JP7707933B2 - 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, in known operating methods such as the rotary kiln operating method described in Patent Document 1, the inside of the rotary kiln is treated as one type of gas phase, and the formation of multiple different types of gas phases due to the influence of the bed layer is not considered. The gas phase supplied to the rotary kiln is mixed with the product gas generated from the raw ore, so two or more layers with different gas components are generated, such as a layer that is easily affected by the bed layer and a layer that is not easily affected by the bed layer. Therefore, when simulating the behavior of the raw ore, etc. in a reactor such as a rotary kiln, it is necessary to accurately calculate the reaction in the furnace, taking into account the fact that two or more phases with different gas components are generated in the gas phase due to the product gas generated from the raw ore, etc.

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.

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 first gas phase quantity correction unit for correcting a quantity of a first gas phase flowing through one of two gas regions, the first gas region being one of the two gas regions divided according to a gas region influence factor including a generated gas generated from a bed layer including the raw material ore, among the gas regions including the combustion gas, to obtain a corrected first gas phase;
a second gas phase quantity correction unit that corrects a quantity of a second gas phase flowing through the other second gas region of the two gas regions to obtain a corrected second gas phase;
a gas mixing amount calculation unit for calculating a flow rate of an inlet gas moving from the second gas region to the bed layer;
a first gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between the modified first gas phase and a first substance present in the first gas region among substances including at least one of a solid substance and a liquid substance present in the gas region;
a second gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between the modified second gas phase and a second substance present in the second gas region among the substances;
a bed layer equilibrium reaction calculation unit for calculating an equilibrium reaction between the 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 first gas phase quantity correction step of correcting a quantity of a first gas phase flowing through one of two gas regions, which are divided according to a gas region influence factor including a generated gas generated from a bed layer including the raw material ore, among the gas regions including the combustion gas, to obtain a corrected first gas phase;
a second gas phase amount correction step of correcting an amount of the second gas phase flowing through the other second gas region of the two gas regions to obtain a corrected second gas phase;
a gas mixing amount calculation step of calculating a flow rate of an inlet gas moving from the second gas region to the bed layer;
a first gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the modified first gas phase and a first substance present in the first gas region among substances including at least one of a solid substance and a liquid substance present in the gas region;
a second gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the modified second gas phase and a second substance present in the second gas region among the substances;
a bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the bed layer and the inflow gas;
Includes.

One aspect of the reactor reaction calculation device of the present invention can calculate the reaction in the reactor with high accuracy.

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; FIG. 2 is an explanatory diagram showing the state of segregation of bed layers in a rotary kiln. FIG. 2 is an explanatory diagram showing the state of segregation of bed layers in the longitudinal direction in a rotary kiln. 1 is a flowchart illustrating a method for calculating an in-furnace reaction according to an embodiment of the present invention. 6 is a flowchart showing the operation of the first gas region equilibrium reaction implementation step (step S22) of FIG. 5. 6 is a flowchart showing the operation of the second gas region equilibrium reaction implementation step (step S23) of FIG. 5. 6 is a flowchart showing the operation of the first bed layer equilibrium reaction implementation step (step S24) of FIG. 5. 6 is a flowchart showing the operation of the second bed layer equilibrium reaction implementation step (step S25) of FIG. 5. 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 region is the region within the rotary kiln 1 where the gas phase flows, and is divided into a first gas region and a second gas region so that a predetermined volume ratio is achieved in each region divided according to gas region influence factors including generated gas generated from the bed layer.
The gas region influence factors include the positions of fuel supply equipment such as the raw material supply pipe 15 and the combustion material supply pipe 12, the positions of gas supply equipment such as the burner 16, the generated gas generated in the bed layer, dust, and the gas concentration inside the furnace.
The first gas region is a gas region that is less affected by the gas region influence factor.
The second gas region refers to a gas region where the gas region influence factor has a large effect.

The gas phase supplied into the rotary kiln 1 is referred to as gas phase G1.
The "gas phase G1" is the combustion gas flowing into region A from one adjacent region (region (A+1)). The combustion gas includes gases that contribute to equilibrium reactions, 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 reactions in the first gas region equilibrium reaction calculation unit 214-1 and the second gas region equilibrium reaction calculation unit 214-2 described below.

The gas phases present in the region A are described as the first gas phase G11, the additive-containing first gas phase G12, the corrected first gas phase G13, the first mixed gas phase G14, the second gas phase G21, the corrected second gas phase G22A, the adjusted second gas phase G22B, the second mixed gas phase G23, or the second combined gas phase G24. Each gas phase in the region A is defined as follows.
The "first gas phase G11" refers to the gas phase flowing in the first gas region among the gas phase G1 flowing into region A from one adjacent region (region (A+1)). The first gas phase G11 may contain an inactive substance that does not contribute to the reaction in the first gas region equilibrium reaction calculation unit 214-1 described later, similar to the gas phase G1.
The "additive-containing first gas phase G12" is a gas phase obtained by combining the additive gas phase distributed from the combustion material and the first gas phase.
The "first diffusion gas G121" is a gas contained in the additive-containing first gas phase G12 present in the first gas region that moves to the second gas region by convection or diffusion.
The "second diffusion gas G122" is a gas contained in the second gas phase G21 present in the second gas region that moves to the first gas region by convection or diffusion.
The "modified first gas phase G13" is a first gas phase in which the quantity of the additive-containing first gas phase G12 has been modified taking into account the amount of gas contained in the additive-containing first gas phase G12 moving to the second gas region and the amount of gas contained in the second gas phase G21 present in the second gas region moving to the additive-containing first gas phase G12.
The "first gas mixture phase G14" is the first gas phase generated in a first gas mixture phase calculation unit 216-1, which will be described later.
The "second gas phase G21" refers to the gas phase that passes through the second gas region of the gas phase G1 that flows into region A from one adjacent region (region (A+1)). The second gas phase G21, like the gas phase G1, may contain an inactive substance that does not contribute to the reaction in the second gas region equilibrium reaction calculation unit 214-2 described later.
The "modified second gas phase G22A" is a second gas phase in which the quantity of the first gas phase G12 containing the additive has been modified taking into account the amount of the second substance contained in the first gas phase G12 containing the additive present in the first gas region that moves to the second gas phase G21 and the amount of the third substance contained in the second gas phase G21 that moves to the first gas phase G12 containing the additive.
The "adjusted second gas phase G22B" is a second gas phase obtained by removing the flow rate of the inflow gas that has moved from the corrected second gas phase G22A to the bed layer in the gas mixture amount calculation unit 204 described later.
The "second gas mixture phase G23" is a second gas phase generated in a second gas mixture phase calculation unit 216-2, which will be described later.
The "second combined gas phase G24" is a gas phase generated in the gas amount combining unit 222 described later.

The bed layer fed into the rotary kiln 1 is described as bed layer S1.
The "bed layer S1" refers to raw ore supplied from the charging end 14A in the kiln body 11. The raw ore includes solid materials including compounds in the ore such as nickel oxide, iron oxide, and magnesium oxide, fixed carbon, and liquid materials, and may also include inactive materials that do not contribute to reactions in the first bed layer equilibrium reaction calculation unit 215-1 and the second bed layer equilibrium reaction calculation unit 215-2 described later.

The bed layers present in the region A are described as the first bed layer S11, the additive-containing first bed layer S12, the preliminarily corrected first bed layer S13A, the corrected first bed layer S13B, the first mixed bed layer S14, the second bed layer S21, the preliminarily corrected second bed layer S21A, the corrected second bed layer S21B, or the second mixed bed layer S22. Each bed layer in the region A is defined as follows.
The "first bed layer S11" refers to a bed layer present in a portion of the bed layer S1 that flows into the region A from one adjacent region (region (A-1)) and has good contact with the gas region on the surface of the bed layer. The first bed layer S11 may contain an inactive substance or the like that does not contribute to the reaction in the first bed layer equilibrium reaction calculation unit 215-1 described later, similar to the bed layer S1.
The "additive-containing first bed layer S12" is a bed layer obtained by combining the additive bed layer distributed from the combustion material and the first bed layer S11.
The "preliminarily corrected first bed layer S13A" is a first bed layer in which the quantity of the additive-containing first bed layer S12 has been corrected taking into consideration the amount of movement of the seventh substance, which contains at least one of a solid substance or a liquid substance and is contained in the additive-containing first bed layer S12, to the gas region, and the amount of movement of the eighth substance, which contains at least one of a solid substance or a liquid substance and is contained in the second mixture M22 and is present in the gas region, in the second mixture substance primary quantity correction unit 223 described later.
The "modified first bed layer S13B" is a first bed layer in which the amount of material of the preliminary modified first bed layer S13A has been modified taking into account the amount of a sixth substance, which is contained in the preliminary modified first bed layer S13A and includes at least one of a solid substance or a liquid substance, moving to the preliminary modified second bed layer S21A, and the amount of a fifth substance, which is contained in the preliminary modified second bed layer S21A and includes at least one of a solid substance or a liquid substance, moving to the preliminary modified first bed layer S13A.
The "first mixed bed layer S14" is a bed layer generated in the first mixed bed layer calculation unit 218-1 described later.
The "second bed layer S21" refers to a bed layer other than the first bed layer S11 among the bed layers S1 flowing into the region A from one adjacent region (region A-1), and is a bed layer present in a portion of the bed layer S1 that is less susceptible to the influence of the gas region inside the bed layer. The second bed layer S21 may contain an inactive substance or the like that does not contribute to the reaction in the second bed layer equilibrium reaction calculation unit 215-2 described later, similar to the bed layer S1.
The "preliminarily corrected second bed layer S21A" is the quantity of the second bed layer S21 corrected by subtracting the amount of a ninth substance, which is contained in the second bed layer S21 and includes at least one of a solid component and a liquid component, that moves into the gas region.
The "modified second bed layer S21B" is a second bed layer in which the quantity of material in the preliminary correction second bed layer S21A has been modified taking into account the amount of movement of the sixth substance contained in the preliminary correction first bed layer S13A to the preliminary correction second bed layer S21A and the amount of movement of the fifth substance contained in the preliminary correction second bed layer S21A to the preliminary correction first bed layer S13A.
The "second mixed bed layer S22" is a bed layer generated in the second mixed bed layer calculation unit 218-2 described later.

In addition, the gases flowing into the bed layer from the gas region in region A are described as inlet gas G221, first inlet gas G221-1, second inlet gas G221-2, first mixed inlet gas G222A, second mixed inlet gas G222B, or mixed inlet gas G223. In the following description, each inlet gas in region A is defined as follows.
"Inflow gas G221" is the gas flowing from the gas region in region A into the bed layer.
The "first inflow gas G221-1" is the inflow gas that flows into the first bed layer S11 out of the inflow gas G221 that has flowed into the bed layer.
The "second inflow gas G221-2" is the inflow gas that flows into the second bed layer S21 out of the inflow gas G221 that has flowed into the bed layer.
The "first mixed inflow gas G222A" is a gas obtained by mixing the unreacted portion of the first bed layer and the product of the first inflow gas generated in the first bed layer equilibrium reaction calculation section 215-1.
The "second mixed inflow gas G222B" is a gas obtained by mixing the corrected second bed layer unreacted portion and the second inflow gas product generated in the second bed layer equilibrium reaction calculation section 215-2.
The "mixed inflow gas G223" is a gas obtained by combining the first mixed inflow gas G222A and the second mixed inflow gas G222B.

The material fed into rotary kiln 1 is designated as material M1.
The term "substance M1" includes at least one of a solid substance and a liquid substance that exists in a gas region.

The substances present in the region A are described as the first substance M11, the second substance M21, the third substance M3, the fourth substance M4, the fifth substance M5, the sixth substance M6, the seventh substance M7, the eighth substance M8, the ninth substance M9, the first mixed substance M12, the first modified mixed substance M13, the second mixed substance M22, the second modified mixed substance M23, or the second modified mixed substance M24. In the following description, each substance in the region A is defined as follows.
The "first material M11" is the material that flows into the first gas region out of the material M1 that has flowed into the gas region.
The "second material M21" is the material that flows into the second gas region out of the material M1 that has flowed into the gas region.
The "third material M3" is a material that includes at least one of a solid material and a liquid material and is contained in the second modified mixed material M23 that exists in the second gas region.
The "fourth substance M4" is a substance that includes at least one of a solid substance and a liquid substance and is contained in the first mixed substance M12 that exists in the first gas region.
The "fifth substance M5" includes at least one of a solid substance and a liquid substance contained in the second mixed bed layer S21A present in the second bed layer.
The "sixth substance M6" includes at least one of a solid substance and a liquid substance contained in the preliminary corrected first bed layer S13A present in the first bed layer.
The "seventh substance M7" includes at least one of a solid substance and a liquid substance contained in the additive-containing first bed layer S12 present in the first bed layer.
The "eighth substance M8" is a substance that includes at least one of a solid substance and a liquid substance and is contained in the second mixed substance M22 that exists in the second gas region.
The "ninth substance M9" includes at least one of a solid substance and a liquid substance contained in the second bed layer S21 present in the second bed layer.
The "first mixed material M12" is a mixture of the first material M1 generated in a first mixed material calculation unit 217-1, which will be described later.
The 'first modified mixed material M13' is a mixture of the first material M1 produced in the first mixed material amount modifying unit 220 described below.
The "second mixed substance M22" is the second mixed substance M21 obtained by mixing the unreacted portion Mr21 of the second substance and the product portion MP21 of the second substance in a second mixed substance calculation section 217-2 described later.
The "second modified mixed substance M23" is obtained by modifying the quantity of the second mixed substance M22 in the second mixed substance primary quantity modification unit 223 described later by subtracting the movement amount of the eighth substance M8 contained in the second mixed substance M22 and adding to the second mixed substance M22 the movement amounts of the seventh substance M7 moving from the first bed layer and the ninth substance M9 moving from the second bed layer.
The "second modified mixed substance M24" is obtained by modifying the quantity of the second modified mixed substance M23 in the second mixed substance secondary quantity modification unit 224 described later by adding the movement amount of the fourth substance M4 contained in the first mixed substance M12 to the second modified mixed substance M23 and subtracting the third substance M3 that moves from the second modified mixed substance M23 to the first gas region.

In addition, the reacted, unreacted and product fractions calculated within region A are: first gas reacted fraction GR1, first gas unreacted fraction Gr1, first gas product fraction GP1, second gas reacted fraction GR2, second gas unreacted fraction Gr2, second gas product fraction GP2, first substance reacted fraction MR11, first substance unreacted fraction Mr11, first substance product fraction MP11, second substance reacted fraction MR21, second substance unreacted fraction Mr21, second substance product fraction MP21, first flow fraction These are written as the inlet gas reaction portion GR221, the first inlet gas unreacted portion Gr221, the first inlet gas product portion GP221, the second inlet gas reaction portion GR222, the second inlet gas unreacted portion Gr222, the second inlet gas product portion GP222, the first bed layer reaction portion SR1, the first bed layer unreacted portion Sr1, the first bed layer product portion SP1, the second bed layer reaction portion SR2, the second bed layer unreacted portion Sr2, or the second bed layer product portion SP2. These are calculated by any of the parts constituting the furnace reaction calculation device shown in FIG. 2.

The configuration of the furnace reaction calculation device shown in Figure 2 will be described. As shown in Figure 2, the furnace reaction calculation device 20 includes a distribution section (distribution section) 201 of combustion material, a first gas phase quantity correction section 202, a second gas phase quantity correction section 203, a gas mixture quantity calculation section 204, a first bed layer reserve quantity correction section 205, a first bed layer quantity correction section 206, a second bed layer reserve quantity correction section 207, a second bed layer quantity correction section 208, an inflow gas distribution section 209, a first gas reaction amount calculation section 210-1, a first material reaction amount calculation section 211-1, a second gas reaction amount calculation section 210-2, a second material reaction amount calculation section 211-2, a first bed layer reaction amount calculation section 212-1, a second bed layer reaction amount calculation section 212-2, a first inflow gas reaction amount calculation section 213-1, The system includes a second inflow gas reaction amount calculation unit 213-2, a first gas region equilibrium reaction calculation unit 214-1, a second gas region equilibrium reaction calculation unit 214-2, a bed layer equilibrium reaction calculation unit 215, a first mixed gas phase calculation unit 216-1, a second mixed gas phase calculation unit 216-2, a first mixed substance calculation unit 217-1, a second mixed substance calculation unit 217-2, a first mixed bed layer calculation unit 218-1, a second mixed bed layer calculation unit 218-2, a first mixed inflow gas calculation unit 219-1, a second mixed inflow gas calculation unit 219-2, a first mixed substance amount correction unit 220, an inflow gas summation unit 221, a gas amount summation unit 222, a second mixed substance primary amount correction unit 223, and a second mixed substance secondary amount correction unit 224.

