Steel production begins by charging a mixture of different iron-ore particle types into a blast furnace, a tall shaft reactor designed to extract iron through melting and chemical reduction. The main materials are pellets, fired near-spherical agglomerates of iron-ore concentrate
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Steel production begins by charging a mixture of different iron-ore particle types into a blast furnace, a tall shaft reactor designed to extract iron through melting and chemical reduction. The main materials are pellets, fired near-spherical agglomerates of iron-ore concentrates, and sinter, fused agglomerates of fine ore and fluxes. The mixture is charged in layers, and these layers collectively form the packed bed in the furnace. During operation, hot reducing gas must flow through the void space of this packed bed to drive the reduction reactions and provide heat for melting, which makes bed permeability critical. Observing how these materials distribute during charging is difficult because of harsh operating conditions and scale, yet this distribution governs bed permeability and thereby the gas flow that affects efficiency, energy use, and emissions. As a result, it remains unclear whether the deposited mixture is uniform and, if not, how to improve it. Despite decades of industrial use, the blast furnace therefore remains, to some extent, a “black box”.
The Discrete Element Method (DEM) is well suited to this problem because it resolves the motion of individual particles and their interactions, which enables a detailed assessment of mixture distribution within and between layers. This thesis develops a calibrated DEM framework to predict mixed-layer formation and to assess its implications for blast furnace permeability. The focus is on component distribution (pellet versus sinter) and packing distribution as key descriptors of the burden structure in the charged layers. The model adopts the Hertz-Mindlin contact law with rolling model C for coarse, free-flowing materials and treats a 15-parameter interaction set for the pellet–sinter mixture.
A pre-calibration step evaluates three inter-component parameters: restitution, sliding friction, and rolling friction, using porosity as a proxy for permeability. Sensitivity analyses show that all three parameters strongly affect porosity and component distribution, and they are therefore retained in the full calibration. Robust calibration requires conditions representative of charging and multiple constraints. To that end, a high-velocity laboratory setup with a 4.7 m drop height enables systematic piling tests for pellets, sinter, and their 50/50 mixture. Five KPIs (hopper discharge time, heap mass, heap contour, heap center height, and heap porosity) are used in a stepwise calibration, first for the single components and then for the inter-component interactions. The calibrated model reproduces experiments across discharge heights with maximum deviations of 5.5% at the highest drop, which indicates reliable predictive performance over a range of velocities.
Industrial-scale charging is addressed via particle up-scaling. While a factor of 2 is insufficient for practical runtimes, factors up to 5 preserve layering, segregation, and porosity patterns when mass flow rate is adjusted, without compromising the final packed-layer structure. Using this up-scaled model, case studies quantify how operating conditions shape component and packing distributions in successive layers, and they offer practical guidance for charging strategies that improve mixture distribution and, consequently, overall furnace performance.