first mixed material amount correction unit 214. This allows the furnace reaction calculation device 20 to include the second material M2 that moves from the bed layer in the first mixed material M11 that exists in the gas region. The second material M2 mainly includes dust generated from the bed layer. Therefore, the furnace reaction calculation device 20 can more accurately calculate the amount of dust generated from the bed layer that moves to the charging end 14A.

The reactor reaction calculation device 20 can include a bed layer reaction amount calculation unit 206 and an inflow gas reaction amount calculation unit 207. As a result, the reactor reaction calculation device 20 can calculate the bed layer reaction amount SR1 that contributes to the equilibrium reaction from the second bed layer S2 in the bed layer reaction amount calculation unit 206, and can calculate the inflow gas reaction amount GR11 that contributes to the equilibrium reaction from the first material M1 in the inflow gas reaction amount calculation unit 207. Therefore, the reactor reaction calculation device 20 can calculate the reaction amount of the second bed layer S2 and the first material M1 to be used in the bed layer equilibrium reaction calculation unit 208-2, and can reliably perform equilibrium reaction calculation in the bed layer using the necessary reaction amount.

The reactor reaction calculation device 20 can include a mixed bed layer calculation unit 211 and a mixed inflow gas calculation unit 212. The mixed bed layer calculation unit 211 can at least calculate the flow rate of the third bed layer S3, which is a mixture of the bed layer unreacted portion Sr1 and the bed layer product SP1 generated by the bed layer equilibrium reaction calculation unit 208-2. The mixed inflow gas calculation unit 212 can at least calculate the flow rate of the inflow gas present in the bed layer, which is a mixture of the inflow gas unreacted portion Gr11 and the inflow gas product GP11 generated by the bed layer equilibrium reaction calculation unit 208-2. Therefore, the reactor reaction calculation device 20 can more accurately calculate the amount of movement of the third bed layer S3 to the discharge end 14B and can determine the flow rate of the inflow gas G11 remaining in the bed layer.

The furnace reaction calculation device 20 can be equipped with a gas mixing unit 213. This allows the furnace reaction calculation device 20 to mix the mixed inflow gas G12 generated in the bed layer into the third gas phase G3, so that the gas components present in the bed layer can also be included in the third gas phase G3. Therefore, the furnace reaction calculation device 20 can reliably move the gas components present in region A to region (A-1).

The furnace reaction calculation device 20 includes a distribution section 201, which can distribute the gas phase and bed layer contained in the combustion material 230 introduced during the movement of the raw ore to the added gas phase AG11 and the added bed layer AS11 at a mass flow rate. The furnace reaction calculation device 20 distributes the combustion material 230 introduced from the middle of the rotary kiln 1 to the first gas phase G1 and the first bed layer S1, and treats them as separate fuels, and the added gas phase AG11 can be a component that constitutes the second gas phase, and the added bed layer AS11 can be a component that constitutes the second bed layer. As a result, the furnace reaction calculation device 20 calculates the gas reaction amount GR1 from the second gas phase G2 and the bed layer reaction amount SR1 from the second bed layer S2, and in the bed layer equilibrium reaction calculation section 208-2, the equilibrium reaction can be calculated based on the reaction amount required for the equilibrium reaction from the second gas phase G2 and the second bed layer S2. Therefore, the furnace reaction calculation device 20 can analyze the behavior of materials in the rotary kiln 1 while taking into account the combustion material 230 that is added halfway through the rotary kiln 1, so it is possible to perform highly accurate calculations of the furnace reaction even when the combustion material 230 is used.

In this way, the furnace reaction calculation device 20 can calculate the equilibrium reactions occurring in the furnace with high accuracy, taking into account the reactions in the gas region of the dust generated from the bed layer in the rotary kiln 1. Therefore, by applying the furnace reaction calculation device 20 to the entire region in the rotary kiln 1, it is possible to calculate the entire reaction process in the rotary kiln 1 with high accuracy.