In this embodiment, the bed layer equilibrium reaction calculation unit 215 is composed of two bed layers (first bed layer equilibrium reaction calculation unit 215-1 and second bed layer equilibrium reaction calculation unit 215-2).

The reactor reaction calculation device 20 can also include a gas domain distribution unit 231 that distributes the gas phase G1 into two types of distributed gas phases (first gas phase G11 and second gas phase G21) in advance according to gas domain influence factors including the product gas generated from the bed layer. In this embodiment, the reactor reaction calculation device 20 supplies the first gas phase G11 generated in the gas domain distribution unit 231 to the first gas phase quantity correction unit 202, and supplies the second gas phase G21 generated in the gas domain distribution unit 231 to the second gas phase quantity correction unit 203.

The reactor reaction calculation device 20 can include a first substance distribution unit 232 that distributes the first substance M1 into two types of first substances (first substance M11, second substance M21) in advance. In this embodiment, the reactor reaction calculation device 20 supplies the first substance M11 produced in the first substance distribution unit 232 to the first substance reaction amount calculation unit 211-1, and supplies the second substance M21 produced in the first substance distribution unit 232 to the second substance reaction amount calculation unit 211-2.

The reactor reaction calculation device 20 can be equipped with a bed layer distribution unit 233 that distributes the bed layer S1 into two types of distribution bed layers (first bed layer S11, second bed layer S21) in advance according to the reaction rate-attributable conditions of the solid and liquid materials contained in the bed layer S1. In this embodiment, the reactor reaction calculation device 20 supplies the first bed layer S11 generated in the bed layer distribution unit 233 to the first bed layer reserve quantity correction unit 205, and supplies the second bed layer S21 generated in the bed layer distribution unit 233 to the second bed layer reserve quantity correction unit 207.

In the rotary kiln 1, the thermal decomposition and reaction of the raw materials generates post-reaction gases (product gases) such as steam and gas from the bed layer. For example, in a rotary kiln that burns dried nickel oxide ore and performs partial reduction treatment, steam is generated from the bed layer due to dehydration of adhering water and crystallization water remaining in the dried ore, or CO, _CO2 gas, etc. are generated due to combustion of coal added midway through the rotary kiln and partial reduction of the ore. When these post-reaction gases are released from the bed layer to the gas region, they are diffused throughout the gas region by convection and diffusion, but a certain residence time of the gas in the furnace is required for the concentration in the gas region to become uniform, and it is usually considered that the gas concentration in the gas region in the rotary kiln 1 is distributed between the vicinity of the bed layer and other regions.

For example, as shown in FIG. 3, the bed layer is likely to have a first bed layer S11 that is not easily affected by gas, and a second bed layer S21 that has good contact with the gas region. As shown in FIG. 4, the first bed layer S11 and the second bed layer S21 are formed along the longitudinal direction of the rotary kiln 1. In addition, the gas region is also likely to have a first gas phase G11 that does not contain much generated gas, dust, etc., and a second gas phase G21 that contains a lot of generated gas, dust, etc., as the post-reaction gas and dust generated in the bed layer scatters in the gas region. As shown in FIG. 4, the first gas phase G11 and the second gas phase G21 are formed along the longitudinal direction of the rotary kiln 1. Therefore, the reaction in the gas region is easily affected by the generated gas, dust, etc. contained in the gas phase.

In addition, the reaction of the bed layer is greatly affected by the gas composition. For example, in the case of an Fe-C-O system or when the CO gas partial pressure is low, the reaction product is Fe ₃ O ₄ , but as the CO partial pressure increases, the product changes to FeO or M-Fe. Therefore, in order to simulate the reaction in the furnace of the rotary kiln 1 and accurately grasp the reaction behavior of the raw materials in the rotary kiln 1, it is necessary to express the gas concentration (gas partial pressure) used in the equilibrium reaction calculation of the bed layer in more detail.

Methods for simulating rotary kilns can be broadly divided into two types: one assumes that the gas generated in the ore layer spreads instantly throughout the entire gas region, and treats the gas components in the gas region at the same position in the longitudinal direction as a single concentration, and the other performs coupled calculations by calculating the gas phase using three-dimensional thermal fluid calculations. The former method cannot represent the gas atmosphere in the gas region near the bed layer, where the concentration of gas generated from the bed layer is high. The latter method requires enormous calculation resources and time.

The furnace reaction calculation device 20 divides the gas region into two gas regions (first gas region and second gas region) in the rotary kiln 1, and performs equilibrium reaction calculations in each bed layer of the first gas phase G11 flowing in the first gas region and the second gas phase G21 flowing in the second gas region. That is, when performing a simulation of the furnace reaction based on the Gibbs energy minimization method, the furnace reaction calculation device 20 takes into account the post-reaction gas, dust, etc. from the bed layer contained in the gas region in the rotary kiln 1. Then, the furnace reaction calculation device 20 calculates the reaction amount required for the equilibrium reaction independently for the first gas phase G11, which contains almost no post-reaction gas, dust, etc., and the second gas phase G21, which contains a lot of product gas, dust, etc., of the gas phase G1. As a result, the reactor reaction calculation device 20 can calculate equilibrium reactions based on the Gibbs energy minimization method with high accuracy, taking into account the effects of post-reaction gas, dust, and the like contained in the first gas phase G11 and the second gas phase G21. The reactor reaction calculation device 20 can represent a gas atmosphere with a high concentration of gas produced from the bed layer in the gas region near the bed layer without requiring huge calculation resources, so the reactor reaction calculation device 20 can analyze the reactor reaction with high accuracy without imposing a large burden.

The furnace reaction calculation device 20 also performs equilibrium reaction calculations between the bed layer and the inflow gas mixed into the bed layer based on the Gibbs energy minimization method. This makes it possible to calculate the equilibrium reaction in the bed layer in the rotary kiln 1.

Therefore, by taking into consideration that the gas phase in the rotary kiln 1 exhibits two different types of reaction behavior depending on the gas produced from the bed layer, dust, etc., contained in the gas phase, the furnace reaction calculation device 20 can analyze the reactions occurring in the rotary kiln 1 with high precision, thereby improving the calculation accuracy of the reactions. Therefore, the furnace reaction calculation device 20 can calculate the reactions in the rotary kiln 1 with higher precision.

As shown in FIG. 2, the reactor reaction calculation device 20 inputs the quantities, temperatures, pressures, etc. of the first gas phase G11 and the second gas phase G21 flowing into the gas region of region A, and the first bed layer S11 and the second bed layer S21 flowing into the bed layer of region A. The reactor reaction calculation device 20 uses these input values to perform mass transfer and reaction calculations within each divided region A.

The first gas phase G11 and the second gas phase G21 are determined according to the amount of material when the gas phase G1 supplied from the discharge end 14B in the kiln body 11 is distributed in the region N including the discharge end 14B and moves to the region A.

The first bed layer S11 and the second bed layer S21 are determined according to the amount of material when the bed layer S1 supplied from the charging end 14A in the kiln body 11 is distributed in the area 1 including the charging end 14A and moved to the area A.

When calculating the mass transfer and reactions in region A, the reactor reaction calculation device 20 defines the amount of gas (inlet gas G221) that is mixed into the bed layer from the second gas phase G21 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 due to scattering or volatilization of solid or liquid materials moving in the bed layer, and the amount of mass transfer to the bed layer due to falling (settling) or coagulation of solid or liquid materials moving in the gas region. For example, the amount of mass transfer can be defined for each calculation material based on the settling velocity calculated from the specific gravity, particle size, etc. of the solid or liquid material.

The material produced after the reaction, which includes at least one of a solid material and a liquid material, is added to the unreacted material in each bed layer (first bed layer, second bed layer) and used as the input value for each bed layer in the next adjacent region. In addition, the post-reaction gas produced in each bed layer is added to the unreacted gas, and is further added to the post-reaction gas in each bed layer and the second gas region to use as the input value for the adjacent gas region.

As shown in FIG. 2, the distribution unit 201 distributes the combustion material 240 to the gas phase and bed layer contained in the combustion material 240 at a mass flow rate by setting the type, components, etc. of the combustion material 240 in advance.

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

A first gas phase G11, which is a combustion gas flowing from one adjacent region (region (A+1)) into the first gas region of region A in the furnace, and an additive-containing first gas phase G12, which includes an additive gas phase AG11 of the combustion material distributed by the distribution section 201, flow through the first gas region.

The first gas phase quantity correction unit 202 corrects the quantity of the additive-containing first gas phase G12 flowing through the first gas region, and calculates the corrected first gas phase G13.

The second gas phase quantity correction unit 203 corrects the quantity of the second gas phase G21 flowing through the second gas region and calculates the corrected second gas phase G22A.

The gas mixing amount calculation unit 204 calculates the mass flow rate of the inlet gas G221 moving from the modified second gas phase G22A in the second gas region to the bed layer.

The gas mixture amount calculation unit 204 calculates the gas phase obtained by subtracting the inflow gas G221 from the corrected second gas phase G22A as the adjusted second gas phase G22B.

The first bed layer preliminary quantity correction unit 205 corrects the quantity of the additive-containing first bed layer S12, which is a mixture of the first bed layer S11 and the additive bed layer AS11, to calculate the preliminary corrected first bed layer S13A.

The amount of material in the first bed layer S12 containing the additive is adjusted taking into consideration the amount of the seventh substance M7, which is contained in the first bed layer S12 containing the additive and contains at least one of a solid substance or a liquid substance, transferred to the second mixed substance M22 present in the gas region, and the amount of the eighth substance M8, which is contained in the second mixed substance M22 and contains at least one of a solid substance or a liquid substance, transferred to the first bed layer S12 containing the additive.

The first bed layer quantity correction unit 206 corrects the quantity of the preliminary corrected first bed layer S13A and calculates the corrected first bed layer S13B, taking into consideration the amount of movement of the sixth substance M6, which is contained in the preliminary corrected first bed layer S13A and contains at least one of a solid substance or a liquid substance, to the second bed layer S21, and the amount of movement of the fifth substance M5, which is contained in the second bed layer S21 and contains at least one of a solid substance or a liquid substance, to the preliminary corrected first bed layer S13A.

In this embodiment, the first bed layer quantity correction unit 206 corrects the quantity of the preliminary corrected first bed layer S13A by subtracting the amount of movement of the sixth substance M6 to the second bed layer S21 and adding the amount of movement of the fifth substance M5 contained in the second bed layer S21 to the preliminary corrected first bed layer S13A, and calculates the corrected first bed layer S13B.

The second bed layer preliminary quantity correction unit 207 corrects the quantity of the second bed layer S21 taking into account the amount of movement of the ninth substance M9, which contains at least one of a solid substance and a liquid substance and is contained in the second bed layer S21, to the second mixed substance M22 present in the gas region, and calculates the preliminary corrected second bed layer S21A.

The second bed layer quantity correction unit 208 corrects the quantity of the preliminary correction second bed layer S21A and calculates the corrected second bed layer S21B, taking into account the amount of movement of the sixth substance M6 contained in the preliminary correction 21st bed layer S13A to the second bed layer S21 and the amount of movement of the fifth substance M5 contained in the preliminary correction second bed layer S21A to the preliminary correction first bed layer S13A.

In this embodiment, the second bed layer quantity correction unit 208 corrects the quantity of the second bed layer S21 by adding the amount of movement of the sixth substance M6 contained in the preliminary correction 21st bed layer S13A to the second bed layer S21 and subtracting the amount of movement of the fifth substance M5 contained in the preliminary correction 21st bed layer S21A to the preliminary correction 1st bed layer S13A, thereby calculating the corrected second bed layer S21B.

The inflow gas distribution unit 209 has the function of distributing the inflow gas G221 into a first inflow gas G221-1 and a second inflow gas G221-2 by mass flow rate by presetting the type and components of the inflow gas G221 calculated by the gas mixture calculation unit 204.

The first gas reaction amount calculation unit 210-1 calculates the amount of the first gas reaction that contributes to the equilibrium state of the modified first gas phase G13 with the first substance M11. That is, the first gas reaction amount calculation unit 210-1 calculates the amount of the first gas reaction that is expected to occur when the modified first gas phase G13 reacts in equilibrium with the first substance M11 during the residence time of the modified first gas phase G13 that exists in the first gas region in region A. The reaction amount during the residence time of the modified first gas phase G13 in region A is calculated using the reaction rate parameters set for each individual substance and the residence time in region A.

The first gas reaction amount calculation unit 210-1 can calculate the amount of the first gas reacting during the residence time in region A using a reaction rate equation.

The first gas reaction amount calculation unit 210-1 calculates the first gas reaction amount GR1 that contributes to the equilibrium state with the first substance M11 in the modified first gas phase G13 from the first gas reaction amount.

In this specification, the reactive portion refers to the flow rate that contributes to the reaction by contact with the modified first gas phase G13 or the first substance M11 present in the gas region during the residence time during which the modified first gas phase G13 in region A or the first substance M11 present in the gas region passes through. Hereinafter, other reactive portions also refer to the flow rate that contributes to the reaction by contacting any of the gas phase, solid phase, and substance with any of the gas phase, solid phase, and substance.

That is, the first gas reaction portion GR1 is the reaction portion of the modified first gas phase G13 that contributes to the equilibrium reaction with the first substance M11 present in the first gas region. The first substance reaction portion MR11 is the reaction portion of the first substance M11 present in the first gas region that contributes to the equilibrium state with the modified first gas phase G13.

The first gas reaction amount calculation unit 210-1 can determine the amount of the modified first gas phase G13 and the solid or liquid substance present in the first substance M11 that reaches an equilibrium state by employing, for example, a model that can calculate the amount from the reaction rate according to an Arrhenius reaction rate equation and the residence time of the modified first gas phase G13 in region A. The first gas reaction amount calculation unit 210-1 then divides the amount into a first gas reaction amount GR1 that corresponds to the gas reaction amount and a first gas unreacted amount Gr1 that corresponds to the remaining unreacted mass flow rate.

In the rotary kiln 1, the modified first gas phase G13 and the first substance M11 present in the first gas region flow in parallel. The modified first gas phase G13 has a high flow rate and a short residence time in region A, and the modified first gas phase G13 and the first substance M11 present in the first gas region do not reach equilibrium. In this embodiment, the first gas reaction amount calculation unit 210-1 assumes that only a portion of the modified first gas phase G13 in a certain region (region A) in the rotary kiln 1 reaches equilibrium with the first substance M11 present in the first gas region, and divides the modified first gas phase G13 into a gas reaction portion GR1 and a gas unreacted portion Gr1 other than the gas reaction portion GR1 according to the corresponding first gas reaction amount.

The second gas reaction amount calculation unit 210-2 calculates the amount of the second gas reaction that contributes to the equilibrium state with the second substance M21 of the adjusted second gas phase G22B, which is obtained by subtracting the inflow gas G221 from the modified second gas phase G22A. That is, the second gas reaction amount calculation unit 210-2 calculates the amount of the second gas reaction that is expected to occur in equilibrium with the second substance M21 during the residence time of the adjusted second gas phase G22B that exists in the first gas region in region A. The reaction amount during the residence time of the adjusted second gas phase G22B in region A is calculated using the reaction rate parameters set for each individual substance and the residence time in region A.

The second gas reaction amount calculation unit 210-2 can calculate the amount of the second gas reacting during the residence time in region A using a reaction rate equation.

The second gas reaction amount calculation unit 210-2 calculates the second gas reaction amount GR2 that contributes to the equilibrium state with the second substance M21 in the adjusted second gas phase G22B from the second gas reaction amount.

That is, the first gas reaction portion GR2 is the reaction portion of the adjusted second gas phase G22B that contributes to an equilibrium reaction with the second substance M21 present in the second gas region. The second substance reaction portion MR21 is the reaction portion of the second substance M21 present in the second gas region that contributes to an equilibrium state with the adjusted second gas phase G22B.

The second gas reaction amount calculation unit 210-2 can determine the amount of the adjusted second gas phase G22B that reaches an equilibrium state with the solid or liquid substance present in the second substance M21 by employing, for example, a model that can calculate the amount from the reaction rate according to an Arrhenius-type reaction rate equation and the residence time of the adjusted second gas phase G22B in the region A. The second gas reaction amount calculation unit 210-2 then divides the amount into a second gas reaction amount GR2 that corresponds to the gas reaction amount and a second gas unreacted amount Gr2 that corresponds to the remaining unreacted mass flow rate.

In the rotary kiln 1, the flow of the adjusted second gas phase G22B and the flow of the second substance M21 present in the second gas region are parallel, the flow velocity of the adjusted second gas phase G22B is high and the residence time in region A is short, and the adjusted second gas phase G22B and the second substance M21 present in the second gas region do not reach an equilibrium state. In this embodiment, the second gas reaction amount calculation unit 210-2 assumes that only a portion of the adjusted second gas phase G22B in region A reaches an equilibrium state with the second substance M21 present in the second gas region, and divides the adjusted second gas phase G22B into the second gas reaction amount GR2 and the second gas unreacted amount Gr2 other than the second gas reaction amount GR2 according to the corresponding second gas reaction amount.

The first material reaction amount calculation unit 211-1 calculates the first material reaction amount that contributes to the equilibrium state of the first material M11 with the modified first gas phase G13. That is, the first material reaction amount calculation unit 211-1 calculates the reaction amount that is expected to undergo equilibrium reaction of the first material M11 with the modified first gas phase G13 during the residence time of the first material M11 present in the gas region in region A as the first material reaction amount. The first material reaction amount can be calculated from the reaction rate equation. The first material reaction amount calculation unit 211-1 determines the first material reaction portion MR11 of the first material M11 that contributes to the equilibrium state with the modified first gas phase G13 from the first material reaction amount.

The first substance reaction amount calculation unit 211-1, like the first gas reaction amount calculation unit 210-1, can use a reaction rate equation to calculate the amount of the modified first gas phase G13 and the first substance M11 present in the first gas region that reach equilibrium.

The first substance reaction amount calculation unit 211-1, like the first gas reaction amount calculation unit 210-1, can determine the amount of the first substance M11 present in the first gas region that reaches an equilibrium state with the modified first gas phase G13 by employing, for example, a model that can calculate the amount from a reaction rate according to an Arrhenius reaction rate equation and the residence time of the first substance M11 in region A. The first substance reaction amount calculation unit 211-1 then divides the amount into a first substance reaction amount MR11 that corresponds to the first substance reaction amount and an unreacted first substance amount Mr11 that corresponds to the remaining unreacted mass flow rate.

As described above, in the rotary kiln 1, the modified first gas phase G13 and the first material M11 flow in parallel, the modified first gas phase G13 has a high flow rate and a short residence time in region A, and the modified first gas phase G13 and the first material M11 do not reach equilibrium. In this embodiment, the first material reaction amount calculation unit 211-1 assumes that only a portion of the first material M11 in a certain region (region A) in the rotary kiln 1 reaches equilibrium with the modified first gas phase G13, and divides the first material M11 into a first material reacted portion MR11 and an unreacted portion Mr11 of the first material other than the first material reacted portion MR11 according to the corresponding first material reaction amount.

The second material reaction amount calculation unit 211-2 calculates the second material reaction amount that contributes to the equilibrium state of the second material M21 with the adjusted second gas phase G22B. That is, the second material reaction amount calculation unit 211-2 calculates the reaction amount that is expected to undergo equilibrium reaction of the second material M21 with the adjusted second gas phase G22B during the residence time of the second material M21 present in the second gas region in region A as the second material reaction amount. The second material reaction amount can be calculated from the reaction rate equation. The second material reaction amount calculation unit 211-2 calculates the second material reaction portion MR21 of the second material M21 that contributes to the equilibrium state with the adjusted second gas phase G22B from the second material reaction amount.

The second material reaction amount calculation unit 211-2, like the first gas reaction amount calculation unit 210-1, can determine the amount of the adjusted second gas phase G22B and the second material M21 present in the second gas region that reaches equilibrium by employing, for example, a model that can calculate the amount from a reaction rate according to an Arrhenius reaction rate equation and the residence time of the second material M21 in region A. The second material reaction amount calculation unit 211-2 then divides the amount into a second material reaction amount MR21 that corresponds to the second material reaction amount and an unreacted amount Mr21 of the second material that corresponds to the remaining unreacted mass flow rate.

As described above, in the rotary kiln 1, the flow of the adjusted second gas phase G22B and the second material M21 are parallel, the flow velocity of the adjusted second gas phase G22B is high and the residence time in the region A is short, and the adjusted second gas phase G22B and the second material M21 do not reach equilibrium. In this embodiment, the second material reaction amount calculation unit 211-2 assumes that only a portion of the adjusted second gas phase G22B in the region A reaches equilibrium with the second material M21, and divides the second material M21 into the reacted portion of the second material MR21 and the unreacted portion of the second material other than the reacted portion of the second material MR21, Mr21, according to the corresponding second material reaction amount.

The first bed layer reaction amount calculation unit 212-1 uses a reaction rate equation to calculate the first bed layer reaction amount that contributes to the equilibrium state of the modified first bed layer S13B with the first inflow gas G221-1. That is, the first bed layer reaction amount calculation unit 212-1 uses the first reaction rate equation to calculate the first bed layer reaction amount that is expected to occur in equilibrium reaction of the modified first bed layer S13B with the first inflow gas G221-1 during the movement time of the modified first bed layer S13B in region A.

The first bed layer reaction amount calculation unit 212-1 can calculate the first bed layer reaction amount by using, for example, reaction rate parameters set for each individual substance contained in the modified first bed layer S13B in region A, residence time in region A, etc., in the first reaction rate equation. Then, the first bed layer reaction amount calculation unit 212-1 calculates the first bed layer reaction amount SR1 of the modified first bed layer S13B that contributes to the equilibrium reaction with the first inflow gas G221-1 from the first bed layer reaction amount.

That is, the first bed layer reaction portion SR1 is the reaction portion that contributes to the equilibrium reaction with the first inflow gas G221-1 in the modified first bed layer S13B.

The first bed layer reaction amount calculation unit 212-1 can calculate the first bed layer reaction amount by adopting, for example, a model that can be calculated from the reaction rate according to the Arrhenius reaction rate equation and the movement time of the modified first bed layer S13B in the region A. The first bed layer reaction amount calculation unit 212-1 calculates the first bed layer reaction amount of the modified first bed layer S13B that contributes to the equilibrium reaction with the first inflow gas G221-1 only for the amount that is estimated to have reached an equilibrium state between the modified first bed layer S13B and the first inflow gas G221-1 based on the residence time of the modified first bed layer S13B using the Arrhenius reaction rate equation. Then, the first bed layer reaction amount calculation unit 212-1 divides it into a first bed layer reaction amount SR1 corresponding to the first bed layer reaction amount and a first bed layer unreacted amount Sr1 corresponding to the remaining unreacted mass flow rate.

In the rotary kiln 1, the flow of the modified first bed layer S13B and the first inflow gas G221-1 are countercurrent. The flow rate of the first inflow gas G221-1 is high and the residence time in area A is short, so the modified first bed layer S13B and the first inflow gas G221-1 do not reach equilibrium. In this embodiment, the first bed layer reaction amount calculation unit 212-1 assumes that only a portion of the modified first bed layer S13B in a certain area (area A) in the rotary kiln 1 reaches equilibrium with the first inflow gas G221-1, and divides the modified first bed layer S13B into the first bed layer reaction portion SR1 and the first bed layer unreacted portion Sr1 other than the first bed layer reaction portion according to the corresponding first bed layer reaction amount.

The second bed layer reaction amount calculation unit 212-2 uses a reaction rate equation to calculate the amount of bed reaction that contributes to the equilibrium state of the modified second bed layer S21B with the second inflow gas G221-2. That is, the second bed layer reaction amount calculation unit 212-2 calculates the amount of second bed layer reaction that is expected to occur in equilibrium reaction of the modified second bed layer S21B with the second inflow gas G221-2 during the movement time of the modified second bed layer S21B in region A.

The second bed layer reaction amount calculation unit 212-2 calculates the second bed layer reaction amount SR2 of the corrected second bed layer S21B that contributes to the equilibrium state with the second inflow gas G221-2 from the obtained second bed layer reaction amount.

The second bed layer reaction amount calculation unit 212-2 can calculate the reaction amount that reaches an equilibrium state between the modified second bed layer S21B and the second inflow gas G221-2 in the same manner as the first bed layer reaction amount calculation unit 212-1, for example, by adopting a model that can be calculated from the reaction rate according to the Arrhenius reaction rate equation and the movement time of the preliminary modified second bed layer S21A in region A. The second bed layer reaction amount calculation unit 212-2 calculates the second bed layer reaction amount of the modified second bed layer S21B that contributes to the reaction with the second inflow gas G2211-2 only for the amount that is estimated to reach an equilibrium state between the modified second bed layer S21B and the second inflow gas G221-2 based on the residence time of the modified second bed layer S21B using the Arrhenius reaction rate equation. Then, the second bed layer reaction amount calculation unit 212-2 divides it into a second bed layer reaction amount SR2, which corresponds to the second bed layer reaction amount, and a second bed layer unreacted amount Sr2, which corresponds to the remaining unreacted mass flow rate.

The second bed layer reaction portion SR2 is the reaction portion that contributes to the equilibrium reaction with the second inlet gas G221-2 in the modified second bed layer S21B.

In the rotary kiln 1, the flow of the modified second bed layer S21B and the second inflow gas G221-2 are countercurrent. The flow velocity of the second inflow gas G221-2 is high and the residence time in the region A is short, so the modified second bed layer S21B and the second inflow gas G221-2 do not reach equilibrium. In this embodiment, the second bed layer reaction amount calculation unit 212-2 assumes that only a portion of the modified second bed layer S21B in the region A reaches equilibrium with the second inflow gas G221-2, and divides the modified second bed layer S21B into the second bed layer reacted portion SR2 and the remaining second bed layer unreacted portion Sr2 according to the corresponding second bed layer reaction amount.

The first inflow gas reaction amount calculation unit 213-1 calculates the first inflow gas reaction amount that contributes to the equilibrium state of the first inflow gas G221-1 with the modified first bed layer S13B. That is, the first inflow gas reaction amount calculation unit 213-1 calculates the first inflow gas reaction amount that is expected to cause an equilibrium reaction of the first inflow gas G221-1 with the modified first bed layer S13B during the residence time of the first inflow gas G221-1 present in the bed layer in region A. The first inflow reaction amount during the residence time of the first inflow gas G221-1 in region A can be calculated using the reaction rate parameters set for each substance and the residence time in region A, and can be calculated using, for example, a reaction rate equation. Then, the first inflow gas reaction amount calculation unit 213-1 calculates the first inflow gas reaction amount GR221 that contributes to the equilibrium reaction with the modified first bed layer S13B from the first inflow gas reaction amount.

That is, the first inflow gas reaction portion GR221 is the reaction portion of the first inflow gas G221-1 that contributes to the equilibrium state of the first modified bed layer S13B.

The first inflow gas reaction amount calculation unit 213-1 can calculate the reaction amount at which the first inflow gas G221-1 reaches equilibrium with the modified first bed layer S13B, for example, using a model similar to the model used in the first bed layer reaction amount calculation unit 212-1.

Then, the first inflow gas reaction amount calculation unit 213-1 divides it into a first inflow gas reaction amount GR221, which corresponds to the first inflow gas reaction amount, and a first inflow gas unreacted amount Gr221, which corresponds to the unreacted mass flow rate other than the remaining first inflow gas reaction amount GR221.

As described above, in the rotary kiln 1, the first inflow gas G221-1 and the modified first bed layer S13B flow in countercurrent, the first inflow gas G221-1 has a high flow rate and a short residence time in region A, and the first inflow gas G221-1 and the modified first bed layer S13B do not reach equilibrium. In this embodiment, the first inflow gas reaction amount calculation unit 213-1 assumes that only a portion of the first inflow gas G221-1 in region A in the rotary kiln 1 reaches equilibrium with the modified first bed layer S13B, and divides the first inflow gas G221-1 into the first inflow gas reacted portion GR221 and the remaining first inflow gas unreacted portion Gr221 according to the corresponding gas reaction amount.

The second inflow gas reaction amount calculation unit 213-2 calculates the second inflow gas reaction amount that contributes to the equilibrium state of the second inflow gas G221-2 with the modified second bed layer S21B. That is, the second inflow gas reaction amount calculation unit 213-2 calculates the second inflow gas reaction amount that is expected to react in equilibrium with the modified second bed layer S21B during the residence time of the second inflow gas G221-2 present in the bed layer in region A. The second inflow reaction amount during the residence time of the second inflow gas G221-2 in region A can be calculated using the reaction rate parameters set for each individual substance and the residence time in region A, and can be calculated, for example, from a reaction rate equation. Then, the second inflow gas reaction amount calculation unit 213-2 calculates the second inflow gas reaction amount GR222 that contributes to the equilibrium reaction with the modified second bed layer S21B of the second inflow gas G221-2.

That is, the second inflow gas reaction portion GR222 is the reaction portion of the second inflow gas G221-2 that contributes to the equilibrium state of the second corrected bed layer S21B.

The second inflow gas reaction amount calculation unit 213-2 can calculate the reaction amount at which the second inflow gas G221-2 reaches equilibrium with the modified second bed layer S21B, for example, using a model similar to the model used in the second bed layer reaction amount calculation unit 212-2.

The second inflow gas reaction amount calculation unit 213-2 divides it into a second inflow gas reaction amount GR222, which corresponds to the second inflow gas reaction amount, and a second inflow gas unreacted amount Gr222, which corresponds to the unreacted mass flow rate other than the remaining second inflow gas reaction amount.

As described above, in the rotary kiln 1, the second inflow gas G221-2 and the modified second bed layer S21B flow in countercurrent, the second inflow gas G221-2 has a high flow rate and a short residence time in region A, and the second inflow gas G221-2 and the modified second bed layer S21B do not reach equilibrium. In this embodiment, the second inflow gas reaction amount calculation unit 213-2 assumes that only a portion of the modified second bed layer S21B in region A in the rotary kiln 1 reaches equilibrium with the second inflow gas G221-2, and divides the second inflow gas G221-2 into the second inflow gas reacted portion GR222 and the remaining second inflow gas unreacted portion Gr222 according to the corresponding second inflow gas reaction amount.

The first gas region equilibrium reaction calculation unit 214-1 calculates the equilibrium reaction between the modified first gas phase G13 flowing in the first gas region in region A and the first substance M11 present in the first gas region. That is, the first gas region equilibrium reaction calculation unit 214-1 performs equilibrium reaction calculations for the first gas region using the gas reaction portion GR1 that contributes to the equilibrium reaction with the first substance M11 present in the first gas region of the modified first gas phase G13 and the first substance reaction portion MR11 that contributes to the equilibrium reaction with the first gas reaction portion GR1 of the first substance M11, and calculates at least the composition, amount, etc. of the first gas reactant GR1 and the first substance reactant MR11, and the change in the heat quantity and flow rate of each of the first gas reactant GR1 and the first substance reactant MR11 when they reach an equilibrium state.

The first gas region equilibrium reaction calculation unit 214-1 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 first gas reaction portion GR1 and the first material reaction portion MR11, 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 first gas region equilibrium reaction calculation unit 214-1 can perform equilibrium reaction calculations based on the Gibbs energy minimization method. The first gas region equilibrium reaction calculation unit 214-1 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product, etc., when the first gas reaction portion GR1 and the first material reaction portion MR11 reach an equilibrium state.

The first gas region equilibrium reaction calculation unit 214-1 calculates the product gas generated by the reaction between the first gas reaction amount GR1 and the first substance reaction amount MR11, and the unused portion of the first gas reaction amount GR1, as the first gas product amount GP1.

The first gas region equilibrium reaction calculation unit 214-1 also calculates the product material resulting from the reaction between the first gas reaction amount GR1 and the first substance reaction amount MR11, and the unused portion of the first substance reaction amount MR11, as the first substance product amount MP11.

In other words, the first gas product GP1 is a gas phase resulting from the reaction of the first gas reaction GR1 with the first substance reaction MR11, combined with the unused portion of the first gas reaction GR1. The first substance product MP11 is a gas phase resulting from the reaction of the first gas reaction GR1 with the first substance reaction MR11, combined with the unused portion of the first substance reaction MR11.

The second gas region equilibrium reaction calculation unit 214-2 calculates the equilibrium reaction between the second gas phase G22B flowing in the second gas region in region A and the second substance M21 present in the second gas region. That is, the second gas region equilibrium reaction calculation unit 214-2 performs equilibrium reaction calculation of the second gas region using the gas reaction portion GR2 that contributes to the equilibrium reaction with the second substance M21 present in the second gas region of the second gas phase G22B and the second substance reaction portion MR21 that contributes to the equilibrium reaction with the second gas reaction portion GR2 of the second substance M21, and calculates at least the composition, amount, etc. of the second gas reactant GR2 and the first substance reactant MR21, and the change in heat quantity and flow rate of each when the second gas reactant GR2 and the second substance reactant MR21 reach an equilibrium state.

The second gas region equilibrium reaction calculation unit 214-2 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 second gas reaction portion GR2 and the second material reaction portion MR21, 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 second gas region equilibrium reaction calculation unit 214-2 can perform equilibrium reaction calculations based on the Gibbs energy minimization method. The second gas region equilibrium reaction calculation unit 214-2 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product, etc., when the second gas reaction portion GR2 and the second material reaction portion MR21 reach an equilibrium state.

The second gas region equilibrium reaction calculation unit 214-2 calculates the product gas generated by the reaction between the second gas reaction amount GR2 and the second substance reaction amount MR21, and the unused portion of the second gas reaction amount GR2, as the second gas product amount GP2.