The case where the furnace reaction calculation device 20 is applied to the entire rotary kiln 1 will be described. For example, as shown in FIG. 7, when the rotary kiln 1 is divided into multiple regions and the reaction process in one region A is assumed to be a unit operation model, the furnace reaction calculation device 20 can model the reaction process in the rotary kiln 1 by combining unit operation models. The furnace reaction calculation device 20 then repeatedly performs calculations in multiple regions in the rotary kiln 1 along the flow of raw ore or the flow of combustion gas (including the assumed flow) (see the arrows in FIG. 7). The furnace reaction calculation device 20 then repeatedly performs calculations until the difference between the calculated value in a specified region and the previous calculated value in that region falls within a specified range.

Figure 8 shows a flowchart of the application of the furnace reaction calculation device 20 to the entire rotary kiln 1. As shown in Figure 8, the furnace reaction calculation device 20 models the reaction process occurring in the rotary kiln 1 by combining multiple unit operation models (modeling process: step S21).

The reactor reaction calculation device 20 shown in FIG. 2 is applied to the unit operation model. For each unit operation model, the gas mixture amount calculation unit 202, bed layer mass correction unit 203, gas region equilibrium reaction calculation unit 208-1, bed layer equilibrium reaction calculation unit 208-2, etc., which constitute the unit operation model, are prepared in advance.

Each unit operation model is interconnected along the flow of raw ore and combustion gas (including assumed flows).

Next, the reactor reaction calculation device 20 performs calculations on the unit operation model modeled in step S21 (calculation process: step S22). Flow information is input to the unit operation model.

The flow information is data such as the components, flow rate, temperature, and rotation speed of the raw ore, combustion gas, and combustion material. When the flow information is input, the unit operation model performs a predetermined calculation and outputs the calculated values (components, flow rate, temperature, etc. of the raw ore, combustion gas, and combustion material). From these calculation results, values used for each component of the calculation device 20 for the furnace reaction shown in FIG. 2 are calculated. The values used for each model of the calculation device 20 for the furnace reaction are the flow rates of various gas phases in region A such as the first gas phase G1, the flow rates of various bed layers in region A such as the first bed layer S1, the flow rates of various substances such as the flow rate of the first substance M1, the flow rates of various reacted, unreacted, and generated components in region A such as the gas reacted portion GR1, the gas unreacted portion Gr1, and the gas generated portion GP1, etc.

In this embodiment, calculations of the unit operation model are performed starting from the unit operation model located closest to the loading end 14A.

Next, the reactor reaction calculation device 20 determines whether calculations have been completed up to the final unit operation model (step S23).

If calculations have been performed up to the final unit operation model (step 23: Yes), the reactor reaction calculation device 20 determines whether or not there is a previous calculation value for the unit operation model (step S24).

If a previous calculation value is available (step S24: Yes), the reactor reaction calculation device 20 compares the calculation value calculated in the calculation process (step S22) with the previous calculation value (step S25).

Next, the reactor reaction calculation device 20 determines whether the difference between the calculated value and the previous calculated value satisfies the convergence condition (comparison process: step S26).

The convergence condition is, for example, that the difference between the calculated value and the previous calculated value is within a range of a few degrees Celsius (e.g., 1 degree Celsius).

If the difference between the calculated value and the previous calculated value satisfies the convergence condition (step S26: Yes), the furnace reaction calculation device 20 ends the calculation. This allows the reaction process occurring throughout the entire kiln body 11 of the rotary kiln 1 to be analyzed.

On the other hand, in step S23, if the final unit operation model has not been calculated (step S23: No), the reactor reaction calculation device 20 moves to another adjacent unit operation model, that is, a unit operation model located in region (A+1) or region (A-1) (step S27). Then, the reactor reaction calculation device 20 performs calculations for the unit operation model located in region (A+1) or region (A-1) (step S22).

If there is no previous calculation value in step S24 (step S24: No), or if the difference between the calculation value and the previous calculation value in step S26 does not satisfy the convergence condition (step S26: No), the reactor reaction calculation device 20 moves to the first unit operation model (step S28).