The second gas region equilibrium reaction calculation unit 214-2 calculates the product material resulting from the reaction between the second gas reaction amount GR2 and the second substance reaction amount MR21, and the unused portion of the second substance reaction amount MR21, as the second substance product amount MP21.

In other words, the second gas product GP2 is a gas phase resulting from the reaction of the second gas reaction GR2 with the second substance reaction MR21, combined with the unused portion of the second gas reaction GR2. The first substance product MP21 is a gas phase resulting from the reaction of the gas reaction GR2 with the second substance reaction MR21, combined with the unused portion of the second substance reaction MR21.

The bed layer equilibrium reaction calculation unit 215 calculates the equilibrium reaction between the bed layer in region A and the inflow gas G221.

The bed layer equilibrium reaction calculation unit 215 has a first bed layer equilibrium reaction calculation unit 215-1 and a second bed layer equilibrium reaction calculation unit 215-2.

The first bed layer equilibrium reaction calculation unit 215-1 calculates the equilibrium reaction between the modified first bed layer S13B moving through the bed layer in region A and the first inflow gas G221-1 present in the modified first bed layer S13B. That is, the first bed layer equilibrium reaction calculation unit 215-1 performs the equilibrium reaction calculation of the first bed layer using the first bed layer reaction SR1 that contributes to the equilibrium reaction with the first inflow gas G221-1 of the modified first bed layer S13B and the first inflow gas reaction GR221 that contributes to the equilibrium state with the modified first bed layer S13B. As a result, the first bed layer equilibrium reaction calculation unit 215-1 calculates at least the change in heat quantity and flow rate of each of the first bed layer reactant SR1 and the first inflow gas reactant GR221 when they reach an equilibrium state.

The first bed layer equilibrium reaction calculation unit 215-1 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 first bed layer reaction SR1 and the first inflow gas reaction GR221, 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 first bed layer equilibrium reaction calculation unit 215-1 can perform equilibrium reaction calculations based on the Gibbs energy minimization method, similar to the gas region equilibrium reaction calculation unit 213. The first bed layer equilibrium reaction calculation unit 215-1 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product, etc., when the first bed layer reaction SR1 and the first inflow gas reaction GR221 reach an equilibrium state.

The first bed layer equilibrium reaction calculation unit 215-1 calculates the product material produced by the reaction between the first bed layer reaction SR1 and the first inflow gas reaction GR221, and the unused portion of the first bed layer reaction SR1, as the first bed layer product SP1. The first bed layer equilibrium reaction calculation unit 215-1 also calculates the product gas produced by the reaction between the first bed layer reaction SR1 and the first inflow gas reaction GR221, and the unused portion of the first inflow gas reaction GR221, as the first inflow gas product GP221.

That is, the first bed layer product SP1 is the sum of the product material produced by the reaction of the first bed layer reaction SR1 with the first inflow gas reaction GR221 and the unused portion of the first bed layer reaction SR1. The first inflow gas product GP221 is the sum of the product gas produced by the reaction of the first bed layer reaction SR1 with the first inflow gas reaction GR221 and the unused portion of the first inflow gas reaction GR221.

The second bed layer equilibrium reaction calculation unit 215-2 calculates the equilibrium reaction between the modified second bed layer S21B moving through the bed layer in the region A and the second inflow gas G221-2 present in the bed layer. That is, the second bed layer equilibrium reaction calculation unit 215-2 performs equilibrium reaction calculation of the modified second bed layer S21B using the second bed layer reaction SR2 that contributes to the equilibrium reaction with the second inflow gas G221-2 of the modified second bed layer S21B and the second inflow gas reaction GR222 that contributes to the equilibrium state with the modified second bed layer S21B. This calculates at least the composition, amount, etc. of the second bed layer reactant SR2 and the second inflow gas reaction GR222, and the change in the heat quantity and flow rate of each when the second bed layer reactant SR2 and the second inflow gas reaction GR222 reach an equilibrium state.

The second bed layer equilibrium reaction calculation unit 215-2 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 second bed layer reaction SR2 and the second inflow gas reaction GR222, 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 second bed layer equilibrium reaction calculation unit 215-2 can perform equilibrium reaction calculations based on the Gibbs energy minimization method, similar to the first bed layer equilibrium reaction calculation unit 215-1. The second bed layer equilibrium reaction calculation unit 215-2 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product, etc., when the second bed layer reaction SR2 and the second inflow gas reaction GR222 reach an equilibrium state.

The second bed layer equilibrium reaction calculation unit 215-2 calculates the product material produced by the reaction between the second bed layer reaction SR2 and the second inflow gas reaction GR222, and the unused portion of the second bed layer reaction SR2, as the second bed layer product SP2. The second bed layer equilibrium reaction calculation unit 215-2 also calculates the product gas produced by the reaction between the second bed layer reaction SR2 and the second inflow gas reaction GR222, and the unused portion of the second inflow gas reaction GR222, as the second inflow gas product GP222.

In other words, the second bed layer product SP2 is the sum of the product material generated by the reaction of the second bed layer reaction SR2 with the second inflow gas reaction GR222 and the unused portion of the second bed layer reaction SR2. The second inflow gas product GP222 is the sum of the product gas generated by the reaction of the second bed layer reaction SR2 with the second inflow gas reaction GR222 and the unused portion of the first inflow gas reaction GR222.

The first mixed gas phase calculation unit 216-1 has the function of mixing multiple flows, and calculates the flow rate and composition data of the first mixed gas phase G14, which is a mixed gas phase obtained by mixing the first gas unreacted portion Gr1 separated by the first gas reaction amount calculation unit 210-1 and the first gas product portion GP1 generated by the first gas region equilibrium reaction calculation unit 214-1.

The second mixed gas phase calculation unit 216-2 has the function of mixing multiple flows, and calculates the flow rate and composition data of the second mixed gas phase G23, which is a mixed gas phase obtained by mixing the second gas unreacted portion Gr2 separated by the second gas reaction amount calculation unit 210-2 and the second gas product portion GP2 generated by the second gas region equilibrium reaction calculation unit 214-2.

The first mixed substance calculation unit 217-1 has the function of mixing multiple flows, and calculates the flow rate and composition data of the first mixed substance M12, which is a mixture of the unreacted portion of the first substance Mr11 separated by the first substance reaction amount calculation unit 211-1 and the product portion of the first substance MP11 generated by the first gas region equilibrium reaction calculation unit 214-1.

The second mixed substance calculation unit 217-2 has the function of mixing multiple flows, and calculates the flow rate and composition data of the second mixed substance M22, which is a mixture of the unreacted portion of the second substance Mr21 separated by the second substance reaction amount calculation unit 211-2 and the product portion of the second substance MP21 generated by the second gas region equilibrium reaction calculation unit 214-2.

The first mixed bed layer calculation unit 218-1 has the function of mixing multiple flows, and calculates the flow rate and composition data of the first mixed bed layer S14, which is a mixture of the first bed layer unreacted portion Sr1 separated by the first bed layer reaction amount calculation unit 212-1 and the first bed layer product portion SP1 generated by the first bed layer equilibrium reaction calculation unit 215-1.

The second mixed bed layer calculation unit 218-2 has the function of mixing multiple flows, and calculates the flow rate and composition data of the second mixed bed layer S22, which is a mixture of the second bed layer unreacted portion Sr2 separated by the second bed layer reaction amount calculation unit 212-2 and the second bed layer product portion SP2 generated by the second bed layer equilibrium reaction calculation unit 215-2.

The first mixed inflow gas calculation unit 219-1 has the function of mixing multiple flows, and calculates the flow rate and composition data of the first mixed inflow gas G222A, which is a mixture of the first inflow gas unreacted portion Gr221 separated by the first inflow gas reaction amount calculation unit 213-1 and the first inflow gas product portion GP221 generated by the first bed layer equilibrium reaction calculation unit 215-1.

The second mixed inflow gas calculation unit 219-2 has the function of mixing multiple flows, and calculates the flow rate and composition data of the second mixed inflow gas G222B, which is a mixture of the second inflow gas unreacted portion Gr222 separated by the second inflow gas reaction amount calculation unit 213-2 and the second inflow gas product portion GP222 generated by the second bed layer equilibrium reaction calculation unit 215-2.

The first mixed substance quantity correction unit 220 corrects the quantity of the first mixed substance M12 and calculates the first corrected mixed substance M13, taking into account the amount of the third substance M3 contained in the second mixed substance M23 that moves to the first mixed substance M12 that exists in the first gas region and the amount of the fourth substance M4 contained in the first mixed substance M12 that exists in the first gas region that moves to the second mixed substance M23.

The first mixed substance quantity correction unit 220 corrects the quantity of the first mixed substance M12 by adding the amount of the third substance M3 contained in the second mixed substance M23 that moves to the first mixed substance M12 that exists in the first gas region and subtracting the amount of the fourth substance M4 contained in the first mixed substance M12 that exists in the first gas region that moves to the second mixed substance M23.

The inflow gas combining unit 221 has the function of mixing multiple flows, and combines the first mixed inflow gas G222A generated in the first mixed inflow gas calculation unit 219-1 and the second mixed inflow gas G222B generated in the second mixed inflow gas calculation unit 219-2 to calculate the mixed inflow gas G223.

The gas amount summing unit 222 has the function of mixing multiple flows, and sums the second mixed gas phase G23 generated in the second mixed gas phase calculation unit 216-2 and the mixed inflow gas G223 generated in the inflow gas summing unit 221 to calculate the second combined gas phase G24.

The second mixed substance primary quantity correction unit 223 corrects the quantity of the second mixed substance M22 and calculates the second corrected mixed substance M23, taking into consideration the amount of movement of the seventh substance M7, which contains at least one of a solid substance or a liquid substance and is contained in the additive-containing first bed layer S12 generated in the first bed layer preliminary quantity correction unit 205, to the second mixed substance M22, the amount of movement of the eighth substance M8, which contains at least one of a solid substance or a liquid substance and is contained in the second mixed substance M22 generated in the second mixed substance calculation unit 217-2, to the additive-containing first bed layer S12, and the amount of movement of the ninth substance M9, which is contained in the second mixed bed layer S21 generated in the second bed layer preliminary quantity correction unit 207, to the second mixed substance M22.

The second mixed substance primary quantity correction unit 223 corrects the quantity of the second mixed substance M22 by adding the amount of the seventh substance M7 contained in the additive-containing first bed layer S12 transferred to the second mixed substance M22 and the amount of the ninth substance M9 contained in the second mixed bed layer S21 transferred to the second mixed substance M22, and subtracting the amount of the eighth substance M8 contained in the second mixed substance M22 transferred to the additive-containing first bed layer S12.

The second mixed substance secondary quantity correction unit 224 corrects the quantity of the second modified mixed substance M23 and calculates the second modified mixed substance M24, taking into consideration the amount of the third substance M3 contained in the second modified mixed substance M23 generated in the second mixed substance primary quantity correction unit 223 that moves to the first mixed substance M12 present in the first gas region and the amount of the fourth substance M4 contained in the first mixed substance M12 that moves to the second modified mixed substance M23.

The second mixed substance secondary quantity correction unit 224 corrects the quantity of the second modified mixed substance M23 by subtracting the amount of the third substance M3 contained in the second modified mixed substance M23 that has moved to the first mixed substance M12 and adding the amount of the fourth substance M4 contained in the first mixed substance M12 that has moved to the second modified mixed substance M23.

In this embodiment, at least one of the first gas region equilibrium reaction calculation unit 214-1 and the second gas region equilibrium reaction calculation unit 214-2 may be provided in two or more units. At least one of the first gas phase G11 and the second gas phase G21 is further separated into multiple gas phases, so that the gas region in the rotary kiln 1 is divided into three or more types of multiple systems.

In this embodiment, at least one of the first bed layer equilibrium reaction calculation unit 215-1 and the second bed layer equilibrium reaction calculation unit 215-2 may be provided in two or more units. At least one of the first bed layer S11 and the first bed layer S21 is further separated into multiple bed layers, so that the bed layers in the rotary kiln 1 are divided into three or more types of multiple systems.

In this embodiment, the furnace reaction calculation device 20 does not need to be equipped with a distribution section 201 if the combustion material 240 is not dropped into the rotary kiln 1.

In this embodiment, the reactor reaction calculation device 20 may not include one or more of the first bed layer preliminary quantity correction unit 205, the first bed layer quantity correction unit 206, the second bed layer preliminary quantity correction unit 207, and the second bed layer quantity correction unit 208. For example, if the reactor reaction calculation device 20 does not include the first bed layer preliminary quantity correction unit 205 and the first bed layer quantity correction unit 206, the first bed layer reaction quantity calculation unit 212-1 uses the first bed layer S12 instead of the corrected first bed layer S13B. Also, if the reactor reaction calculation device 20 does not include the second bed layer preliminary quantity correction unit 207 and the second bed layer quantity correction unit 208, the second bed layer reaction quantity calculation unit 212-2 uses the second bed layer S21 instead of the preliminary corrected second bed layer S21A.

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

<Calculation method for reactor reactions>
Next, the calculation method of the 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 240 is charged from the middle of the movement, and the raw ore is brought into contact with the combustion gas supplied from the burner 16 provided on the discharge end 14B side, thereby drying and reducing the raw ore.

Figure 5 is a flowchart explaining the method for calculating the furnace reaction according to this embodiment. As shown in Figure 5, the furnace reaction calculation device 20 checks whether the combustion material 240 has been dropped into the rotary kiln 1 (checking process: step S11).

If the combustion material 240 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, and distributes the combustion material 240 added to the rotary kiln 1 to the gas phase and the bed layer by mass flow rate using the distribution unit 201 (distribution process: step S12).

Next, the furnace reaction calculation device 20 provides as input materials the first gas phase G11, which is the combustion gas flowing into region A from one adjacent region (region (A+1)), and the added gas phase AG11, which is the gas phase of the combustion material 240 distributed by the distribution section 201. The furnace reaction calculation device 20 mixes the first gas phase G11 and the added gas phase AG11 to calculate the added content-containing first gas phase G12, which includes the first gas phase G11 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 first gas phase quantity correction unit 202 to correct the quantity of the additive-containing first gas phase G12 flowing through the first gas region, and calculates the corrected first gas phase G13 (second gas phase quantity correction process: step S14).

Next, the reactor reaction calculation device 20 uses the second gas phase quantity correction unit 203 to correct the quantity of the second gas phase G21 flowing through the second gas region, and calculates the corrected second gas phase G22A (second gas phase quantity correction process: step S15).

Next, the reactor reaction calculation device 20 uses the gas mixing amount calculation unit 204 to calculate the flow rate of the inflow gas G221 moving from the modified second gas phase G22A in the second gas region to the bed layer (gas mixing amount calculation process: step S16).

Next, the reactor reaction calculation device 20 provides as input materials the first bed layer S11, which is a bed layer of the combustion material distributed by the distribution unit 201, and the additive bed layer AS11, which is a bed layer of the combustion material distributed by the distribution unit 201, as input materials. The reactor reaction calculation device 20 mixes the first bed layer S11 and the additive bed layer AS11 to calculate the additive-containing first bed layer S12 (bed layer mixing process of the first bed layer and the additive bed layer: step S17).

Next, the reactor reaction calculation device 20 provides as input materials the first bed layer S12 containing the additive, the amount of the seventh substance M7 contained in the first bed layer S12 moving to the second mixed substance M22 present in the second gas region, and the amount of the eighth substance M8 contained in the second mixed substance M22 moving to the first bed layer S12 containing the additive.

The reactor reaction calculation device 20 corrects the quantity of the additive-containing first bed layer S12 by subtracting the amount of the seventh substance M7 contained in the additive-containing first bed layer S12 transferred to the second mixed substance M22 using the first bed layer preliminary quantity correction unit 205, and adding the amount of the eighth substance M8 contained in the second mixed substance M22 transferred to the additive-containing first bed layer S12, thereby calculating the preliminary corrected first bed layer S13A (first bed layer preliminary quantity correction process: step S18).

Next, the reactor reaction calculation device 20 provides as input materials the preliminary correction first bed layer S13A, the amount of the sixth substance M6 contained in the preliminary correction first bed layer S13A moving to the second bed layer S21A, and the fifth substance M5 in the second bed layer S21A divided by the second bed layer quantity correction unit 208.

The reactor reaction calculation device 20 uses the first bed layer quantity correction unit 206 to subtract the movement amount of the sixth substance M6 contained in the preliminary correction first bed layer S13A from the preliminary correction first bed layer S13A, and adds the movement amount of the fifth substance M5 in the second bed layer S21A divided by the second bed layer quantity correction unit 208 to the preliminary correction first bed layer S13A. As a result, the reactor reaction calculation device 20 corrects the quantity of the preliminary correction first bed layer S13A and calculates the corrected first bed layer S13B (preliminary correction first bed layer quantity correction process: step S19).