Therefore, the furnace reaction calculation device 20 models the reaction process occurring in the rotary kiln 1 by combining multiple unit operation models, and performs calculations based on the values set for each unit operation model in accordance with the connection order of the unit operation models. In this embodiment, calculations for each unit operation model are performed in sequence from the charging end 14A side to the discharge end 14B side of the rotary kiln 1, and then from the discharge end 14B side to the charging end 14A side (see Figure 5). Then, a series of operations is repeated until the calculated value in a predetermined area A satisfies a predetermined convergence condition. As a result, calculation results such as the flow rate of the combustion gas and raw ore in each area in the rotary kiln 1 are derived. This makes it possible to more accurately analyze the behavior of each substance that constitutes the combustion gas and raw ore throughout the kiln body 11 of the rotary kiln 1.

In this way, the furnace reaction calculation device 20 can analyze the reactions in the reactor with high precision by taking into account the reactions in the gas region of the dust generated from the bed layer in the reactor as the entire reaction process in the rotary kiln 1. Therefore, the behavior of each substance in the rotary kiln 1 can be analyzed more accurately while changing the operating conditions of the rotary kiln 1 (e.g., the size and rotation speed of the rotary kiln 1, the type of raw ore, the supply amount, etc.). Therefore, the furnace reaction calculation device 20 can be effectively used for changing the type and supply amount of raw ore, pre-examination of equipment improvements to the rotary kiln 1, and investigation of the effects of operating conditions, etc.

In this embodiment, the raw material supplied to the rotary kiln 1 may be a raw material other than raw ore.

In this embodiment, the combustion material dropped into the rotary kiln 1 shown in FIG. 1 from the middle does not necessarily have to contain both the gas phase and the bed layer, and may contain other substances such as ash in addition to the gas phase and the bed layer.

In this embodiment, in addition to the rotary kiln 1 shown in FIG. 1, any reactor that heats raw ore while moving it from the charging end 14A to the discharge end 14B may be used.

Although the embodiments have been described above, they are presented as examples, and the present invention is not limited to the above embodiments. The above embodiments can be implemented in various other forms, and various combinations, omissions, substitutions, modifications, etc. can be made without departing from the gist of the invention. These embodiments and their variations are included in the scope and gist of the invention, and are included in the scope of the invention and its equivalents described in the claims.

Reference Signs List 1 Rotary kiln 11 Kiln body 16 Burner 20 Furnace reaction calculation device 201 Combustion material distribution section (distribution section)
202 Gas mixture amount calculation unit 203 Bed layer amount correction unit 204 Gas reaction amount calculation unit 205 First substance reaction amount calculation unit 206 Bed layer reaction amount calculation unit 207 Inflow gas reaction amount calculation unit 208-1 Gas region equilibrium reaction calculation unit 208-2 Bed layer equilibrium reaction calculation unit 209 Mixed gas phase calculation unit 210 First mixed substance calculation unit 2 Mixed bed layer calculation unit 212 Mixed inflow gas calculation unit 213 Gas summation unit 214 First mixed substance amount correction unit G1 First gas phase G2 Second gas phase G3 Third gas phase G3' Third mixed gas phase G11 Inflow gas G12 Mixed inflow gas S1 First bed layer S2 Second bed layer S2A Second corrected bed layer S3 Third bed layer M1 First substance M2 Second substance M11 First mixed substance GR1: reacted gas Gr1: unreacted gas GP1: produced gas MR1: reacted first substance Mr1: unreacted first substance MP1: produced first substance GR11: reacted inflow gas Gr11: unreacted inflow gas GP11: produced inflow gas SR1: reacted bed layer Sr1: unreacted bed layer SP1: produced bed layer

Claims (7)

A calculation device for a reaction in a reactor, the device comprising: a raw material ore supplied from one end of a reactor, the raw material ore being moved through the reactor toward the other end, the raw material ore being brought into countercurrent contact with a combustion gas supplied from the other end, and the raw material ore being dried and reduced, the calculation device comprising:
a gas mixing amount calculation unit that calculates a flow rate of an inflow gas moving from the gas region containing the combustion gas in the reactor to a bed layer containing the raw material ore, among the gas phase containing the combustion gas flowing through the gas region in the reactor;
a bed layer material amount correction unit for correcting the flow rate of the first bed layer by subtracting the amount of a second substance, which is included in the first bed layer and includes the raw ore moving through the bed layer, from the amount of the second substance, which is included in the first bed layer and includes at least one of a solid substance and a liquid substance, moving to the gas region, to calculate a corrected first bed layer;
a gas reaction amount calculation unit that calculates a gas reaction amount that contributes to an equilibrium state of the gas phase with a first substance including at least one of a solid substance and a liquid substance present in the gas region, and obtains a gas reaction amount that contributes to an equilibrium reaction of the gas phase;
A first substance reaction amount calculation unit that calculates a first substance reaction amount that contributes to an equilibrium state of the first substance with the gas phase to obtain a first substance reaction amount that contributes to the equilibrium reaction of the first substance;
a bed layer reaction amount calculation unit for calculating a bed layer reaction amount contributing to an equilibrium state of the modified first bed layer with the inflow gas, and determining a bed layer reaction amount contributing to the equilibrium reaction of the modified first bed layer;
an inflow gas reaction amount calculation unit for calculating an inflow gas reaction amount contributing to an equilibrium state of the inflow gas with the modified first bed layer, and determining an inflow gas reaction amount contributing to the equilibrium reaction of the inflow gas;
a gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between the gas reaction component and the first substance reaction component , and calculates at least a change in heat quantity and a flow rate of each of the gas reaction component and the first substance reaction component when the gas reaction component and the first substance reaction component reach an equilibrium state ;
a bed layer equilibrium reaction calculation unit that calculates an equilibrium reaction between the modified first bed layer and the inflow gas, and calculates at least the change in heat quantity and the flow rate of each of the bed layer reactant and the inflow gas reactant when they reach an equilibrium state ;
Equipped with
The reactor reaction calculation device is applied to each of the unit operation models when the reactor is divided into a plurality of regions and the reaction process in one region is assumed to be a unit operation model, and models the reaction process in the reactor by combining the unit operation models. The calculation of the unit operation models in the plurality of regions in the reactor is repeatedly performed along the flow of the raw ore or the flow of the combustion gas, and the calculation is repeated until the difference between the calculated value, which is the temperature of the gas phase and the bed layer in a specified region, and the previous calculated value in that region satisfies a specified convergence condition . a mixed gas phase calculation unit that calculates at least a flow rate of a mixed gas phase obtained by mixing an unreacted gas amount generated in the gas reaction amount calculation unit and a gas product generated by the reaction of the gas reaction amount and the first substance reaction amount in the gas region equilibrium reaction calculation unit;
a first mixed substance calculation unit that calculates at least a flow rate of a first mixed substance obtained by mixing an unreacted portion of the first substance generated in the first substance reaction amount calculation unit and a first substance product generated by the reaction of the gas reaction portion and the first substance reaction portion in the gas region equilibrium reaction calculation unit;
The apparatus for calculating a reaction in a reactor according to claim 1 . 3. The reactor reaction calculation device according to claim 2, further comprising a first mixed substance quantity correction unit that corrects the flow rate of the first mixed substance by adding the movement amount of the second substance generated in the bed layer quantity correction unit to the first mixed substance generated in the first mixed substance calculation unit, thereby calculating a first corrected mixed substance. a mixed bed layer calculation unit that calculates at least a flow rate of a mixed bed layer obtained by mixing a bed layer unreacted portion generated in the bed layer reaction amount calculation unit and a bed layer product generated by the reaction of the bed layer reacted portion and the inflow gas reacted portion in the bed layer equilibrium reaction calculation unit;