Next, the reactor reaction calculation device 20 provides the second bed layer S21 and the amount of the ninth substance M9 contained in the second bed layer S21 moving to the second mixed substance M22 present in the second gas region as input substances.

The reactor reaction calculation device 20 uses the second bed layer preliminary quantity correction unit 207 to correct the quantity of the second bed layer S21 by subtracting the amount of the ninth substance M9 contained in the second bed layer S21 that has moved to the second mixed substance M22, and calculates the preliminary corrected second bed layer S21A.

Next, the reactor reaction calculation device 20 provides as input materials the preliminary correction second bed layer S21A, the movement amount of the sixth substance M6 in the preliminary correction first bed layer S13A divided by the first bed layer quantity correction unit 206, and the movement amount of the fifth substance M5 in the preliminary correction second bed layer S21A divided by the second bed layer quantity correction unit 208.

The reactor reaction calculation device 20 uses the second bed layer quantity correction unit 208 to subtract the movement amount of the fifth substance M5 contained in the preliminary corrected second bed layer S21A from the preliminary corrected second bed layer S21A, and adds the movement amount of the sixth substance M6 divided by the first bed layer quantity correction unit 206 to the preliminary corrected second bed layer S21A. As a result, the reactor reaction calculation device 20 corrects the quantity of the preliminary corrected second bed layer S21A and calculates the corrected second bed layer S21B (second bed layer quantity correction process: step S21).

Next, the reactor reaction calculation device 20 performs the first gas region equilibrium reaction (first gas region equilibrium reaction execution process: step S22).

Next, the reactor reaction calculation device 20 performs the second gas region equilibrium reaction (step S23: carrying out the second gas region equilibrium reaction).

Next, the reactor reaction calculation device 20 performs the first bed layer equilibrium reaction (first bed layer equilibrium reaction execution process: step S24).

Next, the reactor reaction calculation device 20 performs the second bed layer equilibrium reaction (step S25: carrying out the second bed layer equilibrium reaction).

Next, the reactor reaction calculation device 20 uses the inflow gas summing unit 221 to sum the first mixed inflow gas G222A generated in the first bed layer equilibrium reaction implementation process (step S24) with the second mixed inflow gas G222B generated in the second bed layer equilibrium reaction implementation process (step S25) to obtain a mixed inflow gas G223 (inflow gas summing process: step S26).

Next, the reactor reaction calculation device 20 uses the gas amount summing unit 222 to sum the second mixed gas phase G23 generated in the second gas region equilibrium reaction implementation step (step S19) with the mixed inflow gas G223 generated in the inflow gas summing step (step S26) to obtain a second combined gas phase G24 (gas amount summing step: step S27).

The furnace reaction calculation device 20 moves the second combined gas phase G24 to a region (region (A-1)) closer to the charging end 14A than region A.

Next, the reactor reaction calculation device 20 corrects the quantity of the first mixed substance M12 by subtracting the amount of the fourth substance M4 contained in the first mixed substance M12 that moves to the second gas region, which occurs in the first gas region equilibrium reaction implementation process (step S19), and adding the amount of the third substance M3 contained in the second mixed substance M23 that moves to the first mixed substance M12, using the first mixed substance quantity correction unit 220, to calculate the first corrected mixed substance M13 (first mixed substance quantity correction process: step S28).

The furnace reaction calculation device 20 moves the first modified mixed material M13 to a region (region (A-1)) closer to the charging end 14A than region A.

Next, the reactor reaction calculation device 20 uses the second mixed substance primary quantity correction unit 223 to add the amount of the seventh substance M7 contained in the additive-containing first bed layer S12 transferred to the second mixed substance M22 generated in the correction process (step S16) of the preliminary quantity of the first bed layer, and the amount of the ninth substance M9 contained in the second mixed bed layer S21 transferred to the second mixed substance M22 generated in the second bed layer preliminary quantity correction unit 207, and subtract the amount of the eighth substance M8 contained in the second mixed substance M22 transferred to the additive-containing first bed layer S12 generated in the implementation process (step S25) of the second bed layer equilibrium reaction. As a result, the reactor reaction calculation device 20 corrects the quantity of the second mixed substance M22 and calculates the second corrected mixed substance M23 (second mixed substance primary quantity preliminary correction process: step S29).

Next, the reactor reaction calculation device 20 uses the second mixed substance secondary quantity correction unit 224 to subtract the transfer amount of the third substance M3 contained in the second corrected mixed substance M23 generated in the second mixed substance quantity preliminary correction process (step S29) to the first mixed substance M12, and add the transfer amount of the fourth substance M4 contained in the first mixed substance M12 generated in the first mixed substance quantity correction process (step S28) to the second corrected mixed substance M23 to correct the quantity of the second corrected mixed substance M23 and calculate the second corrected mixed substance M24 (second mixed substance secondary quantity correction process: step S30).

The furnace reaction calculation device 20 moves the second modified mixed material M24 to a region (region (A-1)) closer to the charging end 14A than region A.

Next, the first gas region equilibrium reaction implementation step (step S22) will be described. FIG. 6 is a flowchart showing the operation of the first gas region equilibrium reaction implementation step (step S22) in FIG. 5. As shown in FIG. 6, in the first gas region equilibrium reaction implementation step (step S22), the reactor reaction calculation device 20 uses the first gas reaction amount calculation unit 210-1 to calculate the first gas reaction amount that contributes to the equilibrium state of the modified first gas phase G13 with the first substance M11 (first gas reaction amount calculation step: step S221).

In other words, the furnace reaction calculation device 20 calculates the amount of gas reaction that contributes to the reaction when the modified first gas phase G13 reacts with the first substance M11 present in the first gas region to reach an equilibrium state, assuming that the modified first gas phase G13 reacts with the first substance M11 present in the first gas region to reach an equilibrium state.

Then, based on the calculation result of the first gas reaction amount, the furnace reaction calculation device 20 divides it into a first gas reaction amount GR1 corresponding to the first gas reaction amount and a first gas unreacted amount Gr1 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 uses the first substance reaction amount calculation unit 211-1 to calculate the first substance reaction amount that contributes to the equilibrium state with the modified first gas phase G13 from the first substance M11 present in the first gas region (first substance reaction amount calculation process: step S222).

In other words, the furnace reaction calculation device 20 calculates the amount of reaction of the first substance that contributes to the reaction when the first substance M11 present in the first gas region reacts with the modified first gas phase G13 to reach an equilibrium state, assuming that the first substance M11 present in the first gas region reacts with the modified first gas phase G13 to reach an equilibrium state.

Then, based on the calculation result of the amount of reaction of the first substance, the reactor reaction calculation device 20 divides the amount of reaction of the first substance into a reacted amount of the first reactant MR11 corresponding to the amount of reaction of the first substance and an unreacted amount of the first substance Mr11 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 provides the first gas reaction amount GR1 obtained in the first gas reaction amount calculation step (step S221) and the first substance reaction amount MR11 obtained in the first substance reaction amount calculation step (step S222) as input materials. The reactor reaction calculation device 20 uses the first gas region equilibrium reaction calculation unit 214-1 to calculate the equilibrium reaction between the first gas reaction amount GR1 and the first substance reaction amount MR11, and calculates at least the change in heat quantity and flow rate of each of the first gas reaction amount GR1 and the first substance reaction amount MR11 when they reach equilibrium (first gas region equilibrium reaction calculation step: step S223).

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

The furnace reaction calculation device 20 calculates the gas phase produced by the reaction between the first gas reaction amount GR1 and the first substance reaction amount MR11 and the unused portion of the first gas reaction amount GR1 as the first gas product amount GP1, and calculates the product material produced by the reaction between the first gas reaction amount GR1 and the first substance reaction amount MR11 and the unused portion of the first substance reaction amount MR11 as the first substance product amount MP11.

Next, the reactor reaction calculation device 20 provides the first gas unreacted portion Gr1 obtained in the first gas reaction amount calculation step (step S221) and the first gas generated portion GP1 obtained in the first gas region equilibrium reaction calculation step (step S223) as input materials. The reactor reaction calculation device 20 uses the first mixed gas phase calculation unit 216-1 to calculate the flow rate, composition data, etc. of the first mixed gas phase G14 containing the first gas unreacted portion Gr1 and the first gas generated portion GP1 (first mixed gas phase calculation step: step S224).

The first gas reaction amount GR1 calculated in the first gas reaction amount calculation process (step S221) is the reaction amount when it is assumed that the first mixture phase G13 and the first substance M11 have reached equilibrium, and therefore is normally all used. However, the first gas reaction amount GR1, which is a gas phase, may contain substances that exist in an amount 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 first mixture phase calculation process (step S223), there are substances that exist in an amount 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 first gas region equilibrium reaction calculation unit 214-1 is calculated as the gas production amount GP1.

Next, the reactor reaction calculation device 20 provides the first substance unreacted portion Mr11 obtained in the first substance reaction amount calculation step (step S222) and the first substance product portion MP11 obtained in the first gas region equilibrium reaction calculation step (step S223) as input materials. The reactor reaction calculation device 20 uses the first mixed material calculation unit 217-1 to calculate the flow rate, composition data, etc. of the first mixed material M12 obtained by mixing the first substance unreacted portion Mr11 and the first substance product portion MP11 (first mixed material calculation step: step S225).

Next, the second gas region equilibrium reaction implementation step (step S23) will be described. FIG. 7 is a flowchart showing the operation of the second gas region equilibrium reaction implementation step (step S23) in FIG. 5. As shown in FIG. 7, in the second gas region equilibrium reaction implementation step (step S23), the reactor reaction calculation device 20 uses the second gas reaction amount calculation unit 210-2 to calculate the second gas reaction amount that contributes to the equilibrium state with the second substance M21 of the adjusted second gas phase G22B (second gas reaction amount calculation step: step S231).

In other words, the furnace reaction calculation device 20 calculates the amount of second gas reaction that contributes to the reaction when the adjusted second gas phase G22B reacts with the second substance M21 present in the second gas region to reach an equilibrium state, assuming that the adjusted second gas phase G22B reacts with the second substance M21 present in the second gas region to reach an equilibrium state.

Then, based on the calculation result of the second gas reaction amount, the reactor reaction calculation device 20 divides it into a second gas reaction amount GR2 corresponding to the second gas reaction amount and a second gas unreacted amount Gr2 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 uses the second material reaction amount calculation unit 211-2 to calculate the second material reaction amount of the second material M21 present in the second gas region that contributes to the equilibrium state with the adjusted second gas phase G22B (second material reaction amount calculation process: step S232).

In other words, the furnace reaction calculation device 20 calculates the amount of reaction of the second substance that contributes to the reaction when the second substance M21 present in the second gas region reacts with the adjusted second gas phase G22B to reach an equilibrium state, assuming that the second substance M21 present in the second gas region reacts with the adjusted second gas phase G22B to reach an equilibrium state.

Then, based on the calculation result of the reaction amount of the second substance, the reactor reaction calculation device 20 divides it into a reacted portion of the second reactant MR21 corresponding to the reacted amount of the second substance and an unreacted portion of the second substance Mr21 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 provides the second gas reaction amount GR2 obtained in the second gas reaction amount calculation step (step S231) and the second material reaction amount MR21 obtained in the second material reaction amount calculation step (step S232) as input materials. The reactor reaction calculation device 20 uses the second gas region equilibrium reaction calculation unit 214-2 to calculate the equilibrium reaction between the second gas reaction amount GR2 and the second material reaction amount MR21, and calculates at least the change in heat quantity and flow rate of each of the second gas reaction amount GR2 and the second material reaction amount MR21 when they reach equilibrium (second gas region equilibrium reaction calculation step: step S233).

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

The furnace reaction calculation device 20 calculates the gas phase produced by the reaction between the second gas reaction amount GR2 and the second substance reaction amount MR21 and the unused portion of the second gas reaction amount GR2 as the second gas product amount GP2, and calculates the product material produced by the reaction between the second gas reaction amount GR2 and the second substance reaction amount MR21 and the unused portion of the second substance reaction amount MR21 as the second substance product amount MP21.

Next, the reactor reaction calculation device 20 provides the second gas unreacted portion Gr2 obtained in the second gas reaction amount calculation step (step S231) and the second gas generated portion GP2 obtained in the second gas region equilibrium reaction calculation step (step S233) as input materials. The reactor reaction calculation device 20 uses the second mixed gas phase calculation unit 216-2 to calculate the flow rate, composition data, etc. of the second mixed gas phase G23 containing the second gas unreacted portion Gr2 and the second gas generated portion GP2 (second mixed gas phase calculation step: step S234).

The second gas reaction amount GR2 calculated in the second gas reaction amount calculation process (step S231) is the reaction amount when it is assumed that the second mixture phase G21 and the second substance M21 have reached an equilibrium state, and therefore is normally used in its entirety. However, the second gas reaction amount GR2, which is a gas phase, may contain substances that exist in an amount 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 second mixture phase calculation process (step S233), substances that exist in an amount greater than the stoichiometric ratio of the reaction and that result in the existence of inactive substances or substances that remain after the equilibrium reaction exist. The unused portion that remains unused in the second gas region equilibrium reaction calculation unit 214-2 is calculated as the gas production amount GP2.

Next, the reactor reaction calculation device 20 provides the unreacted portion of the second substance Mr21 obtained in the second substance reaction amount calculation step (step S232) and the second substance product portion MP21 obtained in the second gas region equilibrium reaction calculation step (step S233) as input materials. The reactor reaction calculation device 20 uses the second mixed material calculation unit 217-2 to calculate the flow rate, composition data, etc. of the second mixed material M22 obtained by mixing the unreacted portion of the second substance Mr21 and the second substance product portion MP21 (second mixed material calculation step: step S235).

Next, the first bed layer equilibrium reaction implementation process (step S24) will be described. FIG. 8 is a flowchart showing the operation of the first bed layer equilibrium reaction implementation process (step S24) in FIG. 5. As shown in FIG. 8, in the first bed layer equilibrium reaction implementation process (step S24), the reactor reaction calculation device 20 uses the first bed layer reaction amount calculation unit 212-1 to calculate the first bed layer reaction amount that contributes to the equilibrium state with the first inflow gas reaction amount GR221 in the corrected first bed layer S13B (first bed layer reaction amount calculation process: step S241).

In other words, the furnace reaction calculation device 20 calculates the amount of first bed layer reaction that contributes to the reaction when the modified first bed layer S13B reacts with the first inflow gas G221-1 to reach an equilibrium state, assuming that the modified first bed layer S13B and the first inflow gas G221-1 react to reach an equilibrium state.

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

Next, the reactor reaction calculation device 20 uses the first inflow gas reaction amount calculation unit 213-1 to calculate the first inflow gas reaction amount of the first inflow gas G221-1 that contributes to the equilibrium state with the modified first bed layer S13B (first inflow gas reaction amount calculation process: step S242).

In other words, the furnace reaction calculation device 20 calculates the amount of first inflow gas reaction that contributes to the reaction when the first inflow gas G221-1 reacts with the modified first bed layer S13B to reach an equilibrium state, assuming that the first inflow gas G221-1 reacts with the modified first bed layer S13B to reach an equilibrium state.

Then, based on the calculation result of the first inflow gas reaction amount, the furnace reaction calculation device 20 divides it into a first inflow gas reaction amount GR221 corresponding to the first inflow gas reaction amount and a first inflow gas unreacted amount Gr221 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 provides the first bed layer reaction amount SR1 obtained in the first bed layer reaction amount calculation step (step S241) and the first inflow gas reaction amount GR221 obtained in the first inflow gas reaction amount calculation step (step S202) as input materials. The reactor reaction calculation device 20 uses the first bed layer equilibrium reaction calculation unit 215-1 to calculate the equilibrium reaction between the first bed layer reaction amount SR1 and the first inflow gas reaction amount GR221, and calculates at least the change in heat quantity and flow rate of each of the first bed layer reaction amount SR1 and the first inflow gas reaction amount GR221 when they reach equilibrium (first bed layer equilibrium reaction calculation step S203).

The furnace reaction calculation device 20 calculates the bed layer generated by the reaction of the first bed layer reaction portion SR1 with the first inflow gas reaction portion GR221 and the unused portion of the first bed layer reaction portion SR1 as the first bed layer product portion SP1. The furnace reaction calculation device 20 also calculates the unused portion of the first inflow gas reaction portion GR221 generated by the reaction of the first bed layer reaction portion SR1 with the first inflow gas reaction portion GR221 as the first inflow gas product portion GP221.

Next, the reactor reaction calculation device 20 provides the first bed layer unreacted portion Sr1 obtained in the first bed layer reaction amount calculation step (step S241) and the first bed layer product portion SP1 obtained in the first bed layer equilibrium reaction calculation step (step S243) as input materials. The reactor reaction calculation device 20 uses the first bed layer equilibrium reaction calculation unit 215-1 to calculate the flow rate, composition data, etc. of the additive-containing first bed layer S14, which contains the first bed layer unreacted portion Sr1 and the first bed layer product portion SP1 (first mixed bed layer calculation step: step S244).