a mixed inflow gas calculation unit that calculates at least a flow rate of a mixed inflow gas obtained by mixing an inflow gas unreacted portion generated in the inflow gas reaction amount calculation unit and an inflow gas product generated by the reaction of the bed layer reaction portion and the inflow gas reaction portion in the bed layer equilibrium reaction calculation unit;
The apparatus for calculating a reaction in a reactor according to claim 1 . 5. The apparatus for calculating reactions in a furnace as described in claim 4, further comprising a gas mixing unit that mixes the mixed inflow gas generated in the mixed inflow gas calculation unit with a gas phase generated in the gas region equilibrium reaction calculation unit by an equilibrium reaction between the gas phase from which the inflow gas has been removed and the first substance present in the gas region, as the gas product generated in the gas region equilibrium reaction calculation unit. A distribution unit is provided for distributing the combustion material, which is introduced during the movement of the raw material ore and includes at least one of the gas phase and the bed layer , to the additional gas phase and the additional bed layer at a mass flow rate, with the gas phase being an additional gas phase and the bed layer being an additional bed layer ;
the gas mixture amount calculation unit calculates a flow rate of the inflow gas using a second gas phase including the gas phase and the added gas phase;
6. The apparatus for calculating a reaction in a furnace according to claim 1 , wherein the bed layer material amount correction unit corrects a flow rate of a second bed layer including the first bed layer and the additive bed layer. A method for calculating a reaction in a reactor, the method comprising: moving a raw material ore supplied from one end of a reactor toward the other end of the reactor in the reactor; bringing the raw material ore into countercurrent contact with a combustion gas supplied from the other end of the reactor, thereby drying and reducing the raw material ore, the method comprising the steps of:
a gas mixing amount calculation step of calculating a flow rate of an inflow gas moving from the gas region containing the combustion gas in the reactor to a bed layer containing the raw material ore, among the gas phase containing the combustion gas flowing through the gas region in the reactor;
a bed layer material amount correction step of correcting the flow rate of the first bed layer by subtracting the amount of a second substance, which is contained in the first bed layer and contains the raw ore moving through the bed layer, from the amount of the second substance, which is contained in the first bed layer and contains at least one of a solid substance and a liquid substance, moving to the gas region, to calculate a corrected first bed layer;
a gas reaction amount calculation step of calculating an amount of gas reaction that contributes to an equilibrium state of the gas phase with a first substance including at least one of a solid substance and a liquid substance present in the gas region, to obtain a gas reaction amount that contributes to an equilibrium reaction of the gas phase;
A first substance reaction amount calculation step of calculating a first substance reaction amount contributing to an equilibrium state of the first substance with the gas phase to obtain a first substance reaction amount contributing to the equilibrium reaction of the first substance;
a bed layer reaction amount calculation step of calculating a bed layer reaction amount contributing to an equilibrium state of the modified first bed layer with the inflow gas, and determining a bed layer reaction amount contributing to the equilibrium reaction of the modified first bed layer;
an inflow gas reaction amount calculation step of calculating an inflow gas reaction amount contributing to an equilibrium state of the inflow gas with the modified first bed layer, and determining an inflow gas reaction amount contributing to the equilibrium reaction of the inflow gas;
a gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the gas reaction component and the first substance reaction component, and calculating at least the change in heat quantity and the flow rate of each of the gas reaction component and the first substance reaction component when the gas reaction component and the first substance reaction component reach an equilibrium state ;
a step of calculating an equilibrium reaction between the modified first bed layer and the inflow gas , and calculating at least the change in heat quantity and the flow rate of each of the bed layer reactant and the inflow gas reactant when the bed layer reactant and the inflow gas reactant reach an equilibrium state ;
Including,
The method for calculating reactions within a reactor is applied to each of the unit operation models when the reactor is divided into a plurality of regions and the reaction process in one region is assumed to be a unit operation model, the reaction process within the reactor is modeled by combining the unit operation models, and calculations of the unit operation models in the plurality of regions within the reactor are repeatedly performed along the flow of the raw material ore or the flow of the combustion gas until the difference between the calculated value, which is the temperature of the gas phase and the bed layer in a specified region, and the previous calculated value in that region satisfies a specified convergence condition .

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