The first bed layer reaction amount SR1 of the first bed layer calculated in the first bed layer reaction amount calculation step (step S241) may contain substances that are present in an amount greater than the stoichiometric ratio of the reaction and inactive substances that do not contribute to the reaction. In the first mixed bed layer calculation step (step S244), the portion of the first bed layer reaction amount SR1 that is present in an amount greater than the stoichiometric ratio of the reaction and is not used in the reaction as a result, and the inactive portion are calculated by including them in the first bed layer product amount SP1 as the unused portion that remains unused in the first bed layer equilibrium reaction calculation step (step S243).

The reactor reaction calculation device 20 moves the first mixed bed layer S14 to a region (region (A+1)) closer to the discharge end 14B than region A.

Next, the furnace reaction calculation device 20 provides the first inflow gas unreacted portion Gr221 obtained in the first inflow gas reaction amount calculation step (step S222) and the first inflow gas product portion GP221 obtained in the first bed layer equilibrium reaction calculation step (step S233) as input materials. The furnace reaction calculation device 20 uses the first mixed inflow gas calculation unit 219-1 to calculate the flow rate, composition data, etc. of the first mixed inflow gas G222A containing the first inflow gas unreacted portion Gr221 and the first inflow gas product portion GP221 (first mixed inflow gas calculation step: step S205).

Next, the second bed layer equilibrium reaction implementation process (step S21) will be described. FIG. 9 is a flowchart showing the operation of the second bed layer equilibrium reaction implementation process (step S21) in FIG. 5. As shown in FIG. 9, in the second bed layer equilibrium reaction implementation process (step S25), the reactor reaction calculation device 20 uses the second bed layer reaction amount calculation unit 212-2 to calculate the second bed layer reaction amount that contributes to the equilibrium state with the second inflow gas reaction amount GR222 of the corrected second bed layer S21B (second bed layer reaction amount calculation process: step S251).

In other words, the reactor reaction calculation device 20 calculates the amount of second bed layer reaction that contributes to the reaction when the modified second bed layer S21B reacts with the second inflow gas G221-2 to reach an equilibrium state, assuming that the modified second bed layer S21B and the second inflow gas G221-2 react to reach an equilibrium state.

Then, based on the calculation result of the second bed layer reaction amount, the reactor reaction calculation device 20 divides it into a second bed layer reaction amount SR2 corresponding to the second bed layer reaction amount and a second bed layer unreacted amount Sr2 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 uses the second inflow gas reaction amount calculation unit 213-2 to calculate the second inflow gas reaction amount of the second inflow gas G221-2 that contributes to the equilibrium state with the modified second bed layer S21B (second inflow gas reaction amount calculation process: step S252).

In other words, the furnace reaction calculation device 20 calculates the amount of second inflow gas reaction that contributes to the reaction when the second inflow gas G221-2 reacts with the modified second bed layer S21B to reach an equilibrium state, assuming that the second inflow gas G221-2 reacts with the modified second bed layer S21B to reach an equilibrium state.

Then, based on the calculation result of the second inflow gas reaction amount, the furnace reaction calculation device 20 divides it into a second inflow gas reaction amount GR222 corresponding to the second inflow gas reaction amount and a second inflow gas unreacted amount Gr222 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 provides the second bed layer reaction amount SR2 obtained in the second bed layer reaction amount calculation step (step S251) and the second inflow gas reaction amount GR222 obtained in the second inflow gas reaction amount calculation step (step S252) as input materials. The reactor reaction calculation device 20 uses the second bed layer equilibrium reaction calculation unit 215-2 to calculate the equilibrium reaction between the second bed layer reaction amount SR2 and the second inflow gas reaction amount GR222, and calculates at least the change in heat quantity and flow rate of each of the second bed layer reaction amount SR2 and the second inflow gas reaction amount GR222 when they reach equilibrium (second bed layer equilibrium reaction calculation step: step S253).

The furnace reaction calculation device 20 calculates the bed layer generated by the reaction between the second bed layer reaction portion SR2 and the second inflow gas reaction portion GR222 and the unused portion of the second bed layer reaction portion SR2 as the second bed layer product portion SP2. The furnace reaction calculation device 20 also calculates the unused portion of the second inflow gas reaction portion GR222 generated by the reaction between the second bed layer reaction portion SR2 and the second inflow gas reaction portion GR222 as the second inflow gas product portion GP222.

Next, the reactor reaction calculation device 20 provides the second bed layer unreacted portion Sr2 obtained in the second bed layer reaction amount calculation step (step S251) and the second bed layer product portion SP2 obtained in the second bed layer equilibrium reaction calculation step (step S253) as input materials. The reactor reaction calculation device 20 uses the second bed layer equilibrium reaction calculation unit 215-2 to calculate the flow rate, composition data, etc. of the second mixed bed layer S22 containing the second bed layer unreacted portion Sr2 and the second bed layer product portion SP2 (second mixed bed layer calculation step: step S254).

The second bed layer reaction amount SR2 of the second bed layer calculated in the second bed layer reaction amount calculation process (step S251) may contain substances that are present in an amount greater than the stoichiometric ratio of the reaction and inactive substances that do not contribute to the reaction. In the second mixed bed layer calculation process (step S254), the second bed layer reaction amount SR2 contains a portion that is present in an amount 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 second bed layer equilibrium reaction calculation process (step S253) is calculated as the second bed layer product amount SP2.

The reactor reaction calculation device 20 moves the second mixed bed layer S22 to a region (region (A+1)) closer to the discharge end 14B than region A.

Next, the reactor reaction calculation device 20 provides the second inflow gas unreacted portion Gr222 obtained in the second inflow gas reaction amount calculation step (step S252) and the second inflow gas product portion GP222 obtained in the second bed layer equilibrium reaction calculation step (step S253) as input materials. The reactor reaction calculation device 20 uses the second mixed inflow gas calculation unit 219-2 to calculate the flow rate, composition data, etc. of the second mixed inflow gas G222B containing the second inflow gas unreacted portion Gr222 and the second inflow gas product portion GP222 (second mixed inflow gas calculation step: step S255).

In addition, in the method of calculating the furnace reaction according to this embodiment, each step may be performed in parallel or the order of the steps may be changed as appropriate.

For example, the method for calculating the furnace reaction according to this embodiment may perform in parallel at least one of the steps of carrying out the first gas region equilibrium reaction (step S22), the step of carrying out the second gas region equilibrium reaction (step S23), the step of carrying out the first bed layer equilibrium reaction (step S24), and the step of carrying out the second bed layer equilibrium reaction (step S25) shown in FIG. 5.

In the method for calculating the furnace reaction according to this embodiment, the inflow gas summing process (step S26) and the first mixed substance amount correction process (step S28) shown in FIG. 5 may be performed in parallel, or the inflow gas summing process (step S26) may be performed after the first mixed substance amount correction process (step S28).

In the method for calculating the furnace reaction according to this embodiment, the gas amount summing step (step S27) and the first mixed substance amount correction step (step S28) shown in FIG. 5 may be performed in parallel, or the gas amount summing step (step S27) may be performed after the first mixed substance amount correction step (step S28).

In the method for calculating the reaction in the furnace according to this embodiment, the first gas reaction amount calculation step (step S221) and the first substance reaction amount calculation step (step S222) shown in FIG. 6 may be performed in parallel, or the first gas reaction amount calculation step (step S221) may be performed after the first substance reaction amount calculation step (step S222).

In the method for calculating the furnace reaction according to this embodiment, the first mixed gas phase calculation step (step S224) and the first mixed substance calculation step (step S225) shown in FIG. 6 may be performed in parallel, or the first mixed gas phase calculation step (step S224) may be performed after the first mixed substance calculation step (step S225).

In the method of calculating the furnace reaction according to this embodiment, the second gas reaction amount calculation step (step S231) and the second substance reaction amount calculation step (step S232) shown in FIG. 7 may be performed in parallel, or the second gas reaction amount calculation step (step S231) may be performed after the second substance reaction amount calculation step (step S232).

In the method for calculating the furnace reaction according to this embodiment, the second mixed gas phase calculation step (step S234) and the second mixed substance calculation step (step S235) shown in FIG. 7 may be performed in parallel, or the second mixed gas phase calculation step (step S234) may be performed after the second mixed substance calculation step (step S235).

In the method for calculating the furnace reaction according to this embodiment, the first bed layer reaction amount calculation step (step S241) and the first inflow gas reaction amount calculation step (step S242) shown in FIG. 8 may be performed in parallel, or the first bed layer reaction amount calculation step (step S241) may be performed after the first inflow gas reaction amount calculation step (step S242).

In the method for calculating the furnace reaction according to this embodiment, the first mixed bed layer calculation step (step S244) and the first mixed inflow gas calculation step (step S245) shown in FIG. 8 may be performed in parallel, or the first mixed bed layer calculation step (step S244) may be performed after the first mixed inflow gas calculation step (step S245).

In the method for calculating the furnace reaction according to this embodiment, the second bed layer reaction amount calculation step (step S251) and the second inflow gas reaction amount calculation step (step S252) shown in FIG. 9 may be performed in parallel, or the second bed layer reaction amount calculation step (step S251) may be performed after the second inflow gas reaction amount calculation step (step S252).

In the method for calculating the furnace reaction according to this embodiment, the second mixed bed layer calculation step (step S254) and the second mixed inflow gas calculation step (step S255) shown in FIG. 9 may be performed in parallel, or the second mixed bed layer calculation step (step S254) may be performed after the second mixed inflow gas calculation step (step S255).

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. 10 is a hardware configuration diagram of the reactor reaction calculation device. As shown in FIG. 10, the reactor reaction calculation device 20 is composed of, for example, 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 material 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. 10 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 material 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 first gas phase quantity correction step of correcting a quantity of a first gas phase flowing through one of two gas regions, which are divided according to a gas region influence factor including a generated gas generated from a bed layer including the raw material ore, among the gas regions including the combustion gas, to obtain a corrected first gas phase;
a second gas phase amount correction step of correcting an amount of the second gas phase flowing through the other second gas region of the two gas regions to obtain a corrected second gas phase;
a gas mixing amount calculation step of calculating a flow rate of an inlet gas moving from the second gas region to the bed layer;
a first gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the modified first gas phase and a first substance present in the first gas region among substances including at least one of a solid substance and a liquid substance present in the gas region;
a second gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the modified second gas phase and a second substance present in the second gas region among the substances;
a bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the bed layer and the inflow gas;
A program for causing a computer to execute at least the above can be used.

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 first gas phase quantity correction unit 202, a second gas phase quantity correction unit 203, a gas mixture amount calculation unit 204, a first gas region equilibrium reaction calculation unit 214-1, and a second gas region equilibrium reaction calculation unit 214-2. The reactor reaction calculation device 20 corrects the quantities of the additive-containing first gas phase G12 and second gas phase G21 in the first gas phase quantity correction unit 202 and second gas phase quantity correction unit 203, respectively, and then calculates the flow rate of the inflow gas G221 moving from the corrected second gas phase G22A in the second gas region to the bed layer in the gas mixture amount calculation unit 204. Then, the reactor reaction calculation device 20 calculates the equilibrium reaction between the modified first gas phase G13 and the first substance M11 in the first gas region equilibrium reaction calculation unit 214-1, and calculates the equilibrium reaction between the adjusted second gas phase G22B and the second substance M21 in the second gas region equilibrium reaction calculation unit 214-2.

The first gas phase G11 present in the first gas region is a gas phase that contains almost no reactive gas, dust, etc. generated from the bed layer, even within the gas region, and the second gas phase G21 present in the second gas region is a gas phase that contains a large amount of reactive gas, dust, etc., even within the gas region. The furnace reaction calculation device 20 divides the gas region into two regions (first gas region, second gas region) according to the proportion affected by reactive gas, dust, etc. generated from the bed layer, and performs equilibrium reaction calculations for each, thereby making it possible to calculate equilibrium reactions with higher accuracy according to the characteristics of each gas region.

Therefore, the calculation device 20 of the reaction in the furnace divides the gas region in the reactor into two series, the first gas region and the second gas region, and can calculate the equilibrium reaction between the modified first gas phase G13 and the first substance M11 flowing in each region and the equilibrium reaction between the adjusted second gas phase G22B and the second substance M21 based on the Gibbs energy minimization method. As a result, the calculation device 20 of the reaction in the furnace can calculate the equilibrium reaction occurring in the gas region in the two types of gas regions in the rotary kiln 1, taking into account the influence of the post-reaction gas, dust, etc. generated from the bed layer. In addition, the influence of the post-reaction gas, etc. from the bed layer that exists in high concentration near the bed layer can be taken into account when calculating without requiring huge calculation resources. Therefore, the calculation device 20 of the reaction in the furnace can calculate the equilibrium reaction in the gas region with high accuracy without imposing a large burden.

In addition, the furnace reaction calculation device 20 can calculate the equilibrium reaction between the bed layer and the inflow gas G221 from the second gas region in the bed layer equilibrium reaction calculation unit 215, thereby calculating the equilibrium reaction between the bed layer and the inflow gas G221 mixed in from the second gas region. This allows the furnace reaction calculation device 20 to calculate the equilibrium reaction between the bed layer and the inflow gas G221 from the second gas region based on the Gibbs energy minimization method. Therefore, the furnace reaction calculation device 20 can calculate the equilibrium reaction occurring in the bed layer with high accuracy, taking into account the influence of the bed layer post-reaction gas (for example, the reaction gas generated when the bed layer undergoes an equilibrium reaction with the gas flowing in from the gas region or the bed layer in the bed layer) that exists in high concentration near the bed layer in the rotary kiln 1.

The furnace reaction calculation device 20 can therefore calculate the reactions occurring in the rotary kiln 1 with high precision. The furnace reaction calculation device 20 can calculate the furnace reactions occurring in the rotary kiln 1 under conditions close to those in an actual furnace while reducing the burden required for calculations, so that an analysis closer to the conditions in an actual furnace can be performed with a low load.

The reactor reaction calculation device 20 can include a first gas reaction amount calculation unit 210-1 and a first substance reaction amount calculation unit 211-1. As a result, the reactor reaction calculation device 20 can calculate the first gas reaction amount GR1 that contributes to the equilibrium reaction of the modified first gas phase G13 in the first gas reaction amount calculation unit 210-1, and can calculate the first substance reaction amount MR11 that contributes to the equilibrium reaction of the first substance M11 in the first substance reaction amount calculation unit 211-1. Therefore, the reactor reaction calculation device 20 can reliably perform equilibrium reaction calculation between the modified first gas phase G13 and the first substance M11 in the first gas region equilibrium reaction calculation unit 214-1 using the modified first gas phase G13 and first substance M11 required for the reaction.

The furnace reaction calculation device 20 can include a first mixed gas phase calculation unit 216-1 and a first mixed substance calculation unit 217-1. This allows the furnace reaction calculation device 20 to at least calculate the flow rate of the first mixed gas phase G14, which is a mixture of the first gas unreacted portion Gr1 and the first gas product GP1, in the first mixed gas phase calculation unit 216-1. The furnace reaction calculation device 20 can at least calculate the flow rate of the first mixed substance M12, which is a mixture of the first substance unreacted portion Mr11 and the first substance product MP11, in the first mixed substance calculation unit 217-1. This allows the furnace reaction calculation device 20 to more accurately calculate the amount of movement of the first gas phase G11 and the first substance M11 to the charging end 14A.

The reactor reaction calculation device 20 can include a second gas reaction amount calculation unit 210-2 and a second substance reaction amount calculation unit 211-2. As a result, the reactor reaction calculation device 20 can calculate the second gas reaction amount GR2 that contributes to the equilibrium reaction of the adjusted second gas phase G22B in the second gas reaction amount calculation unit 210-2, and can calculate the first substance reaction amount MR21 that contributes to the equilibrium reaction of the second substance M21 in the second substance reaction amount calculation unit 211-2. Therefore, the reactor reaction calculation device 20 can reliably perform equilibrium reaction calculation between the adjusted second gas phase G22B and the second substance M21 in the second gas region equilibrium reaction calculation unit 214-2 using the adjusted second gas phase G22B and second substance M21 required for the reaction.

The furnace reaction calculation device 20 can include a second mixed gas phase calculation unit 216-2 and a second mixed substance calculation unit 217-2. This allows the furnace reaction calculation device 20 to at least calculate the flow rate of the second mixed gas phase G23, which is a mixture of the unreacted gas portion Gr2 and the gas product portion GP2, in the second mixed gas phase calculation unit 216-2. The furnace reaction calculation device 20 can at least calculate the flow rate of the second mixed substance M22, which is a mixture of the unreacted second substance portion Mr21 and the product of the second substance MP21, in the second mixed substance calculation unit 217-2. This allows the furnace reaction calculation device 20 to more accurately calculate the amount of movement of the second gas phase G21 and the second substance M21 to the charging end 14A.

The furnace reaction calculation device 20 may include a first mixed substance amount correction unit 220. This allows the furnace reaction calculation device 20 to calculate the first modified mixed substance M13 by subtracting the amount of the fourth substance M4 contained in the first mixed substance M12 present in the gas region from the amount of the fourth substance M4 that moves to the second gas region, and adding the amount of the third substance M3 that moves to the first mixed substance M12 and is present in the second modified mixed substance M23 in the second gas region. Therefore, the furnace reaction calculation device 20 can accurately calculate the amount of the first substance M11 that has entered the region A that moves to the region (A-1).

The furnace reaction calculation device 20 includes an inflow gas distribution unit 209, and the bed layer equilibrium reaction calculation unit 215 can include a first bed layer equilibrium reaction calculation unit 215-1 and a second bed layer equilibrium reaction calculation unit 215-2. The furnace reaction calculation device 20 distributes the inflow gas G221 into the first inflow gas G221-1 and the second inflow gas G221-2 in the inflow gas distribution unit 209. The furnace reaction calculation device 20 can then calculate the equilibrium reaction between the modified first bed layer S13B and the first inflow gas G221-1 in the first bed layer equilibrium reaction calculation unit 215-1, and calculate the equilibrium reaction between the modified second bed layer S21B and the second inflow gas G221-2 in the second bed layer equilibrium reaction calculation unit 215-2. This allows the furnace reaction calculation device 20 to calculate the equilibrium reaction between the first and second bed layers that occur in the bed layers and the inflow gas G221, making it possible to more accurately calculate the equilibrium reaction between the bed layers in the rotary kiln 1 and the inflow gas G221.

The reactor reaction calculation device 20 can include a first bed layer reaction amount calculation unit 212-1 and a first inflow gas reaction amount calculation unit 213-1. As a result, the reactor reaction calculation device 20 can calculate the first bed layer reaction amount SR1 that contributes to the equilibrium reaction from the corrected first bed layer S13B in the first bed layer reaction amount calculation unit 212-1, and can calculate the first inflow gas reaction amount GR221 that contributes to the equilibrium reaction from the first inflow gas G221-1 in the first inflow gas reaction amount calculation unit 213-1. Therefore, the reactor reaction calculation device 20 can reliably perform equilibrium reaction calculation between the corrected first bed layer S13B and the first inflow gas G221-1 in the first bed layer equilibrium reaction calculation unit 215-1 using the first bed layer reaction amount SR1 and the first inflow gas reaction amount GR221 required for the reaction.

The furnace reaction calculation device 20 can include a first mixed bed layer calculation unit 218-1 and a first mixed inflow gas calculation unit 219-1. As a result, the furnace reaction calculation device 20 can at least calculate the flow rate of the first mixed bed layer S14, which is a mixture of the first bed layer unreacted portion Sr1 and the first bed layer product SP1, in the first mixed bed layer calculation unit 218-1. The furnace reaction calculation device 20 can at least calculate the flow rate of the first mixed inflow gas G222A, which is a mixture of the first inflow gas unreacted portion Gr221 and the first inflow gas product GP221, in the first mixed inflow gas calculation unit 219-1. As a result, the furnace reaction calculation device 20 can accurately calculate the amount of movement of the first mixed bed layer S14 to the discharge end 14B and can accurately calculate the amount of movement of the first inflow gas G221-1.

The reactor reaction calculation device 20 can include a second bed layer reaction amount calculation unit 212-2 and a second inflow gas reaction amount calculation unit 213-2. This allows the reactor reaction calculation device 20 to calculate the second bed layer reaction amount SR2 that contributes to the equilibrium reaction from the modified second bed layer S21B in the second bed layer reaction amount calculation unit 212-2. Also, the reactor reaction calculation device 20 can obtain the second inflow gas reaction amount GR222 that contributes to the equilibrium reaction from the second inflow gas G221-2 in the second inflow gas reaction amount calculation unit 213-2. Therefore, the reactor reaction calculation device 20 can reliably perform the equilibrium reaction calculation between the modified second bed layer S21B and the inflow gas G221-2 in the second bed layer equilibrium reaction calculation unit 215-2 using the second bed layer reaction amount SR2 and the second inflow gas reaction amount GR222 required for the reaction.

The furnace reaction calculation device 20 can include a second mixed bed layer calculation unit 218-2 and a second mixed inflow gas calculation unit 219-2. As a result, the furnace reaction calculation device 20 can at least calculate the flow rate of the second mixed bed layer S22, which is a mixture of the second bed layer unreacted portion Sr2 and the second bed layer product SP2, in the second mixed bed layer calculation unit 218-2. Also, the furnace reaction calculation device 20 can at least calculate the flow rate of the second mixed inflow gas G222B, which is a mixture of the second inflow gas unreacted portion Gr222 and the second inflow gas product GP222, in the second mixed inflow gas calculation unit 219-2. As a result, the furnace reaction calculation device 20 can accurately calculate the amount of movement of the second mixed bed layer S22 to the discharge end 14B and the amount of movement of the second inflow gas G221-2.

The reactor reaction calculation device 20 can include a first bed layer preliminary quantity correction unit 205. In this way, the reactor reaction calculation device 20 can correct the quantity of the additive-containing first bed layer S12 by subtracting the amount of the seventh substance M7 contained in the additive-containing first bed layer S12 transferred to the second mixed substance M22 in the second gas region in the first bed layer preliminary quantity correction unit 205 and adding the amount of the eighth substance M8 contained in the second mixed substance M22 transferred to the additive-containing first bed layer S12, thereby calculating the preliminary correction first bed layer S13A. Therefore, the reactor reaction calculation device 20 can accurately determine the first bed layer reaction quantity SR1 used in the first bed layer equilibrium reaction calculation unit 215-1. Therefore, the reactor reaction calculation device 20 can more accurately perform the first bed layer equilibrium reaction calculation in the first bed layer equilibrium reaction calculation unit 215-1.

The reactor reaction calculation device 20 can include a second bed layer preliminary quantity correction unit 207. This allows the reactor reaction calculation device 20 to correct the quantity of the second bed layer S21 by reducing the amount of the ninth substance M9 contained in the second bed layer S21 that moves to the second mixed substance M22 in the second gas region in the second bed layer preliminary quantity correction unit 207, and calculate the preliminary corrected second bed layer S21A. Therefore, the reactor reaction calculation device 20 can accurately determine the flow rate, etc. of the preliminary corrected second bed layer S21A used to calculate the equilibrium reaction in the second bed layer equilibrium reaction calculation unit 215-2. Therefore, the reactor reaction calculation device 20 can further improve the calculation accuracy of the equilibrium reaction of the preliminary corrected second bed layer S21A in the second bed layer equilibrium reaction calculation unit 215-2.

The furnace reaction calculation device 20 can include an inflow gas summing unit 221. This allows the furnace reaction calculation device 20 to calculate the mixed inflow gas G223 obtained by summing the first mixed inflow gas G222A and the second mixed inflow gas G222B. Therefore, the furnace reaction calculation device 20 can move the mixed inflow gas G223 present in the bed layer after the equilibrium reaction to the second gas region. Therefore, the furnace reaction calculation device 20 can calculate the amount of the mixed inflow gas G223 present in the bed layer after the equilibrium reaction that moves to the second mixed gas phase G23 present in the second gas region.

The furnace reaction calculation device 20 can include a gas amount summing unit 222. This allows the furnace reaction calculation device 20 to mix the mixed inflow gas G223 generated in the bed layer into the second gas phase G23 to obtain the second combined gas phase G24. Therefore, the furnace reaction calculation device 20 can include the mixed inflow gas G223 that has moved from the bed layer in region A to the second gas region in the second gas phase G23 and move it to region (A-1). Therefore, the furnace reaction calculation device 20 can calculate the amount of the second combined gas phase G24, including the mixed inflow gas G223 and the second mixed gas phase G23, moved to region (A-1).

The reactor reaction calculation device 20 may include a second mixed substance primary quantity correction unit 223. As a result, the reactor reaction calculation device 20 may subtract the amount of the eighth substance M8 contained in the second mixed substance M22 generated in the second mixed substance calculation unit 217-2 moving to the first bed layer S12 containing the additive, and add the amount of the seventh substance M7 moved to the second mixed substance M22 contained in the first bed layer S12 containing the additive generated in the first bed layer preliminary quantity correction unit 205 and the amount of the ninth substance M9 moved to the second mixed substance M22 contained in the second mixed bed layer S21 generated in the second bed layer preliminary quantity correction unit 207. As a result, the reactor reaction calculation device 20 may correct the quantity of the second mixed substance M22 and calculate the second corrected mixed substance M23. Therefore, the furnace reaction calculation device 20 can more accurately calculate the amount of the second material M21 moving to the charging end 14A in the second gas region after the equilibrium reaction.

The furnace reaction calculation device 20 can include a second mixed substance secondary quantity correction unit 224. As a result, the furnace reaction calculation device 20 can subtract the amount of the third substance M3 contained in the second corrected mixed substance M23 that moves to the first mixed substance M12 and add the amount of the fourth substance M4 contained in the first mixed substance M12 in the second mixed substance secondary quantity correction unit 224. As a result, the furnace reaction calculation device 20 can correct the amount of the second corrected mixed substance M23 and calculate the second corrected mixed substance M24. Therefore, the furnace reaction calculation device 20 can more accurately calculate the amount of the second substance M21 in the second gas region that moves to the charging end 14A after the equilibrium reaction.

The furnace reaction calculation device 20 can be equipped with a gas region distribution unit 231. As a result, the furnace reaction calculation device 20 can distribute the gas region into the first gas region and the second gas region in advance according to the gas region influence factors contained in the gas region immediately after the combustion gas is supplied from the discharge end 14B of the rotary kiln 1. The furnace reaction calculation device 20 can accurately calculate the mass of the first gas phase G11 flowing in the first gas region from the region N including the discharge end 14B to the region A and the second gas phase G21 flowing in the second gas region. Therefore, the furnace reaction calculation device 20 can more accurately calculate the mass flow rate used for the equilibrium reaction of the first gas phase G11 and the second gas phase G21 in the region A. Therefore, the furnace reaction calculation device 20 can more accurately calculate the equilibrium reaction in each of the first gas region and the second gas region.

The furnace reaction calculation device 20 can include a first material distribution unit 232. This allows the furnace reaction calculation device 20 to distribute the first material contained in the gas region to the first material M11 and the second material M21 in advance immediately after the combustion gas is supplied from the discharge end 14B of the rotary kiln 1. The furnace reaction calculation device 20 can accurately calculate the mass of the first material M11 and the second material M21 flowing through the gas region from the region N including the discharge end 14B to the region A. Therefore, the furnace reaction calculation device 20 can more accurately calculate the mass flow rate used for the equilibrium reaction of the first material M11 and the second material M21 in the region A. Therefore, the furnace reaction calculation device 20 can more accurately calculate the equilibrium reaction in each of the first gas region and the second gas region.

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 240 introduced during the movement of the raw ore to the added gas phase AG11 and the added bed layer AS11 by mass flow rate. The furnace reaction calculation device 20 distributes the combustion material 240 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 first gas phase G11, and the added bed layer AS11 can be a component that constitutes the first bed layer S11. The furnace reaction calculation device 20 can calculate the first gas reaction amount GR1 from the first gas phase G11 and the first bed layer reaction amount SR1 from the first bed layer S11. As a result, the furnace reaction calculation device 20 can calculate the equilibrium reaction in the first gas region equilibrium reaction calculation unit 214-1 based on the reaction amount required for the equilibrium reaction from the corrected first gas phase G13 obtained from the additive-containing first gas phase G12 and the first substance M11. Also, the furnace reaction calculation device 20 can calculate the equilibrium reaction in the first bed layer equilibrium reaction calculation unit 215-1 based on the reaction amount required for the equilibrium reaction from the first inflow gas G221-1 and the corrected first bed layer S13B. Therefore, the furnace reaction calculation device 20 can analyze the behavior of the material in the rotary kiln 1 taking into account the combustion material 240 that is added halfway through the rotary kiln 1, so that the furnace reaction calculation can be performed with high accuracy even when the combustion material 240 is used.

The reactor reaction calculation device 20 may include a first bed layer quantity correction unit 206. That is, the reactor reaction calculation device 20 may correct the quantity of the preliminary corrected first bed layer S13A and calculate the corrected first bed layer S13B, taking into account the amount of movement of the sixth substance M6 contained in the preliminary corrected first bed layer S13A, the quantity of which has been corrected by the first bed layer preliminary quantity correction unit 205, to the preliminary corrected second bed layer S21A, and the amount of movement of the fifth substance M5 contained in the preliminary corrected second bed layer S21A to the preliminary corrected first bed layer S13A. At this time, the first bed layer equilibrium reaction calculation unit 215-1 uses the corrected first bed layer S13B as the first bed layer S11.

The reactor reaction calculation device 20 can subtract the amount of movement of the sixth substance M6 present in the preliminary corrected first bed layer S13A to the second bed layer S21A in the first bed layer quantity correction unit 206, and add the amount of movement of the fifth substance M5 present in the second bed S21A to the preliminary corrected first bed layer S13A. Therefore, the reactor reaction calculation device 20 can more accurately calculate the flow rate of the corrected first bed layer S13B used to calculate the equilibrium reaction in the first bed layer equilibrium reaction calculation unit 215-1, and can further improve the calculation accuracy of the equilibrium reaction of the corrected first bed layer S13B in the first bed layer.

The reactor reaction calculation device 20 can include a second bed layer quantity correction unit 208. That is, the reactor reaction calculation device 20 can correct the quantity of the preliminary corrected second bed layer S21A and calculate the corrected second bed layer S21B by taking into account the amount of movement of the fifth substance M5 contained in the preliminary corrected second bed layer S21A, the quantity of which has been corrected by the second bed layer preliminary quantity correction unit 207, to the preliminary corrected first bed layer S13A, and the amount of movement of the sixth substance M6 contained in the preliminary corrected first bed layer S13A to the preliminary corrected second bed layer S21A. At this time, the second bed layer equilibrium reaction calculation unit 215-2 uses the corrected second bed layer S21B as the second bed layer S21.

In the second bed layer quantity correction unit 208, the reactor reaction calculation device 20 subtracts the amount of movement of the fifth substance M5 present in the second bed layer S21A to the preliminary correction first bed layer S13A, and adds the amount of movement of the sixth substance M6 present in the preliminary correction first bed layer S13A to the second bed layer S21A. Therefore, the reactor reaction calculation device 20 can accurately determine the flow rate, etc. of the preliminary correction second bed layer S21A used to calculate the equilibrium reaction in the second bed layer equilibrium reaction calculation unit 215-2, and can further improve the calculation accuracy of the equilibrium reaction of the corrected second bed layer S21B in the second bed layer.

The reactor reaction calculation device 20 can include the above-mentioned first bed layer quantity correction unit 206 and second bed layer quantity correction unit 208. This allows the reactor reaction calculation device 20 to more accurately calculate the flow rate of the modified first bed layer S13B used in the calculation of the equilibrium reaction in the first bed layer equilibrium reaction calculation unit 215-1, and to accurately determine the flow rate of the modified second bed layer S21B used in the calculation of the equilibrium reaction in the second bed layer equilibrium reaction calculation unit 215-2. Therefore, the reactor reaction calculation device 20 can further improve the calculation accuracy of the equilibrium reaction of the modified first bed layer S13B in the first bed layer S11 and the equilibrium reaction of the modified second bed layer S21B in the second bed layer S21.

The furnace reaction calculation device 20 can include a bed layer distribution unit 233. This allows the furnace reaction calculation device 20 to divide the bed layer S1 into the first bed layer S11 and the second bed layer S21 immediately after it is supplied from the charging end 14A of the rotary kiln 1. The furnace reaction calculation device 20 can accurately calculate the mass of the first bed layer S11 and the second bed layer S21 from the region 1 including the charging end 14A to the region A, so that the mass flow rate used for the equilibrium reaction of the first bed layer S11 and the second bed layer S21 in the region A can be calculated more accurately. Therefore, the furnace reaction calculation device 20 can more accurately calculate the first bed layer equilibrium reaction calculation and the second bed layer equilibrium reaction calculation.

In this way, the furnace reaction calculation device 20 can calculate the equilibrium reactions that occur in the furnace with high accuracy, taking into account that the gas regions in the rotary kiln 1 exhibit multiple different reaction behaviors. Therefore, by applying the furnace reaction calculation device 20 to all regions 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. 11, when the rotary kiln 1 is divided into multiple regions, the furnace reaction calculation device 20 can model the reaction process in the rotary kiln 1 by combining unit operation models when the reaction process in one region A is assumed to be a unit operation model. 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. 11). 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 12 shows a flowchart of the application of the furnace reaction calculation device 20 to the entire rotary kiln 1. As shown in Figure 12, 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 204, the inflow gas distribution unit 209, the first gas region equilibrium reaction calculation unit 214-1, the second gas region equilibrium reaction calculation unit 214-2, the first bed layer equilibrium reaction calculation unit 215-1, the second bed layer equilibrium reaction calculation unit 215-2, 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 part of the calculation device 20 for the furnace reaction are the flow rates of various gas phases in region A such as the bed layer S1 and 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 produced components in region A such as the gas reacted portion GR1, the gas unreacted portion Gr1, and the gas produced 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 the calculation has 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 according to the connection order of the unit operation models. In this embodiment, the 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 6). 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 calculate the reactions in the reactor with high accuracy by at least taking into account that the gas region in the reactor exhibits two different types of reaction behavior for the entire reaction process in the rotary kiln 1, and can reduce the burden of the calculation. Therefore, the furnace reaction calculation device 20 can analyze the behavior of each substance in the rotary kiln 1 more accurately and with a low load 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, and the supply amount). 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 volatile matter and bed layer, and may contain other substances such as ash in addition to volatile matter and 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 First gas phase quantity correction unit 203 Second gas phase quantity correction unit 204 Gas mixture quantity calculation unit 205 First bed layer preliminary quantity correction unit 206 First bed layer quantity correction unit 207 Second bed layer preliminary quantity correction unit 208 Second bed layer quantity correction unit 209 Inflow gas distribution unit 210-1 First gas reaction amount calculation unit 210-2 Second gas reaction amount calculation unit 211-1 First substance reaction amount calculation unit 211-2 Second substance reaction amount calculation unit 212-1 First bed layer reaction amount calculation unit 212-2 Second bed layer reaction amount calculation unit 213-1 First inflow gas reaction amount calculation unit 213-2 Second inflow gas reaction amount calculation unit 214-1 First gas region equilibrium reaction calculation unit 214-2 Second gas region equilibrium reaction calculation unit 215-1 First bed layer equilibrium reaction calculation unit 215-2 Second bed layer equilibrium reaction calculation unit 216-1 First mixed gas phase calculation unit 216-2 Second mixed gas phase calculation unit 217-1 First mixed substance calculation unit 217-2 Second mixed substance calculation unit 218-1 First mixed bed layer calculation unit 218-2 Second mixed bed layer calculation unit 219-1 First mixed inflow gas calculation unit 219-2 Second mixed inflow gas calculation unit 220 First mixed substance quantity correction unit 221 Inflow gas summing unit 222 Gas quantity summing unit 223 Second mixed substance primary quantity correction unit 224 Second mixed substance secondary quantity correction unit G1 Gas phase G11 First gas phase G12 First gas phase containing additive G121 First diffusion gas G122 Second diffusion gas G13 Corrected first gas phase G14 First mixed gas phase G21 Second gas phase G22A Modified second gas phase G22B Adjusted second gas phase G23 Second mixed gas phase G24 Second combined gas phase G221 Inlet gas G221-1 First inlet gas G221-2 Second inlet gas G222A First mixed inlet gas G222B Second mixed inlet gas G223 Mixed inlet gas S1 Bed layer S11 First bed layer S12 First bed layer containing additive S13A Preliminary corrected first bed layer S13B Corrected first bed layer S14 First mixed bed layer S21 Second bed layer S21A Corrected second bed layer S21B Corrected second bed layer S22 Second mixed bed layer M1 Substance M11 First substance M12 First corrected mixed substance M21 Second substance M3 Third substance M4 Fourth substance M5 Fifth substance M6 Sixth substance M7 Seventh substance M8 Eighth substance M9 Ninth substance GR1 First gas reaction product Gr1 First gas unreacted product GP1 First gas product GR2 Second gas reaction product Gr2 Second gas unreacted product GP2 Second gas product MR11 First substance reaction product Mr11 First substance unreacted product MP11 First substance product MR21 Second substance reaction product Mr21 Second substance unreacted product MP21 Second substance product GR221 First inflow gas reaction product Gr221 First inflow gas unreacted product GP221 First inflow gas product GR222 Second inflow gas reaction product Gr222 Second inflow gas unreacted product GP222 Second inflow gas product SR1 First bed layer reaction product Sr1 First bed layer unreacted product SP1 1st bed layer product SR2 2nd bed layer reacted product Sr2 2nd bed layer unreacted product SP2 2nd bed layer product

Claims (22)

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 brought into contact with a combustion gas supplied from the other end of the reactor while moving the raw material ore toward the other end of the reactor, the raw material ore being dried and reduced, the calculation device comprising:
a first gas phase quantity correction unit for correcting a quantity of a first gas phase flowing through one of two gas regions, the first gas region being one of the two gas regions divided according to a gas region influence factor including a generated gas generated from a bed layer including the raw material ore, among the gas regions including the combustion gas, to obtain a corrected first gas phase;
a second gas phase quantity correction unit that corrects a quantity of a second gas phase flowing through the other second gas region of the two gas regions to obtain a corrected second gas phase;
a gas mixing amount calculation unit for calculating a flow rate of an inlet gas moving from the second gas region to the bed layer;
a first gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between the modified first gas phase and a first substance present in the first gas region among substances including at least one of a solid substance and a liquid substance present in the gas region;
a second gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between the modified second gas phase and a second substance present in the second gas region among the substances;
a bed layer equilibrium reaction calculation unit for calculating an equilibrium reaction between the bed layer and the inflow gas;
A reactor reaction calculation device comprising: a first gas reaction amount calculation unit that calculates a first gas reaction amount that contributes to an equilibrium state with the first substance in the first gas phase, and obtains a first gas reaction amount that contributes to an equilibrium reaction of the first 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 first gas phase, and obtains a first substance reaction amount that contributes to the equilibrium reaction of the first substance;
The apparatus for calculating a reaction in a reactor according to claim 1 . a first mixed gas phase calculation unit that calculates at least a flow rate of a first mixed gas phase obtained by mixing a first gas unreacted amount other than the first gas reaction amount generated in the first gas reaction amount calculation unit and a first gas product generated by the reaction of the first gas reaction amount and the first substance reaction amount generated in the first substance reaction amount calculation unit in the first 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 the unreacted portion of the first substance and a first substance product portion generated by the reaction of the first gas reactant and the first substance reactant in the first gas region equilibrium reaction calculation unit;
The apparatus for calculating a reaction in a reactor according to claim 2 . a second gas reaction amount calculation unit that calculates a second gas reaction amount that contributes to an equilibrium state with the second substance in the second gas phase, and obtains a second gas reaction amount that contributes to an equilibrium reaction of the second gas phase;
A second substance reaction amount calculation unit that calculates a second substance reaction amount that contributes to an equilibrium state of the second substance with the second gas phase to obtain a second substance reaction amount that contributes to the equilibrium reaction of the second substance;
The reactor reaction calculation device according to any one of claims 1 to 3, comprising: a second mixed gas phase calculation unit that calculates at least a flow rate of a second mixed gas phase obtained by mixing a second gas unreacted amount other than the second gas reaction amount generated in the second gas reaction amount calculation unit and a second gas product amount generated by the reaction of the second gas reaction amount and the second substance reaction amount generated in the second substance reaction amount calculation unit in the second gas region equilibrium reaction calculation unit;
a second mixed substance calculation unit that calculates at least a flow rate of a second mixed substance obtained by mixing the unreacted second substance and a second substance product generated by the reaction of the second gas reactant and the second substance reactant in the second gas region equilibrium reaction calculation unit;
The apparatus for calculating a reaction in a reactor according to claim 4 . The reactor reaction calculation device according to any one of claims 1 to 5, further comprising a first mixed substance quantity correction unit that corrects the quantity of the first mixed substance in consideration of the amount of movement of a fourth substance, including at least one of a solid substance or a liquid substance, to the second gas region, which is contained in a first mixed substance including a first substance product generated after an equilibrium reaction of the first substance and an unreacted portion of the first substance in the first gas region equilibrium reaction calculation unit, and the amount of movement of a third substance, including at least one of a solid substance or a liquid substance, to the first mixed substance, which is contained in a second mixed substance including a second substance product generated after an equilibrium reaction of the second substance and an unreacted portion of the second substance in the second gas region equilibrium reaction calculation unit. An inflow gas distribution unit that distributes the inflow gas into a first inflow gas and a second inflow gas,
The bed layer equilibrium reaction calculation unit
A first bed layer equilibrium reaction calculation unit that calculates an equilibrium reaction between a first bed layer, which is one of two types of distributed bed layers distributed according to segregation and concentrations of solid and liquid components contained in the bed layer, and the first inflow gas;
a second bed layer equilibrium reaction calculation unit for calculating an equilibrium reaction between the second bed layer of the other of the two types of distributed bed layers and the second inflow gas;
The reactor reaction calculation device according to any one of claims 1 to 6, comprising: a first bed layer reaction amount calculation unit that calculates a first bed layer reaction amount contributing to an equilibrium state of the first bed layer with the first inflow gas, and obtains a first bed layer reaction amount contributing to an equilibrium reaction of the first bed layer;
a first inflow gas reaction amount calculation unit that calculates a gas reaction amount contributing to an equilibrium state of the first inflow gas with the first bed layer, and obtains a first inflow gas reaction amount contributing to an equilibrium reaction of the first inflow gas;
The apparatus for calculating a reaction in a reactor according to claim 7 . a first mixed bed layer calculation unit that calculates at least a flow rate of a first mixed bed layer obtained by mixing a first bed layer unreacted portion other than the first bed layer reacted portion generated in the first bed layer reaction amount calculation unit and a first bed layer product portion generated by a reaction between the first bed layer reacted portion and the first inflow gas reacted portion in the first bed layer equilibrium reaction calculation unit;
a first mixed inflow gas calculation unit that calculates at least a flow rate of a first mixed inflow gas obtained by mixing a first inflow gas unreacted portion other than the first inflow gas reaction portion generated in the first inflow gas reaction amount calculation unit and a first inflow gas product portion generated by a reaction between the first bed layer reaction portion and the first inflow gas reaction portion in the first bed layer equilibrium reaction calculation unit;
The apparatus for calculating a reaction in a reactor according to claim 8 . a second bed layer reaction amount calculation unit that calculates a second bed layer reaction amount contributing to an equilibrium state of the second bed layer with the second inflow gas, and obtains a second bed layer reaction amount contributing to the equilibrium reaction of the second bed layer;
a second inflow gas reaction amount calculation unit that calculates a gas reaction amount contributing to an equilibrium state of the second inflow gas with the second bed layer, and obtains a second inflow gas reaction amount contributing to the equilibrium reaction of the second inflow gas;
The reactor reaction calculation device according to any one of claims 7 to 9, comprising: a second mixed bed layer calculation unit that calculates at least a flow rate of a second mixed bed layer obtained by mixing a second bed layer unreacted portion other than the second bed layer reacted portion generated in the second bed layer reaction amount calculation unit and a second bed layer product portion generated by a reaction between the second bed layer reacted portion and the second inflow gas reacted portion in the second bed layer equilibrium reaction calculation unit;
a second mixed inflow gas calculation unit that calculates at least a flow rate of a second mixed inflow gas obtained by mixing a second inflow gas unreacted portion other than the second inflow gas reaction portion generated in the second inflow gas reaction amount calculation unit and a second inflow gas product portion generated by the reaction of the second bed layer reaction portion and the second inflow gas reaction portion in the second bed layer equilibrium reaction calculation unit;
The apparatus for calculating a reaction in a reactor according to claim 10 . The reactor reaction calculation device according to any one of claims 7 to 11, further comprising a first bed layer preliminary quantity correction unit that corrects the quantity of the first bed layer in consideration of the amount of movement of a seventh substance, including at least one of a solid substance or a liquid substance, contained in the first bed layer to the second gas region, and the amount of movement of an eighth substance, including at least one of a solid substance or a liquid substance, contained in a second mixed substance, including a second substance product generated after an equilibrium reaction of the second substance in the second gas region equilibrium reaction calculation unit and an unreacted portion of the second substance, to the first bed layer. The reactor reaction calculation device according to any one of claims 7 to 12, further comprising a second bed layer preliminary quantity correction unit that corrects the quantity of the second bed layer in consideration of the amount of a ninth substance, including at least one of a solid substance and a liquid substance, that is contained in the second bed layer and that moves to the second gas region. The reactor reaction calculation device according to any one of claims 7 to 13, further comprising an inflow gas mixing unit that mixes a first inflow gas product generated by the reaction of a first bed layer reaction that contributes to the equilibrium reaction of the first bed layer with the first inflow gas in the first bed layer equilibrium reaction calculation unit, and a second inflow gas product generated by the reaction of a second bed layer reaction that contributes to the equilibrium reaction of the second bed layer with the second inflow gas in the second bed layer equilibrium reaction calculation unit. The reactor reaction calculation device according to claim 14, further comprising a gas amount summing unit that mixes a mixed inflow gas generated by mixing the first inflow gas product and the second inflow gas product in the inflow gas summing unit with a second gas product generated by the reaction of the second gas phase with the second substance in the second gas region equilibrium reaction calculation unit. The reactor reaction calculation device according to any one of claims 7 to 15, further comprising a second mixed substance primary quantity correction unit that corrects the quantity of the second mixed substance and calculates a second corrected mixed substance in consideration of the amount of movement of an eighth substance, including at least one of a solid substance or a liquid substance, contained in a second mixed substance including a second substance product generated after an equilibrium reaction of the second substance and an unreacted portion of the second substance, to the bed layer, the amount of movement of a seventh substance, including at least one of a solid substance or a liquid substance, contained in the bed layer, to the second mixed substance, and the amount of movement of a ninth substance, including at least one of a solid substance or a liquid substance, contained in the second bed layer, to the second gas region. The reactor reaction calculation device according to claim 16, further comprising a second mixed substance secondary quantity correction unit that corrects the quantity of the second modified mixed substance in consideration of the amount of a third substance, including at least one of a solid substance or a liquid substance, transferred to the first gas region and contained in the second modified mixed substance generated in the second mixed substance primary quantity correction unit, and the amount of a fourth substance, including at least one of a solid substance or a liquid substance, transferred to the second modified mixed substance and contained in the first mixed substance, including the first substance product generated after the equilibrium reaction of the first substance in the first gas region equilibrium reaction calculation unit and the unreacted portion of the first substance. The reactor reaction calculation device according to any one of claims 1 to 17, further comprising a gas region distribution unit that distributes the gas region into two types of gas regions in advance according to the gas region influence factor. The reactor reaction calculation device according to any one of claims 1 to 18, further comprising a first substance distribution unit that distributes the first substance into two types of the first substance in advance according to a gas region influence factor contained in the first substance. A distribution unit is provided for distributing a combustion material, which is introduced during the movement of the raw material ore and includes at least one of an additive gas phase and an additive bed layer, to the additive gas phase and the additive bed layer at a mass flow rate;
the first gas region equilibrium reaction calculation unit calculates an equilibrium reaction between a first mixture gas phase including the first gas phase and the additive gas phase and the first substance;
the second gas region equilibrium reaction calculation unit calculates an equilibrium reaction between a second mixed gas phase including the first gas phase and the additive gas phase and the second substance;
The reactor reaction calculation device according to any one of claims 1 to 19, wherein the bed layer equilibrium reaction calculation unit calculates an equilibrium reaction between a first mixed bed layer including the bed layer and the additive bed layer and the inflow gas. Assuming that the inside of the reactor is divided into a plurality of regions along its longitudinal direction,
The apparatus for calculating a reaction in a furnace according to any one of claims 1 to 20, wherein the calculation is repeated in the plurality of regions along the flow of the raw material ore or the flow of the combustion gas until a difference between a calculated value in a predetermined region and a previous calculated value in that region falls within a predetermined range. 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 while contacting the raw material ore with a combustion gas supplied from the other end of the reactor to dry and reduce the raw material ore, the method comprising the steps of:
a first gas phase quantity correction step of correcting a quantity of a first gas phase flowing through one of two gas regions, which are divided according to a gas region influence factor including a generated gas generated from a bed layer including the raw material ore, among the gas regions including the combustion gas, to obtain a corrected first gas phase;
a second gas phase amount correction step of correcting an amount of the second gas phase flowing through the other second gas region of the two gas regions to obtain a corrected second gas phase;
a gas mixing amount calculation step of calculating a flow rate of an inlet gas moving from the second gas region to the bed layer;
a first gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the modified first gas phase and a first substance present in the first gas region among substances including at least one of a solid substance and a liquid substance present in the gas region;
a second gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the modified second gas phase and a second substance present in the second gas region among the substances;
a bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the bed layer and the inflow gas;
A method for calculating reactor reactions, including: