JP7793899B2 - 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 primarily composed of iron and nickel.

In the rotary kiln dry smelting method, 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 is then loaded into the charging end of the rotary kiln. The dried ore is then heated using the heat from the combustion of coal supplied from the charging end of the rotary kiln, or a pulverized coal-fired burner or a pulverized coal and heavy oil-fired burner installed at the discharge end of the rotary kiln, to dry and calcinate the dried ore.

Such dry smelting methods using rotary kilns include, for example, using the heat generated by the combustion of coal fed into the kiln from the charging end, the heat generated by burning pulverized coal or heavy oil in a burner, or the heat generated by the combustion of coal fed into the kiln midway through to provide the heat necessary for drying and partial reduction of the dried ore.

For example, 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 dried nickel oxide ore fed into the charging end of the rotary kiln is calcined and partially reduced using the combustion heat generated by the combustion of fossil fuels in a burner. In this rotary kiln operating method, the coal fed into the scoop feeder is thermally decomposed into volatile matter and fixed carbon, and the volatile matter is discharged from the charging end together with the combustion gases inside the furnace, and the fixed carbon is discharged from the discharge end together with the calcined ore produced by drying and reducing the dried ore.

Patent No. 5967616

However, well-known operating methods, such as the rotary kiln operating method described in Patent Document 1, treat the bed layer as a single type of layer and do not consider differences in the reaction rate of the raw ore within the bed layer. The raw ore supplied to a rotary kiln typically has a particle size distribution and varies in density, composition, etc., resulting in differences in reaction rate due to differences in the particle size, density, composition, etc. of the raw ore. Furthermore, when multiple types of raw ore are supplied, the porosity, composition, etc. of the raw ore vary depending on the type of raw ore, resulting in differences in reaction rate. Therefore, when simulating the behavior of raw ore within a reactor such as a rotary kiln, it is necessary to accurately calculate the reaction within the furnace, taking into account differences in reaction rate due to differences in the physical properties of the supplied raw ore, such as particle size, density, composition, and type.

One aspect of the present invention aims to provide a reactor reaction calculation device that can calculate reactions within a reactor with high accuracy.

One aspect of the apparatus for calculating reactions in a furnace according to the present invention is an apparatus for calculating reactions in a furnace, in which raw material ore is supplied from one end of a reactor and moved toward the other end while the raw material ore is brought into contact with combustion gas supplied from the other end, thereby drying and reducing the raw material ore,
a gas mixing amount calculation unit that calculates the flow rate of an inflow gas that moves from the gas region in the reactor to a bed layer containing the raw material ore, among a first gas phase containing the combustion gas that flows through a gas region in the reactor;
an inflow gas distribution unit that distributes the inflow gas into a first inflow gas and a second inflow gas;
a first bed layer reaction amount calculation unit that calculates, using a first reaction rate equation, a first bed layer reaction amount that contributes to an equilibrium state with the first inflow gas in one of two types of distributed bed layers among the bed layers distributed according to reaction rate-dependent conditions of the solid material and the liquid material contained in the bed layer, and obtains a first bed layer reaction amount that contributes to the equilibrium reaction of the first bed layer;
a second bed layer reaction amount calculation unit that calculates a second bed layer reaction amount that contributes to an equilibrium state with the second inflow gas in the other second bed layer of the two types of distributed bed layers using a second reaction rate equation different from the first reaction rate equation, thereby obtaining a second bed layer reaction amount that contributes to the equilibrium reaction in the second bed layer;
a first bed layer equilibrium reaction calculation unit that calculates an equilibrium reaction between the first bed layer reaction component and the first inflow gas;
a second bed layer equilibrium reaction calculation unit that calculates an equilibrium reaction between the second bed layer reaction component and the second inflow gas;
a gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between the first gas phase and a first substance including at least one of a solid substance and a liquid substance present in the gas region;
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 moved toward the other end while 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,
a gas mixing amount calculation step of calculating a flow rate of an inflow gas moving from the gas region in the reactor to a bed layer containing the raw ore, among a first gas phase containing the combustion gas flowing through a gas region in the reactor;
an inlet gas distribution step of dividing the inlet gas into a first inlet gas and a second inlet gas;
a first bed layer reaction amount calculation step of calculating, by using a first reaction rate equation, a first bed layer reaction amount contributing to an equilibrium state with the first inflow gas in one of two types of distributed bed layers distributed among the bed layers according to reaction rate-dependent conditions of the solid and liquid substances contained in the bed layer, thereby obtaining a first bed layer reaction amount contributing to the equilibrium reaction in the first bed layer;
a second bed layer reaction amount calculation step of calculating a second bed layer reaction amount contributing to an equilibrium state with the second inlet gas of the other of the two types of distributed bed layers using a second reaction rate equation different from the first reaction rate equation to obtain a second bed layer reaction amount contributing to the equilibrium reaction of the second bed layer;
a first bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the first bed layer reaction component and the first inflow gas;
a second bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the second bed layer reaction component and the second inflow gas;
a gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the first gas phase and a first substance including at least one of a solid substance and a liquid substance present in the gas region;
Includes.

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

1 shows a schematic configuration of a rotary kiln to which a calculation device for furnace reactions 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. 1 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 a reactor reaction according to an embodiment of the present invention. 6 is a flowchart showing the operation of the gas region equilibrium reaction implementation step (step S19) in FIG. 5. 6 is a flowchart showing the operation of the first bed layer equilibrium reaction implementation step (step S20) of FIG. 5. 4 is a flowchart showing the operation of the second bed layer equilibrium reaction implementation step (step S21) of FIG. 3. FIG. 1 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 illustrating a case where a method for calculating furnace reactions according to an embodiment of the present invention is applied to the entire rotary kiln.

Embodiments of the present invention will be described in detail below. To facilitate understanding, identical components will be designated by the same reference numerals in each drawing, and duplicate explanations will be 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 an 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>
The rotary kiln 1 includes a rotatable, generally cylindrical kiln body 11 and a combustion material supply pipe 12 disposed midway through the kiln body 11. The kiln body 11 is a rotatable, generally cylindrical kiln body, and the combustion material supply pipe 12 is disposed 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 inner wall surface of the kiln body 11 be provided with refractory material 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 Figure 1) that is inserted into and closed by the rotary kiln charging end (hereinafter also referred to as the "charging end") 14A, and an open end 11b at the other end (right side in Figure 1) that is inserted into and closed by the rotary kiln discharge end (hereinafter also referred to as the "discharge end") 14B. The kiln body 11 is arranged at a slight incline from the charging end 14A toward the discharge end 14B, and is supported so that it can rotate freely around its axis.

A raw material supply pipe 15 that introduces raw 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 using a dryer (rotary dryer) to remove some of the adhering moisture. The moisture content of the dried ore is approximately 15% to 25% by mass.

The nickel oxide ore used as the raw material ore is not particularly limited, but garnierite ore is preferably used in the smelting of ferronickel, which is an alloy primarily composed of iron and nickel. A typical composition of garnierite ore, calculated on a dry ore basis, is a Ni content of 2.1% to 2.5% by mass, an Fe content of 11% to 23% by mass, an MgO content of 20% to 28% by mass, an SiO 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-fired burner or a pulverized coal and heavy oil mixed-fired burner. The burner 16 burns pulverized coal or a fuel containing 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 periphery of the kiln body 11 and can supply combustion material into the kiln body 11. The combustion material includes at least one of substances that primarily enter the gas phase, such as volatile matter, and solid substances that primarily enter the bed layer, such as fixed carbon; for example, carbonaceous materials such as coal can be used.

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 Figure 1, only one combustion material supply pipe 12 is provided on the outer peripheral surface of the kiln body 11, but multiple pipes 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.

Combustion materials are often not made of a single type of carbonaceous material, but are often a mixture of multiple different types of carbonaceous material, and the particle size of the carbonaceous material added often has a distribution. The particle size refers to the volume average particle size based on the effective diameter, and is measured, for example, by laser diffraction/scattering, dynamic light scattering, or classification. 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 introduced into the kiln body 11 through the combustion material supply pipe 12. From the discharge end 14B, high-temperature combustion gases generated by burning pulverized coal, heavy oil, etc. using the burner 16 installed at the discharge end 14B are blown from the discharge end 14B toward the charging end 14A, i.e., in the opposite direction to the flow of the raw ore.

Inside the kiln body 11, raw ore is charged through the charging end 14A. As the kiln body 11 rotates at a predetermined speed, the raw ore is transported from the opening end 11a of the kiln body 11 through the raw material supply pipe 15 from one end toward the discharge end 14B. As the raw ore moves through the kiln body 11, it comes into countercurrent contact with combustion gas flowing from the discharge end 14B toward the charging end 14A. The raw ore is heated by the combustion heat and flame of the high-temperature combustion gas generated by burning fuels such as pulverized coal or heavy oil in the burner 16. Furthermore, combustion material introduced into the kiln body 11 through the combustion material supply pipe 12 is combusted by the combustion gas within the kiln body 11. The raw ore is also heated by the combustion heat generated by the combustion of the combustion material introduced through 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 gases generated by the combustion of fuel in the burner 16, and by 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 combustion gas due to the evaporation of moisture contained in the raw ore and combustion materials, the volatilization and condensation of volatile matter contained in the combustion materials, and the scattering and falling of ash contained in the burner fuel and combustion materials. Moisture and volatile matter produced by the thermal decomposition of the combustion materials supplied midway through the rotary kiln 1 move toward the charging end 14A along with the combustion gas, and char particles move toward the discharge end 14B along with the raw ore.

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

The calcined ore has a temperature of, for example, 800-900°C and a particle size of approximately 10-100 mm.

A grate (sieving device) 17 is provided at the discharge opening of the discharge end 14B to separate the cinders with particle diameters of approximately 10 mm to 100 mm from the sintered lumps (particle diameters of approximately 100 mm to 500 mm) generated within the rotary kiln 1. The grate 17 is composed of, for example, an iron grate with a mesh size of approximately 100 mm. After passing through the grate 17, the cinders discharged from the discharge end 14B are transported to the next process via the cinder discharge chute 18.

<Calculation device for reactor reactions>
Next, a 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 region adjacent to region A on the side where combustion gas is blown in is referred to as region (A+1), and the region adjacent to region A on the side where raw material ore is charged is referred to as region (A-1).

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

The gas phases in region A are referred to as a first gas phase G1, a second gas phase G2, a third gas phase G3, or a third mixed gas phase G3'. Each gas phase in region A is defined as follows.
The "first gas phase G1" refers to the combustion gas flowing into region A from one of the adjacent regions (region (A+1)). The combustion gas includes gases that contribute to the equilibrium reaction, such as volatile matter, oxygen, carbon dioxide, carbon monoxide, and hydrogen, and may also include inert substances that do not contribute to the reaction (e.g., nitrogen).
The "second gas phase G2" is a gas phase obtained by combining the added gas phase distributed from the combustion material and the first gas phase.
The "third gas phase G3" is a gas phase generated in the mixed gas phase calculation unit 215 described later.
The "third mixed gas phase G3'" is a gas phase generated in the gas amount summing unit 222, which will be described later.

The bed layer fed into the rotary kiln 1 is referred to 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, such as ore compounds such as nickel oxide, iron oxide, and magnesium oxide, and fixed carbon, as well as liquid materials, and may also include inactive materials that do not contribute to the reactions in the first bed layer equilibrium reaction calculation unit 214-1 and the second bed layer equilibrium reaction calculation unit 214-2, which will be described later.

The bed layers present in region A are described as the first bed layer S11, the preliminary corrected first bed layer S11B, the corrected first bed layer S11C, the first mixed bed layer S12, the second bed layer S21, the corrected second bed layer S21A, or the second mixed bed layer S22. Each bed layer in region A is defined as follows:
The "first bed layer S11" refers to a bed layer that contains solid and liquid substances with fast reaction rates, distributed according to the reaction rate-causing conditions of the solid and liquid substances contained in the bed layer S1, among the bed layers S1 that flow into the region A from one adjacent region (region (A-1)). The first bed layer S11 may contain inactive substances that do not contribute to the reaction in the first bed layer equilibrium reaction calculation unit 214-1 described later, similar to the bed layer S1.
The reaction rate-attributing conditions are set appropriately depending on the properties of the solid and liquid substances contained in the bed layer. The properties of the solid substances include the particle size, specific gravity, type, segregation, etc. of the solid substance. The properties of the liquid substances include the specific gravity, type, segregation, etc. of the liquid substance.
The "first bed layer S11A" 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 S11B" is a first bed layer in which the quantity of material in the first bed layer S11 has been corrected taking into account the amount of movement of a fourth substance, which is contained in the first bed layer S11 and includes at least one of a solid substance or a liquid substance, into the gas region, and the amount of movement of a fifth substance, which is contained in the first mixed substance present in the gas region and includes at least one of a solid substance or a liquid substance, into the first bed layer S11, which is generated in the first mixed substance calculation unit described below.
The "corrected first bed layer S11C" is a first bed layer in which the quantity of material in the preliminary corrected first bed layer S11B has been corrected, taking into account the amount of a second substance contained in the preliminary corrected first bed layer S11B, which contains at least one of a solid substance or a liquid substance, that has moved to the second bed layer S21, and the amount of a third substance contained in the second bed layer S21, which contains at least one of a solid substance or a liquid substance, that has moved to the preliminary corrected first bed layer S11B.
The "first mixed bed layer S12" is a bed layer generated in the first mixed bed layer calculation unit 218 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 which contains solid and liquid substances having a slower reaction rate than the first bed layer S11. Like the bed layer S1, the second bed layer S21 may contain inactive substances that do not contribute to the reaction in the second bed layer equilibrium reaction calculation unit 214-2 described later.
The "modified second bed layer S21A" is a second bed layer in which the quantity of material in the second bed layer S21 has been modified, taking into account the amount of a second substance contained in the preliminary modified first bed layer S11B, which contains at least one of a solid substance or a liquid substance, that has moved to the second bed layer S21, and the amount of a third substance contained in the second bed layer S21, which contains at least one of a solid substance or a liquid substance, that has moved to the preliminary modified first bed layer S11B.
The "second mixed bed layer S22" is a bed layer generated in the second mixed bed layer calculation unit 220 described later.

The gases flowing into the bed layer from the gas region in region A are referred to as inlet gas G11, first inlet gas G111, second inlet gas G112, first mixed inlet gas G111A, second mixed inlet gas G112A, or mixed inlet gas G12. In the following description, the inlet gases in region A are defined as follows:
"Inflow gas G11" is the gas that flows into the bed layer from the gas region in region A.
The "first inflow gas G111" is the inflow gas that flows into the first bed layer S11 out of the inflow gas G11 that has flowed into the bed layer.
The "second inflow gas G112" is the inflow gas that flows into the second bed layer S21 out of the inflow gas G11 that has flowed into the bed layer.
The "first mixed inflow gas G111A" is a gas obtained by mixing the unreacted portion of the first bed layer and the product portion of the first inflow gas generated in the first bed layer equilibrium reaction calculation section 214-1.
The "second mixed inflow gas G112A" is a gas obtained by mixing the corrected second bed layer unreacted portion and the second inflow gas product portion generated in the second bed layer equilibrium reaction calculation unit 214-2.
The "mixed inflow gas G12" is a gas obtained by combining the first mixed inflow gas G111A and the second mixed inflow gas G112A.

The substances present in region A are referred to as first substance M1, second substance M2, third substance M3, fourth substance M4, fifth substance M5, first mixed substance M11, or first modified mixed substance M12. In the following description, each substance in region A is defined as follows:
The "first substance M1" is a substance that flows from the gas region of region (A+1) into the gas region of region A, and includes at least one of a solid substance or a liquid substance present in the gas region of region A.
The "second substance M2", "third substance M3" and "fourth substance M4" include at least one of a solid substance and a liquid substance present in the bed layer.
The "fifth substance M5" is a substance that exists in the gas region and includes at least one of a solid substance and a liquid substance.
The "first mixed material M11" is a mixture of the first material M1 generated in the first mixed material calculation unit 216 described later.
The "first modified mixed material M12" is a mixture of the first material M1 produced in the first mixed material quantity modifying unit 223, which will be described later.

The reacted, unreacted, and product fractions calculated within region A are referred to as gas reacted fraction GR1, gas unreacted fraction Gr1, gas product fraction GP1, first substance reacted fraction MR1, first substance unreacted fraction Mr1, first substance product fraction MP1, first inflow gas reacted fraction GR111, first inflow gas unreacted fraction Gr111, first inflow gas product fraction GP111, second inflow gas reacted fraction GR112, second inflow gas unreacted fraction Gr112, second inflow gas product fraction GP112, first bed layer reacted fraction SR1, first bed layer unreacted fraction Sr1, first bed layer product fraction SP1, second bed layer reacted fraction SR2, second bed layer unreacted fraction Sr2, or second bed layer product fraction SP2. These are calculated by any of the components constituting the furnace reaction calculation device shown in Figure 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 combustion material distribution unit (distribution unit) 201, a gas mixture amount calculation unit 202, a first bed layer preliminary material amount correction unit 203, a first bed layer material amount correction unit 204, a second bed layer material amount correction unit 205, an inflow gas distribution unit 206, a gas reaction amount calculation unit 207, a first material reaction amount calculation unit 208, a first bed layer reaction amount calculation unit 209, a first inflow gas reaction amount calculation unit 210, a second bed layer reaction amount calculation unit 211, a second inflow gas It is equipped with a gas reaction amount calculation unit 212, a gas region equilibrium reaction calculation unit 213, a first bed layer equilibrium reaction calculation unit 214-1, a second bed layer equilibrium reaction calculation unit 214-2, a mixed gas phase calculation unit 215, a first mixed substance calculation unit 216, a first mixed inflow gas calculation unit 217, a first mixed bed layer calculation unit 218, a second mixed inflow gas calculation unit 219, a second mixed bed layer calculation unit 220, an inflow gas summation unit 221, a gas amount summation unit 222, and a first mixed substance amount correction unit 223.

The reactor reaction calculation device 20 can also include a bed layer distribution unit 224 that pre-allocates the bed layer S1 into two types of distributed bed layers (first bed layer S11, second bed layer S21) according to the reaction rate-dependent 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 by the bed layer distribution unit 224 to the first bed layer preliminary quantity correction unit 203, and supplies the second bed layer S21 generated by the bed layer distribution unit 224 to the second bed layer quantity correction unit 205.

When raw ores with different particle size, density, composition, type, and other reaction rates are simultaneously fed into the rotary kiln 1, striped segregation, in which the first bed layer S11 and the second bed layer S21 segregate in stripes, is likely to occur in the bed layer, as shown in Figure 3. When striped segregation occurs, the first bed layer S11 and the second bed layer S21 periodically exhibit uneven composition distribution along the longitudinal direction of the rotary kiln 1, as shown in Figure 4. This may result in significantly different reaction patterns for each stripe. When raw ores with different particle size, density, and other reaction rates are fed into the rotary kiln 1, treating the bed layer in the rotary kiln 1 as a single concentration cannot represent the composition distribution within the raw ore due to the different reaction rates within the bed layer. Therefore, even if the furnace reaction is simulated and analyzed, it is difficult to fit it to the actual furnace reaction. Therefore, when considering phenomena occurring inside the furnace, it is necessary to take into account not only differences in the reaction rates of the raw ore, but also the composition distribution within the bed layer that occurs due to segregation.

The furnace reaction calculation device 20 separates the rotary kiln 1 into a first bed layer S11 and a second bed layer S21 and performs equilibrium reaction calculations for each bed layer. That is, when simulating furnace reactions based on the Gibbs energy minimization method, the furnace reaction calculation device 20 takes into account the different reaction rates of the raw ore within the rotary kiln 1 and the composition distribution (unevenness) within the raw ore. The furnace reaction calculation device 20 then independently calculates the reaction amounts required for the equilibrium reactions in the first bed layer S11, which has a fast reaction rate, and the second bed layer S21, which has a slow reaction rate, using different reaction rate equations. This allows the furnace reaction calculation device 20 to accurately calculate equilibrium reactions based on the Gibbs energy minimization method, taking into account the difference in reaction rates of the raw ore contained in the first bed layer S11 and the second bed layer S12 and the composition distribution within the raw ore. Therefore, the furnace reaction calculation device 20 can analyze furnace reactions in the bed layer with high accuracy. Because the furnace reaction calculation device 20 can perform fitting with higher accuracy, it can be effectively used to analyze operational data. For example, because it can calculate two different states that occur within the rotary kiln 1 simultaneously at the same position, it can also represent a state in which opposing reactions, such as an oxidation reaction caused by an oxidizing gas and a reduction reaction caused by a reducing substance in the bed layer, occur at the same longitudinal position within the rotary kiln 1, which was difficult to achieve with conventional methods. Therefore, the furnace reaction calculation device 20 can perform fitting that is closer to the actual furnace state.

In addition, the furnace reaction calculation device 20 calculates equilibrium reactions between the gas flowing within the gas region and the solid or liquid substances present within the gas region based on the Gibbs energy minimization method. This makes it possible to calculate equilibrium reactions in the gas region within the rotary kiln 1.

Therefore, by taking into account that the bed layer in the rotary kiln 1 exhibits two different types of reaction behavior depending on the particle size of the raw ore, the furnace reaction calculation device 20 can analyze the reactions that occur in the rotary kiln 1 with high precision, thereby improving the accuracy of reaction calculations. As a result, the furnace reaction calculation device 20 can calculate the reactions in the rotary kiln 1 with higher precision.

As shown in Figure 2, the reactor reaction calculation device 20 inputs the quantities, temperatures, pressures, etc. of the first bed layer S11 and second bed layer S21 flowing into the bed layers of region A, and the first gas phase G1 flowing into the gas region. The reactor reaction calculation device 20 uses these input values to perform mass transfer and reaction calculations within each divided region A.

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

When calculating mass transfer and reactions within region A, the reactor reaction calculation device 20 defines the amount of gas (inlet gas G11) that mixes into the bed layer from the first gas phase G1 flowing within the gas region. One method for defining this gas mixing amount is to assign a fixed value to the proportion of the total amount of gas that mixes 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 within 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 within the gas region. One method for defining this amount of mass transfer is to define it for each calculation substance based on factors such as the settling velocity of the solid or liquid material, which is calculated from its specific gravity, particle size, etc.

As shown in Figure 2, the distribution unit 201 distributes the combustion material 230 at a mass flow rate between the gas phase and bed layer contained in the combustion material 230 by setting the type, components, etc. of the combustion material 230 in advance.

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

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

The first bed layer preliminary quantity correction unit 203 corrects the quantity of the first bed layer S11A, which is a mixture of the first bed layer S11 and the additive bed layer AS11, to calculate the preliminary corrected first bed layer S11B.

The amount of material in the first bed layer S11A is adjusted taking into account the amount of movement of the fourth substance M4, which is contained in the first bed layer S11A and includes at least one of a solid substance or a liquid substance, to the first mixed substance M11 present in the gas region, and the amount of movement of the fifth substance M5, which is contained in the first mixed substance M11 present in the gas region and includes at least one of a solid substance or a liquid substance, to the first bed layer S11A.

The first bed layer quantity correction unit 204 corrects the quantity of the first bed layer S11 by subtracting the amount of second material M2, which includes at least one of a solid material and a liquid material and is contained in the preliminary corrected first bed layer S11B, from the amount of material M2 transferred to the second bed layer S21, to calculate the corrected first bed layer S11C.

In this embodiment, the first bed layer quantity correction unit 204 corrects the quantity of the first bed layer S11 by taking into account the amount of movement of the second substance M2 to the second bed layer S21 and the amount of movement of the third substance M3, which is contained in the second bed layer S21 and includes at least one of a solid substance and a liquid substance, to the preliminary corrected first bed layer S11B. This allows the corrected first bed layer S11C to be calculated.

The second bed layer quantity correction unit 205 corrects the quantity of the second bed layer S21 by subtracting the amount of third substance M3 contained in the second bed layer S21 that has moved to the preliminary corrected first bed layer S11B, and calculates the corrected second bed layer S21A.

In this embodiment, the second bed layer quantity correction unit 205 corrects the quantity of the first bed layer S11, taking into account the amount of movement of the second substance M2 contained in the preliminary corrected first bed layer S11B to the second bed layer S21 and the amount of movement of the third substance M3 contained in the second bed layer S21 to the preliminary corrected first bed layer S11B. This allows the corrected first bed layer S11C to be calculated.

The inflow gas distribution unit 206 has the function of distributing the inflow gas G11 into a first inflow gas G111 and a second inflow gas G112 by mass flow rate by presetting the type and components of the inflow gas G11 calculated by the gas mixture calculation unit 202.

The gas reaction amount calculation unit 207 calculates the amount of gas reaction that contributes to the equilibrium state between the second gas phase G2 and the first substance M1. That is, the gas reaction amount calculation unit 207 calculates the amount of gas reaction that is expected to occur when the second gas phase G2 reacts in equilibrium with the first substance M1 during the residence time of the second gas phase G2 in the gas region in region A. The reaction amount during the residence time of the second gas phase G2 in region A is calculated using reaction rate parameters set for each substance and the residence time in region A. The gas reaction amount can be calculated using a reaction rate equation to determine the amount that reacts during the residence time in region A. The gas reaction amount calculation unit 207 then determines the reaction amount that contributes to the equilibrium state between the second gas phase G2 and the first substance M1 from the gas reaction amount as the gas reaction amount GR1.

In this specification, the term "reactive component" refers to the flow rate that contributes to a reaction through contact with the second gas phase G2 or the first substance present in the gas region within region A during the residence time that the first substance M1 passes through. Hereinafter, "other reactive components" also refer to the flow rate that contributes to a reaction through contact between any of the gas phase, solid phase, or substance and any of the gas phase, solid phase, or substance.

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

The gas reaction amount calculation unit 207 can determine the amount of the second gas phase G2 that reaches equilibrium with the solid or liquid substance present in the first substance M1 by employing, for example, a model that can calculate the amount from the reaction rate according to the Arrhenius reaction rate equation and the residence time of the second gas phase G2 in region A. The gas reaction amount calculation unit 207 then divides the amount into a gas reaction portion GR1 that corresponds to the gas reaction amount and an unreacted gas portion Gr1 that corresponds to the remaining unreacted mass flow rate.

In the rotary kiln 1, the second gas phase G2 and the first substance M1 present in the gas region flow in parallel. Because the second gas phase G2 has a high flow rate and a short residence time in region A, the second gas phase G2 and the first substance M1 present in the gas region have not reached equilibrium. In this embodiment, the gas reaction amount calculation unit 207 assumes that only a portion of the second gas phase G2 in a certain region (region A) within the rotary kiln 1 reaches equilibrium with the first substance M1 present in the gas region, and divides the second gas phase G2 into a gas reaction portion GR1 and an unreacted gas portion Gr1 other than the gas reaction portion GR1 according to the corresponding gas reaction amount.

The first material reaction amount calculation unit 208 calculates the amount of first material reaction that contributes to the equilibrium state of the first material M1 with the second gas phase G2. That is, the first material reaction amount calculation unit 208 calculates the amount of reaction that is expected to occur when the first material M1 reacts in equilibrium with the second gas phase G2 during the residence time of the first material M1 in the gas region in region A as the first material reaction amount. The first material reaction amount can be calculated using the reaction rate equation. Then, the first material reaction amount calculation unit 208 calculates the first material reaction portion MR1 of the first material M1 that contributes to the equilibrium state with the second gas phase G2 from the first material reaction amount.

Like the gas reaction amount calculation unit 207, the first material reaction amount calculation unit 208 can determine the amount of the first material M1 present in the gas region that reaches equilibrium with the second gas phase G2 by employing, for example, a model that can calculate the amount from the reaction rate according to the Arrhenius reaction rate equation and the residence time of the first material M1 in region A. The first material reaction amount calculation unit 208 then divides the amount into a first material reaction portion MR1 that corresponds to the first material reaction amount and an unreacted first material portion Mr1 that corresponds to the remaining unreacted mass flow rate.

As described above, in the rotary kiln 1, the second gas phase G2 and the first substance M1 flow in parallel. Because the second gas phase G2 has a high flow rate and a short residence time in region A, the second gas phase G2 and the first substance M1 do not reach equilibrium. In this embodiment, the first substance reaction amount calculation unit 208 assumes that only a portion of the second gas phase G2 in a certain region (region A) within the rotary kiln 1 reaches equilibrium with the first substance M1, and divides the first substance M1 into a reacted portion MR1 of the first substance and an unreacted portion Mr1 of the first substance other than the reacted portion MR1 of the first substance according to the corresponding first substance reaction amount.

The first bed layer reaction amount calculation unit 209 calculates the amount of first bed layer reaction that contributes to the equilibrium state of the modified first bed layer S11C with the first inflow gas G111 using the first reaction rate equation. That is, the first bed layer reaction amount calculation unit 209 calculates the amount of first bed layer reaction that is expected to occur in equilibrium with the first inflow gas G111 during the movement time of the modified first bed layer S11C in region A using the first reaction rate equation.

The first bed layer reaction amount calculation unit 209 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 S11C in region A, the residence time within region A, etc., in the first reaction rate equation. Then, the first bed layer reaction amount calculation unit 209 calculates, from the first bed layer reaction amount, the first bed layer reaction amount SR1 of the modified first bed layer S11C that contributes to the equilibrium reaction with the first inflow gas G111.

In other words, the first bed layer reaction portion SR1 is the reaction portion that contributes to the equilibrium reaction with the first inflow gas G111 in the modified first bed layer S11C.

The first bed layer reaction amount calculation unit 209 can calculate the first bed layer reaction amount by, for example, employing a model that can be calculated from the reaction rate according to the Arrhenius reaction rate equation and the transit time of the modified first bed layer S11C within region A. The first bed layer reaction amount calculation unit 209 calculates the first bed layer reaction amount of the modified first bed layer S11C that contributes to the equilibrium reaction with the first inflow gas G111 only for the amount estimated as the equilibrium state between the modified first bed layer S11C and the first inflow gas G111 based on the residence time of the modified first bed layer S11C using the Arrhenius reaction rate equation. The first bed layer reaction amount calculation unit 209 then divides this 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 modified first bed layer S11C and the first inflow gas G111 flow countercurrently. Because the first inflow gas G111 has a high flow velocity and a short residence time in region A, the modified first bed layer S11C and the first inflow gas G111 have not reached equilibrium. In this embodiment, the first bed layer reaction amount calculation unit 209 assumes that only a portion of the modified first bed layer S11C in a certain region (region A) within the rotary kiln 1 reaches equilibrium with the first inflow gas G111, and divides the first bed layer reaction amount SR1 into a first bed layer reaction amount SR1 and a first bed layer unreacted amount Sr1 other than the first bed layer reaction amount, based on the corresponding first bed layer reaction amount.

The first inflow gas reaction amount calculation unit 210 calculates the first inflow gas reaction amount that contributes to the equilibrium state of the first inflow gas G111 with the modified first bed layer S11C. That is, the first inflow gas reaction amount calculation unit 210 calculates the first inflow gas reaction amount that is expected to occur when the first inflow gas G111 is in equilibrium with the modified first bed layer S11C during the residence time of the first inflow gas G111 in the bed layer in region A. The first inflow reaction amount during the residence time of the first inflow gas G111 in region A can be calculated using reaction rate parameters set for each substance and the residence time in region A, for example, using a reaction rate equation. The first inflow gas reaction amount calculation unit 210 then calculates the first inflow gas reaction amount GR111 of the first inflow gas G111 that contributes to the equilibrium reaction with the modified first bed layer S11C from the first inflow gas reaction amount.

In other words, the first inflow gas reaction portion GR111 is the reaction portion of the first inflow gas G111 that contributes to the equilibrium state of the first modified bed layer S11B.

The first inflow gas reaction amount calculation unit 210 can calculate the reaction amount at which the first inflow gas G111 reaches equilibrium with the modified first bed layer S11C, for example, using a model similar to the model used in the first bed layer reaction amount calculation unit 209.

Then, the first inflow gas reaction amount calculation unit 210 divides it into a first inflow gas reaction amount GR111, which corresponds to the first inflow gas reaction amount, and a first inflow gas unreacted amount Gr111, which corresponds to the unreacted mass flow rate other than the remaining first inflow gas reaction amount GR111.

As described above, in the rotary kiln 1, the first inflow gas G111 and the modified first bed layer S11C flow countercurrently. Because the first inflow gas G111 has a high flow rate and a short residence time in region A, the first inflow gas G111 and the modified first bed layer S11C do not reach equilibrium. In this embodiment, the first inflow gas reaction amount calculation unit 210 assumes that only a portion of the first inflow gas G111 in a certain region (region A) within the rotary kiln 1 reaches equilibrium with the modified first bed layer S11C, and divides the first inflow gas G111 into the first inflow gas reacted portion GR111 and the remaining first inflow gas unreacted portion Gr111 according to the corresponding gas reaction amount.

The second bed layer reaction amount calculation unit 211 uses the second reaction rate equation to calculate the amount of bed reaction that contributes to the equilibrium state of the modified second bed layer S21A with the second inflow gas G112. That is, the second bed layer reaction amount calculation unit 211 uses the second reaction rate equation to calculate the amount of second bed layer reaction that is expected to occur in equilibrium with the second inflow gas G112 during the movement time of the modified second bed layer S21A in region A (i.e., the movement time of each compound, including solid and liquid substances, present in the modified second bed layer S21A).

The second reaction rate equation is a reaction rate equation different from the first reaction rate equation used in the first bed layer reaction amount calculation unit 209.

The second bed layer reaction amount calculation unit 211 calculates the second bed layer reaction amount SR2 of the modified second bed layer S21A that contributes to the equilibrium state with the second inflow gas G112 from the second bed layer reaction amount obtained using the second reaction rate equation.

The second bed layer reaction amount calculation unit 211, like the first bed layer reaction amount calculation unit 209, can calculate the reaction amount that reaches equilibrium between the modified second bed layer S21A and the second inflow gas GR112 by, for example, employing a model that can be calculated from the reaction rate according to the Arrhenius reaction rate equation and the movement time of the modified second bed layer S21A within region A. The second bed layer reaction amount calculation unit 211 calculates the second bed reaction amount of the modified second bed layer S21A that contributes to the reaction with the second inflow gas GR112 only for the amount that is estimated to reach equilibrium between the modified second bed layer S21A and the second inflow gas GR112 based on the residence time of the modified second bed layer S21A using the Arrhenius reaction rate equation. The second bed layer reaction amount calculation unit 211 then divides this 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 G112 in the modified second bed layer S2A.

In the rotary kiln 1, the modified second bed layer S21A and the second inflow gas G112 flow countercurrently. Because the second inflow gas G112 has a high flow rate and a short residence time in region A, the modified second bed layer S21A and the second inflow gas G112 have not reached equilibrium. In this embodiment, the second bed layer reaction amount calculation unit 211 assumes that only a portion of the modified second bed layer S2A in a certain region (region A) within the rotary kiln 1 reaches equilibrium with the second inflow gas G112, and divides the second bed layer reaction amount SR2 into the second bed layer reaction amount SR2 and the remaining second bed layer unreacted amount Sr2 according to the corresponding second bed layer reaction amount.

The second inflow gas reaction amount calculation unit 212 calculates the second inflow gas reaction amount that contributes to the equilibrium state of the second inflow gas G112 with the modified second bed layer S21A. That is, the second inflow gas reaction amount calculation unit 212 calculates the second inflow gas reaction amount that is expected to occur when the second inflow gas G112 is in equilibrium with the modified second bed layer S21A during the residence time of the second inflow gas G112 in the bed layer in region A. The second inflow reaction amount during the residence time of the second inflow gas G112 in region A can be calculated using reaction rate parameters set for each substance and the residence time in region A, and can be calculated, for example, from a reaction rate equation. The second inflow gas reaction amount calculation unit 212 then calculates the second inflow gas reaction amount GR112 that contributes to the equilibrium reaction with the second modified bed layer S21A from the second inflow gas G112.

In other words, the second inflow gas reaction portion GR112 is the reaction portion of the second inflow gas G112 that contributes to the equilibrium state of the second modified bed layer S21A.

The second inflow gas reaction amount calculation unit 212 can calculate the reaction amount at which the second inflow gas G112 reaches equilibrium with the modified second bed layer S21A, for example, using a model similar to the model used in the second bed layer reaction amount calculation unit 211.

The second inflow gas reaction amount calculation unit 212 divides the second inflow gas into a second inflow gas reaction amount GR112, which corresponds to the second inflow gas reaction amount, and a second inflow gas unreacted amount Gr112, 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 G112 and the modified second bed layer S21A flow countercurrently. Because the second inflow gas G112 has a high flow rate and a short residence time in region A, the second inflow gas G112 and the modified second bed layer S21A do not reach equilibrium. In this embodiment, the second inflow gas reaction amount calculation unit 212 assumes that only a portion of the modified second bed layer S21A in a certain region (region A) within the rotary kiln 1 reaches equilibrium with the second inflow gas G112, and divides the second inflow gas G112 into the second inflow gas reacted portion GR112 and the remaining second inflow gas unreacted portion GR112 according to the corresponding second inflow gas reaction amount.

The gas region equilibrium reaction calculation unit 213 calculates the equilibrium reaction between the second gas phase G2 flowing in the gas region within region A and the first substance M1 present in the gas region. That is, the gas region equilibrium reaction calculation unit 213 performs equilibrium reaction calculations for the gas region using the gas reaction portion GR1 of the second gas phase G2 that contributes to the equilibrium reaction with the first substance M1 present in the gas region, and the first substance reaction portion MR1 of the first substance M1 that contributes to the equilibrium reaction with the gas reaction portion GR1, and calculates at least the composition, amount, etc. of the gas reactant GR1 and the first substance reactant MR1, as well as the change in heat quantity and flow rate of each when the gas reactant GR1 and the first substance reactant MR1 reach equilibrium.

The gas region equilibrium reaction calculation unit 213 has the function of performing equilibrium reaction calculations to determine the type, phase, flow rate, etc. of the product by presetting the type, phase, flow rate, etc. of the substance (product) that may be produced by the reaction between the gas reaction component GR1 and the first material reaction component MR1 so that the free energy of the product is minimized. In other words, the gas region equilibrium reaction calculation unit 213 can perform equilibrium reaction calculations based on the Gibbs energy minimization method. The gas region equilibrium reaction calculation unit 213 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product, etc., when the gas reaction component GR1 and the first material reaction component MR1 reach equilibrium.

The gas region equilibrium reaction calculation unit 213 calculates the product gas generated by the reaction between the gas reaction amount GR1 and the first substance reaction amount MR1, and the unused portion of the gas reaction amount GR1, as the gas production amount GP1.

In addition, the gas region equilibrium reaction calculation unit 213 calculates the product material produced by the reaction between the gas reaction amount GR1 and the first substance reaction amount MR1, and the unused portion of the first substance reaction amount MR1, as the first substance product amount MP1.

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

The first bed layer equilibrium reaction calculation unit 214-1 calculates the equilibrium reaction between the modified first bed layer S11C moving through the bed layer in region A and the first inflow gas G111 present in the modified first bed layer S11C. That is, the first bed layer equilibrium reaction calculation unit 214-1 performs the equilibrium reaction calculation for the first bed layer using the first bed layer reaction portion SR1 that contributes to the equilibrium reaction with the first inflow gas G111 in the modified first bed layer S11C and the first inflow gas reaction portion GR111 that contributes to the equilibrium state with the modified first bed layer S11C. As a result, the first bed layer equilibrium reaction calculation unit 214-1 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 GR111 when they reach equilibrium.

The first bed layer equilibrium reaction calculation unit 214-1 has the function of performing equilibrium reaction calculations to determine the type, phase, flow rate, etc. of the product (product) by presetting the type, phase, flow rate, etc. of the product that may be produced by the reaction between the first bed layer reaction component SR1 and the first inflow gas reaction component GR111, so that the free energy of the product is minimized. In other words, the modified first bed layer S11C, like the gas region equilibrium reaction calculation unit 213, can perform equilibrium reaction calculations based on the Gibbs energy minimization method. The first bed layer equilibrium reaction calculation unit 214-1 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product when the first bed layer reaction component SR1 and the first inflow gas reaction component GR111 reach equilibrium.

The first bed layer equilibrium reaction calculation unit 214-1 calculates the product material produced by the reaction between the first bed layer reaction SR1 and the first inflow gas reaction GR11, 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 214-1 also calculates the product gas produced by the reaction between the first bed layer reaction SR1 and the first inflow gas reaction GR111, and the unused portion of the first inflow gas reaction GR111, as the first inflow gas product GP111.

In other words, the first bed layer product SP1 is the sum of the product material produced by the reaction between the first bed layer reaction SR1 and the first inlet gas reaction GR11, and the unused portion of the first bed layer reaction SR1. The first inlet gas product GP111 is the sum of the product gas produced by the reaction between the first bed layer reaction SR1 and the first inlet gas reaction GR111, and the unused portion of the first inlet gas reaction GR111.

The second bed layer equilibrium reaction calculation unit 214-2 calculates the equilibrium reaction between the modified second bed layer S21A moving through the bed layer in region A and the second inlet gas G112 present in the bed layer. That is, the second bed layer equilibrium reaction calculation unit 214-2 performs equilibrium reaction calculations for the modified second bed layer S21A using the second bed layer reaction portion SR2 that contributes to the equilibrium reaction with the second inlet gas G112 in the modified second bed layer S21A and the second inlet gas reaction portion GR112 that contributes to the equilibrium state with the modified second bed layer S21A. This calculates at least the composition and amount of the second bed layer reactant SR2 and the second inlet gas reactant GR112, as well as the change in heat quantity and flow rate of each when the second bed layer reactant SR2 and the second inlet gas reactant GR112 reach equilibrium.

The second bed layer equilibrium reaction calculation unit 214-2 has the function of performing equilibrium reaction calculations to determine the type, phase, flow rate, etc. of the product (product) that may be produced by the reaction between the second bed layer reaction component SR2 and the second inflow gas reaction component GR112, 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, like the first bed layer equilibrium reaction calculation unit 214-1, the second bed layer equilibrium reaction calculation unit 214-2 can perform equilibrium reaction calculations based on the Gibbs energy minimization method. The second bed layer equilibrium reaction calculation unit 214-2 calculates and outputs the change in heat quantity, flow rate, type, composition, amount, and phase of the product when the second bed layer reaction component SR2 and the second inflow gas reaction component GR112 reach equilibrium.

The second bed layer equilibrium reaction calculation unit 214-2 calculates the product material produced by the reaction between the second bed layer reaction SR2 and the second inflow gas reaction GR112, 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 214-2 also calculates the product gas produced by the reaction between the second bed layer reaction SR2 and the second inflow gas reaction GR112, and the unused portion of the second inflow gas reaction GR112, as the second inflow gas product GP112.

In other words, the second bed layer product SP2 is the sum of the product material produced by the reaction between the second bed layer reaction SR2 and the second inlet gas reaction GR112, and the unused portion of the second bed layer reaction SR2. Furthermore, the second inlet gas product GP112 is the sum of the product gas produced by the reaction between the second bed layer reaction SR2 and the second inlet gas reaction GR112, and the unused portion of the second inlet gas reaction GR112.

The mixed gas phase calculation unit 215 has the function of mixing multiple flows, and calculates the flow rate and composition data of the third gas phase G3, which is a mixed gas phase obtained by mixing the unreacted gas portion Gr1 separated by the gas reaction amount calculation unit 207 and the first gas production portion GP1 generated by the gas region equilibrium reaction calculation unit 213.

The first mixed substance calculation unit 216 has the function of mixing multiple flows, and calculates the flow rate and composition data of the first mixed substance M11, which is a mixture of the unreacted portion of the first substance Mr1 separated by the first substance reaction amount calculation unit 208 and the product portion of the first substance MP1 generated by the gas region equilibrium reaction calculation unit 213.

The first mixed inflow gas calculation unit 217 has the function of mixing multiple flows and calculates the flow rate and composition data of the first mixed inflow gas G111A, which is a mixture of the first inflow gas unreacted portion Gr111 separated by the first inflow gas reaction amount calculation unit 210 and the first inflow gas product portion GP111 generated by the first bed layer equilibrium reaction calculation unit 214-1.

The first mixed bed layer calculation unit 218 has the function of mixing multiple flows, and calculates the flow rate and composition data of the first mixed bed layer S12, which is a mixture of the first bed layer unreacted portion Sr1 separated by the first bed layer reaction amount calculation unit 209 and the first bed layer product portion SP1 generated by the first bed layer equilibrium reaction calculation unit 214-1.

The second mixed inflow gas calculation unit 219 has the function of mixing multiple flows, and calculates the flow rate and composition data of the second mixed inflow gas G112A, which is a mixture of the second inflow gas unreacted portion Gr112 separated by the second inflow gas reaction amount calculation unit 212 and the second inflow gas product portion GP112 generated in the second bed layer equilibrium reaction calculation unit 214-2.

The second mixed bed layer calculation unit 220 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 211 and the second bed layer product portion SP2 generated by the second bed layer equilibrium reaction calculation unit 214-2.

The inflow gas combining unit 221 has the function of mixing multiple flows, and combines the first mixed inflow gas G111A generated by the first mixed inflow gas calculation unit 217 and the second mixed inflow gas G112A generated by the second mixed inflow gas calculation unit 219 to calculate the mixed inflow gas G12.

The gas amount summing unit 222 has the function of mixing multiple flows, and sums the third gas phase G3 generated by the mixed gas phase calculation unit 215 with the mixed inflow gas G12 generated by the inflow gas summing unit 221 to calculate the third mixed gas phase G3'.

The first mixed substance quantity correction unit 223 corrects the quantity of the first mixed substance M11, taking into account the amount of movement of the first mixed substance M11 to the first bed layer S11 generated by the first mixed substance calculation unit 216, and calculates the first corrected mixed substance M12.

The amount of the first mixed substance M11 is adjusted taking into account the amount of the fourth substance M4 contained in the first bed layer S11A that moves to the first mixed substance M11 present in the gas region, and the amount of the fifth substance M5 contained in the first mixed substance M11 that moves to the first bed layer S11A.

In this embodiment, at least one of the first bed layer equilibrium reaction calculation unit 214-1 and the second bed layer equilibrium reaction calculation unit 214-2 may be provided in two or more units. By further separating at least one of the first bed layer S11 and the first bed layer S21 into multiple bed layers, the bed layers in the rotary kiln 1 can be 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 the distribution section 201 if the combustion material 230 is not dropped into the rotary kiln 1. In this case, the gas reaction portion is the reaction portion of the first gas phase G1 that contributes to the equilibrium reaction with the bed layer S1, and the bed reaction portion is the reaction portion of the bed layer S1 that contributes to the equilibrium state with the first gas phase G1.

In this embodiment, the reactor reaction calculation device 20 may not include one or more of the first bed layer preliminary quantity correction unit 203, the first bed layer quantity correction unit 204, and the second bed layer quantity correction unit 205. For example, if the reactor reaction calculation device 20 does not include the first bed layer preliminary quantity correction unit 203 and the first bed layer quantity correction unit 204, the first bed layer reaction quantity calculation unit 209 uses the first bed layer S11 instead of the corrected first bed layer S11C. Furthermore, if the reactor reaction calculation device 20 does not include the second bed layer quantity correction unit 205, the second bed layer reaction quantity calculation unit 211 uses the second bed layer S21 instead of the corrected second bed layer S21A.

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

<Calculation method for reactor reactions>
Next, a method for calculating furnace reactions according to this embodiment will be described using the furnace reaction calculation device according to this embodiment. In this method, raw ore is supplied from the charging end 14A of the rotary kiln 1 and moved toward the discharge end 14B. A combustion material 230 is introduced midway through the movement of the raw ore. The raw ore is then brought into contact with combustion gas supplied from a burner 16 provided at the discharge end 14B, whereby the raw ore is dried and reduced.

Figure 5 is a flowchart illustrating the method for calculating furnace reactions according to this embodiment. As shown in Figure 5, the furnace reaction calculation device 20 checks whether combustion material 230 has been dropped into the rotary kiln 1 (checking step: step S11).

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

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

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

Next, the reactor reaction calculation device 20 receives as input materials the first bed layer S11, which is a pre-distributed bed layer S1 flowing into region A from the other adjacent region (region (A-1)), and the additive bed layer AS11, which is a bed layer of combustion material distributed by the distribution unit 201. The reactor reaction calculation device 20 mixes the first bed layer S11 and the additive bed layer AS11 to calculate the first bed layer S11A (bed layer mixing process of the first bed layer and the additive bed layer: step S15).

Next, the reactor reaction calculation device 20 provides the first bed layer S11A, the amount of fourth substance M4 contained in the first bed layer S11A that has moved to the gas region, and the amount of fifth substance M5 contained in the first mixed substance quantity correction unit 223 that has moved to the first bed layer S11A as input substances.

The reactor reaction calculation device 20 corrects the quantity of the first bed layer S11A by using the first bed layer preliminary quantity correction unit 203 to subtract the amount of the fourth substance M4 contained in the first bed layer S11A that has moved to the gas region and add the amount of the fifth substance M5 contained in the first mixed substance quantity correction unit 223 that has moved to the first bed layer S11A, thereby calculating the preliminary corrected first bed layer S11B (first bed layer preliminary quantity correction process: step S16).

Next, the reactor reaction calculation device 20 provides as input materials the preliminary correction first bed layer S11B, the amount of fourth substance M4 contained in the preliminary correction first bed layer S11B moving to the second bed layer S21, and the fifth substance M5 in the second bed layer S21 divided by the second bed layer quantity correction unit 205.

The reactor reaction calculation device 20 uses the first bed layer quantity correction unit 204 to subtract the movement amount of the second substance M2 contained in the preliminary correction first bed layer S11B from the preliminary correction first bed layer S11B, and adds the movement amount of the third substance M3 in the second bed layer S21, which is divided by the second bed layer quantity correction unit 205, to the preliminary correction first bed layer S11B. As a result, the reactor reaction calculation device 20 corrects the quantity of the preliminary correction first bed layer S11B and calculates the corrected first bed layer S11C (preliminary correction first bed layer quantity correction process: step S17).

Next, the reactor reaction calculation device 20 provides as input materials the second bed layer S21, the movement amount of the second substance M2 in the preliminary corrected first bed layer S11B divided by the first bed layer quantity correction unit 204, and the third substance M3 in the second bed layer S21 divided by the second bed layer quantity correction unit 205.

The reactor reaction calculation device 20 uses the second bed layer quantity correction unit 205 to subtract the movement amount of the third substance M3 contained in the second bed layer S21 from the second bed layer S21, and adds the movement amount of the second substance M2 divided by the first bed layer quantity correction unit 204 to the second bed layer S21. As a result, the reactor reaction calculation device 20 corrects the quantity of the second bed layer S21 and calculates the corrected second bed layer S21A (second bed layer quantity correction process: step S18).

Next, the reactor reaction calculation device 20 performs gas region equilibrium reactions (gas region equilibrium reaction execution process: step S19).

Next, the reactor reaction calculation device 20 performs the first bed layer equilibrium reaction (first bed layer equilibrium reaction execution process: step S20).

Next, the reactor reaction calculation device 20 performs the second bed layer equilibrium reaction (second bed layer equilibrium reaction execution process: step S21).

Next, the reactor reaction calculation device 20 uses the inflow gas summing unit 221 to sum the first mixed inflow gas G111A generated in the first bed layer equilibrium reaction implementation process (step S20) with the second mixed inflow gas G111B generated in the second bed layer equilibrium reaction implementation process (step S21) to obtain the mixed inflow gas G12 (inflow gas summing process: step S22).

Next, the furnace reaction calculation device 20 uses the gas amount summation unit 222 to sum the third gas phase G3 generated in the gas region equilibrium reaction implementation step (step S19) with the mixed inflow gas G12 generated in the first mixed inflow gas and second mixed inflow gas summation step (step S22) to obtain a third combined gas phase G3' (gas amount summation step: step S23).

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

Next, the furnace reaction calculation device 20 uses the first mixed substance quantity correction unit 223 to correct the quantity of the first mixed substance M11 by dividing the first mixed substance M11 produced in the gas region equilibrium reaction implementation process (step S19) by the amount of movement of the fourth substance M4 produced in the first bed layer preliminary quantity correction process (step S16) and adding the amount of movement of the fifth substance M5 from the first mixed substance M11 to the first bed layer S11, thereby calculating the first corrected mixed substance M12 (first mixed substance quantity correction process: step S24).

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

Next, the gas region equilibrium reaction implementation step (step S19) will be described. Figure 6 is a flowchart showing the operation of the gas region equilibrium reaction implementation step (step S19) in Figure 5. As shown in Figure 6, in the gas region equilibrium reaction implementation step (step S19), the furnace reaction calculation device 20 uses the gas reaction amount calculation unit 207 to calculate the gas reaction amount in the second gas phase G2 that contributes to the equilibrium state with the first material reaction amount MR1 (gas reaction amount calculation step: step S191).

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

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

Next, the reactor reaction calculation device 20 uses the first substance reaction amount calculation unit 208 to calculate the amount of the first substance reaction that contributes to the equilibrium state with the second gas phase G2, out of the first substance M1 present in the gas region (first substance reaction amount calculation process: step S192).

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

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

Next, the reactor reaction calculation device 20 provides the gas reaction amount GR1 obtained in the gas reaction amount calculation step (step S191) and the first material reaction amount MR1 obtained in the first material reaction amount calculation step (step S192) as input materials. The reactor reaction calculation device 20 uses the gas region equilibrium reaction calculation unit 213 to calculate the equilibrium reaction between the gas reaction amount GR1 and the first material reaction amount MR1, and calculates at least the change in heat quantity and flow rate of each when the gas reaction amount GR1 and the first material reaction amount MR1 reach equilibrium (gas region equilibrium reaction calculation step: step S193).

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

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

Next, the reactor reaction calculation device 20 receives as input the unreacted gas portion Gr1 obtained in the gas reaction amount calculation step (step S191) and the gas product portion GP1 obtained in the gas region equilibrium reaction calculation step (step S193). The reactor reaction calculation device 20 then uses the mixed gas phase calculation unit 215 to calculate the flow rate, composition data, etc. of the third gas phase G3 containing the unreacted gas portion Gr1 and the first gas product portion GP1 (mixed gas phase calculation step: step S194).

The gas reaction amount GR1 calculated in the gas reaction amount calculation process (step S191) is the reaction amount when it is assumed that the second gas phase G2 and the first substance M1 have reached equilibrium, and is therefore normally used in its entirety. However, the gas phase gas reaction amount GR1 may contain substances present in amounts greater than the stoichiometric ratio of the reaction or inactive substances that do not contribute to the reaction. Examples of inactive substances include nitrogen. In the mixed gas phase calculation process (step S194), substances present in amounts greater than the stoichiometric ratio of the reaction exist, resulting in the presence of inactive substances or substances remaining after the equilibrium reaction. The unused portion remaining unused in the gas region equilibrium reaction calculation unit 213 is calculated as the gas production amount GP1.

Next, the reactor reaction calculation device 20 receives as input materials the unreacted first substance Mr1 obtained in the first substance reaction amount calculation step (step S192) and the first substance product MP1 obtained in the gas region equilibrium reaction calculation step (step S193). The reactor reaction calculation device 20 uses the first mixed substance calculation unit 216 to calculate the flow rate, composition data, etc. of the first mixed substance M11 obtained by mixing the unreacted first substance Mr1 and the first substance product MP1 (first mixed substance calculation step: step S195).

Next, the first bed layer equilibrium reaction implementation step (step S20) will be described. Figure 7 is a flowchart showing the operation of the first bed layer equilibrium reaction implementation step (step S20) in Figure 5. As shown in Figure 7, in the first bed layer equilibrium reaction implementation step (step S20), the reactor reaction calculation device 20 uses the first bed layer reaction amount calculation unit 209 to calculate the first bed layer reaction amount that contributes to the equilibrium state with the first inflow gas reaction amount GR111 in the modified first bed layer S11C using the first reaction rate equation (first bed layer reaction amount calculation step: step S201).

In other words, assuming that the modified first bed layer S11C and the first inflow gas G111 react to reach equilibrium, the furnace reaction calculation device 20 uses the first reaction rate equation to calculate the amount of first bed layer reaction that contributes to the reaction when the modified first bed layer S11C reacts with the first inflow gas G111 to reach equilibrium.

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 210 to calculate the first inflow gas reaction amount of the first inflow gas G111 that contributes to the equilibrium state with the modified first bed layer S11C (first inflow gas reaction amount calculation process: step S202).

In other words, assuming that the first inflow gas G111 and the modified first bed layer S11C react to reach equilibrium, the furnace reaction calculation device 20 calculates the amount of first inflow gas reaction that contributes to the reaction when the first inflow gas G111 reacts with the modified first bed layer S11C to reach equilibrium.

Then, based on the calculation result of the first inflow gas reaction amount, the furnace reaction calculation device 20 divides the first inflow gas into a first inflow gas reaction amount GR111 corresponding to the first inflow gas reaction amount and a first inflow gas unreacted amount Gr111 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 receives as input the first bed layer reaction fraction SR1 obtained in the first bed layer reaction amount calculation step (step S201) and the first inflow gas reaction fraction GR111 obtained in the first inflow gas reaction amount calculation step (step S202). The reactor reaction calculation device 20 uses the first bed layer equilibrium reaction calculation unit 214-1 to calculate the equilibrium reaction between the first bed layer reaction fraction SR1 and the first inflow gas reaction fraction GR111, and calculates at least the change in heat quantity and flow rate of each when the first bed layer reaction fraction SR1 and the first inflow gas reaction fraction GR111 reach equilibrium (first bed layer equilibrium reaction calculation step S203).

The furnace reaction calculation device 20 calculates the bed layer produced by the reaction between the first bed layer reaction portion SR1 and the first inflow gas reaction portion GR111, and the unused portion of the first bed layer reaction portion SR1, as the first bed layer product portion SP1. Furthermore, the furnace reaction calculation device 20 calculates the gas phase produced by the reaction between the first bed layer reaction portion SR1 and the first inflow gas reaction portion GR111, and the unused portion of the first inflow gas reaction portion GR111, as the first inflow gas product portion GP111.

Next, the reactor reaction calculation device 20 receives as input the first bed layer unreacted fraction Sr1 obtained in the first bed layer reaction amount calculation step (step S201) and the first bed layer product fraction SP1 obtained in the first bed layer equilibrium reaction calculation step (step S203). The reactor reaction calculation device 20 uses the first bed layer equilibrium reaction calculation unit 214-1 to calculate the flow rate, composition data, etc. of the first mixed bed layer S12, which contains the first bed layer unreacted fraction Sr1 and the first bed layer product fraction SP1 (first mixed bed layer calculation step: step S204).

The first bed layer reaction amount SR1 of the first bed layer calculated in the first bed layer reaction amount calculation step (step S201) may contain substances present in amounts greater than the stoichiometric ratio for the reaction and inactive substances that do not contribute to the reaction. In the first mixed bed layer calculation step (step S204), the portion of the first bed layer reaction amount SR1 that is present in amounts greater than the stoichiometric ratio for the reaction and is therefore not used in the reaction, as well as the inactive portion, is calculated and included in the first bed layer product amount SP1 as the unused portion remaining unused in the first bed layer equilibrium reaction calculation step (step S203).

The reactor reaction calculation device 20 moves the first mixed bed layer S12 to a region (region (A+1)) closer to the discharge end 14B than region A.

Next, the furnace reaction calculation device 20 receives as input the first inlet gas unreacted portion Gr111 obtained in the first inlet gas reaction amount calculation step (step S202) and the first inlet gas product portion GP111 obtained in the first bed layer equilibrium reaction calculation step (step S203). The furnace reaction calculation device 20 uses the first mixed inlet gas calculation unit 217 to calculate the flow rate, composition data, etc. of the first mixed inlet gas G111A containing the first inlet gas unreacted portion Gr111 and the first inlet gas product portion GP111 (first mixed inlet gas calculation step: step S205).

Next, the second bed layer equilibrium reaction implementation step (step S21) will be described. Figure 8 is a flowchart showing the operation of the second bed layer equilibrium reaction implementation step (step S21) in Figure 3. As shown in Figure 8, in the second bed layer equilibrium reaction implementation step (step S21), the reactor reaction calculation device 20 uses the second bed layer reaction amount calculation unit 211 to calculate the second bed layer reaction amount that contributes to the equilibrium state with the second inflow gas reaction amount GR112 in the modified second bed layer S21A using the second reaction rate equation (second bed layer reaction amount calculation step: step S211).

In other words, assuming that the modified second bed layer S21A and the second inflow gas G112 react to reach equilibrium, the furnace reaction calculation device 20 uses the second reaction rate equation to calculate the amount of second bed layer reaction that contributes to the reaction when the modified second bed layer S21A reacts with the second inflow gas G112 to reach equilibrium.

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 furnace reaction calculation device 20 uses the second inflow gas reaction amount calculation unit 212 to calculate the second inflow gas reaction amount of the second inflow gas G112 that contributes to the equilibrium state with the modified second bed layer S21A (second inflow gas reaction amount calculation process: step S212).

In other words, assuming that the second inflow gas G112 and the modified second bed layer S21A react to reach equilibrium, the furnace reaction calculation device 20 calculates the amount of second inflow gas reaction that contributes to the reaction when the second inflow gas G112 reacts with the modified second bed layer S21A to reach equilibrium.

Then, based on the calculation result of the second inflow gas reaction amount, the furnace reaction calculation device 20 divides the second inflow gas into a second inflow gas reaction amount GR112 corresponding to the second inflow gas reaction amount and a second inflow gas unreacted amount Gr112 corresponding to the remaining unreacted amount.

Next, the reactor reaction calculation device 20 receives as input the second bed layer reaction portion SR2 obtained in the second bed layer reaction amount calculation step (step S211) and the second inflow gas reaction portion GR112 obtained in the second inflow gas reaction amount calculation step (step S212). The reactor reaction calculation device 20 uses the second bed layer equilibrium reaction calculation unit 214-2 to calculate the equilibrium reaction between the second bed layer reaction portion SR2 and the second inflow gas reaction portion GR112, and calculates at least the change in heat quantity and flow rate of each when the second bed layer reaction portion SR2 and the second inflow gas reaction portion GR112 reach equilibrium (first bed layer equilibrium reaction calculation step: step S213).

The furnace reaction calculation device 20 calculates the bed layer produced by the reaction between the second bed layer reaction portion SR2 and the second inflow gas reaction portion GR112, 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 gas phase produced by the reaction between the second bed layer reaction portion SR2 and the second inflow gas reaction portion GR112, and the unused portion of the second inflow gas reaction portion GR112, as the second inflow gas product portion GP112.

Next, the reactor reaction calculation device 20 receives as input the second bed layer unreacted portion Sr2 obtained in the second bed layer reaction amount calculation step (step S211) and the second bed layer product portion SP2 obtained in the second bed layer equilibrium reaction calculation step (step S213). The reactor reaction calculation device 20 uses the second bed layer equilibrium reaction calculation unit 214-2 to calculate the flow rate, composition data, etc. of the second mixed bed layer S22, which contains the second bed layer unreacted portion Sr2 and the second bed layer product portion SP2 (second mixed bed layer calculation step: step S214).

The second bed layer reaction portion SR2 of the second bed layer calculated in the second bed layer reaction amount calculation step (step S211) may contain substances present in amounts greater than the stoichiometric ratio for the reaction and inactive substances that do not contribute to the reaction. In the second mixed bed layer calculation step (step S214), the second bed layer reaction portion SR2 contains a portion that is present in amounts greater than the stoichiometric ratio for the reaction and is therefore not used in the reaction, as well as an inactive portion. The unused portion that remains unused in the second bed layer equilibrium reaction calculation step (step S213) is calculated as the second bed layer product portion 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 furnace reaction calculation device 20 receives as input the second inlet gas unreacted portion Gr112 obtained in the second inlet gas reaction amount calculation step (step S212) and the second inlet gas product portion GP112 obtained in the second bed layer equilibrium reaction calculation step (step S213). The furnace reaction calculation device 20 uses the second mixed inlet gas calculation unit 219 to calculate the flow rate, composition data, etc. of the second mixed inlet gas G112A containing the second inlet gas unreacted portion Gr112 and the second inlet gas product portion GP112 (second mixed inlet gas calculation step: step S215).

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

For example, the method for calculating furnace reactions according to this embodiment may perform at least one of the steps of performing gas-phase equilibrium reactions (step S19), performing first bed layer equilibrium reactions (step S20), and performing second bed layer equilibrium reactions (step S21) in parallel.

In the method for calculating the furnace reaction according to this embodiment, the inflow gas summing process (step S22) and the first mixture substance quantity correction process (step S24) may be performed in parallel, or the inflow gas summing process (step S22) may be performed after the first mixture substance quantity correction process (step S24).

In the method for calculating the furnace reaction according to this embodiment, the gas amount summing step (step S23) and the first mixed substance amount correction step (step S24) may be performed in parallel, or the gas amount summing step (step S23) may be performed after the first mixed substance amount correction step (step S24).

In the method for calculating the furnace reaction according to this embodiment, the gas reaction amount calculation step (step S191) and the first substance reaction amount calculation step (step S192) may be performed in parallel, or the gas reaction amount calculation step (step S191) may be performed after the first substance reaction amount calculation step (step S192).

In the method for calculating the furnace reaction according to this embodiment, the mixed gas phase calculation step (step S194) and the first mixed substance calculation step (step S195) may be performed in parallel, or the mixed gas phase calculation step (step S194) may be performed after the first mixed substance calculation step (step S195).

In the method for calculating the furnace reaction according to this embodiment, the first bed layer reaction amount calculation step (step S201) and the first inflow gas reaction amount calculation step (step S202) may be performed in parallel, or the first bed layer reaction amount calculation step (step S201) may be performed after the first inflow gas reaction amount calculation step (step S202).

In the method for calculating the furnace reaction according to this embodiment, the first mixed bed layer calculation step (step S204) and the first mixed inflow gas calculation step (step S205) may be performed in parallel, or the first mixed bed layer calculation step (step S204) may be performed after the first mixed inflow gas calculation step (step S205).

In the method for calculating the furnace reaction according to this embodiment, the second bed layer reaction amount calculation step (step S211) and the second inflow gas reaction amount calculation step (step S212) may be performed in parallel, or the second bed layer reaction amount calculation step (step S211) may be performed after the second inflow gas reaction amount calculation step (step S212).

In the method for calculating the furnace reaction according to this embodiment, the second mixed bed layer calculation step (step S214) and the second mixed inlet gas calculation step (step S215) may be performed in parallel, or the second mixed bed layer calculation step (step S214) may be performed after the second mixed inlet gas calculation step (step S215).

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

<Hardware configuration of reactor reaction calculation device>
Next, an example of the hardware configuration of a reactor reaction calculation device will be described. FIG. 9 is a hardware configuration diagram of the reactor reaction calculation device. As shown in FIG. 9, 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, a display device 26, which is an output device, and the like. These are connected to each other by a bus 27. Note that 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 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 analysis screen.

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

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

The auxiliary storage device 24 is a storage device such as an SSD (Solid State Drive) or HDD (Hard Disk Drive), and stores, for example, the 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 external data recording servers 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 Figure 9 are realized by loading simulation software (including a reactor reaction calculation program) into a main memory device such as RAM 22 or ROM 23 or an auxiliary memory device 24, and executing a raw ore reaction calculation program stored in RAM 22, ROM 23, or auxiliary memory device 24 by the CPU 21, thereby reading and writing data from RAM 22, etc., and operating the input/output interface 25 and display device 26.

The calculation program for the reactor reaction can be a program with the following configuration.
That is, the calculation program for the in-furnace reaction is a program that causes at least a computer to execute calculations for an in-furnace reaction in which raw material ore supplied from one end of a reactor is brought into contact with combustion gas supplied from the other end while moving the raw material ore toward the other end, thereby drying and reducing the raw material ore,
a gas mixing amount calculation step of calculating a flow rate of an inflow gas moving from the gas region in the reactor to a bed layer containing the raw ore, among a first gas phase containing the combustion gas flowing through a gas region in the reactor;
an inlet gas distribution step of dividing the inlet gas into a first inlet gas and a second inlet gas;
a first bed layer reaction amount calculation step of calculating, by using a first reaction rate equation, a first bed layer reaction amount contributing to an equilibrium state with the first inflow gas in one of two types of distributed bed layers distributed among the bed layers according to reaction rate-dependent conditions of the solid and liquid substances contained in the bed layer, thereby obtaining a first bed layer reaction amount contributing to the equilibrium reaction in the first bed layer;
a second bed layer reaction amount calculation step of calculating a second bed layer reaction amount contributing to an equilibrium state with the second inlet gas of the other of the two types of distributed bed layers using a second reaction rate equation different from the first reaction rate equation to obtain a second bed layer reaction amount contributing to the equilibrium reaction of the second bed layer;
a first bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the first bed layer reaction component and the first inflow gas;
a second bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the second bed layer reaction component and the second inflow gas;
a gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the first gas phase and a first substance including at least one of a solid substance and a liquid substance present in the gas region;
A program that causes a computer to execute at least the above can be used.

The furnace reaction calculation program is stored in a storage device provided in the computer, such as the main storage device of RAM 22 or ROM 23, or the auxiliary storage device 24. The raw ore reaction calculation program may be transmitted, in part or in whole, via a transmission medium such as a communications line, and received and recorded (including installed) by a communications module or the like provided in the computer. The raw ore reaction calculation program may also be stored, in part or in whole, on a portable storage medium such as a CD-ROM, DVD-ROM, or flash memory, and then recorded (including installed) in the computer.

As described above, the reactor reaction calculation device 20 according to this embodiment includes a gas mixing amount calculation unit 202, an inflow gas distribution unit 206, a first bed layer reaction amount calculation unit 209, a second bed layer reaction amount calculation unit 211, a gas region equilibrium reaction calculation unit 213, a first bed layer equilibrium reaction calculation unit 214-1, and a second bed layer equilibrium reaction calculation unit 214-2. The reactor reaction calculation device 20 uses the first reaction rate equation in the first bed layer reaction amount calculation unit 209 to determine the first bed layer reaction amount SR1 that contributes to the equilibrium reaction from the corrected first bed layer S11C, and the second bed layer reaction amount calculation unit 211 to determine the second bed layer reaction amount SR2 that contributes to the equilibrium reaction from the corrected second bed layer S21A, using the second reaction rate equation. Furthermore, the furnace reaction calculation device 20 calculates the flow rate of inflow gas G11, which moves from the gas region to the bed layer, in the second gas phase G2, in the gas mixture calculation unit 202, and distributes the inflow gas G11 into a first inflow gas G111 and a second inflow gas G112 in the inflow gas distribution unit 206. The furnace reaction calculation device 20 calculates the equilibrium reaction between the first bed layer reaction component S11B and the first inflow gas G111 in the first bed layer equilibrium reaction calculation unit 214-1, and calculates the equilibrium reaction between the second bed layer reaction component SR2 and the second inflow gas reaction component GR112 in the second bed layer equilibrium reaction calculation unit 214-2.

The modified first bed layer S11C is the portion of the bed layer S11 where the reaction rate is fast, and the modified second bed layer S21A is the portion of the bed layer S11 where the reaction rate is slow. The reactor reaction calculation device 20 calculates the first bed layer reaction portion SR1 using the first reaction rate equation for the portion of the bed layer S11 where the reaction rate is fast, such as the modified first bed layer S11C, and calculates the second bed layer reaction portion SR2 using the second reaction rate equation for the portion of the bed layer S11 where the reaction rate is slow, such as the modified second bed layer S21A.

The furnace reaction calculation device 20 therefore divides the bed layers in the reactor into two series, the modified first bed layer S11C and the modified second bed layer S21A, and can calculate the equilibrium reactions between these and the inflow gas G11 based on the Gibbs energy minimization method. Therefore, by taking into account the reaction behavior of two types of bed layers with different reaction rates within the bed layers in the rotary kiln 1, the furnace reaction calculation device 20 can accurately calculate the equilibrium reactions that occur in the bed layers.

This allows the furnace reaction calculation device 20 to calculate the equilibrium reactions occurring within the bed layer by taking into account areas of the bed layer with different reaction rates and the composition distribution of the raw ore present within the bed layer, allowing for fitting that is closer to the actual conditions within the furnace.

Furnace reaction calculation device 20 also calculates the equilibrium reaction between second gas phase G2 and first substance M1 present in the gas region by calculating the equilibrium reaction using gas reaction portion GR1 and first substance reaction portion MR1 in the gas region equilibrium reaction calculation unit 213. This allows furnace reaction calculation device 20 to calculate the equilibrium reaction between second gas phase G2 present in the gas region and first substance M1 based on the Gibbs energy minimization method. Therefore, furnace reaction calculation device 20 can accurately calculate the equilibrium reaction occurring in the gas region by taking into account the equilibrium reaction between second gas phase G2 and first substance M1 in the gas region within rotary kiln 1.

Therefore, the furnace reaction calculation device 20 can calculate with high accuracy the reactions occurring in the bed layer and gas region within the rotary kiln 1.

The reactor reaction calculation device 20 can be equipped with a first inflow gas reaction amount calculation unit 210. This allows the reactor reaction calculation device 20 to calculate the first inflow gas reaction amount GR111 that contributes to the equilibrium reaction from the first inflow gas G111 in the first inflow gas reaction amount calculation unit 210. Therefore, the reactor reaction calculation device 20 can reliably perform equilibrium reaction calculations with the modified first bed layer S11C in the first bed layer equilibrium reaction calculation unit 214-1 using the required first inflow gas reaction amount GR111.

The furnace reaction calculation device 20 can include a first mixed inlet gas calculation unit 217 and a first mixed bed layer calculation unit 218. As a result, the first mixed inlet gas calculation unit 217 of the furnace reaction calculation device 20 can calculate at least the flow rate of the first mixed inlet gas G111A, which is a mixture of the first inlet gas unreacted portion Gr111 and the first inlet gas product portion GP111. The first mixed bed layer calculation unit 218 of the furnace reaction calculation device 20 can calculate at least the flow rate of the first mixed bed layer S12, which is a mixture of the first bed layer unreacted portion Sr1 and the first bed layer product portion SP1. As a result, the furnace reaction calculation device 20 can accurately calculate the amount of movement of the first inlet gas G111 and the amount of movement of the first mixed bed layer S12 to the discharge end 14B.

The reactor reaction calculation device 20 can be equipped with a second inflow gas reaction amount calculation unit 212. This allows the reactor reaction calculation device 20 to calculate the second inflow gas reaction amount GR112 that contributes to the equilibrium reaction from the second inflow gas G112 in the second inflow gas reaction amount calculation unit 212. Therefore, the reactor reaction calculation device 20 can reliably perform equilibrium reaction calculations with the modified second bed layer S21A in the second bed layer equilibrium reaction calculation unit 214-2 using the required second inflow gas reaction amount GR112.

The furnace reaction calculation device 20 can include a second mixed inlet gas calculation unit 219 and a second mixed bed layer calculation unit 220. As a result, the furnace reaction calculation device 20 can use the second mixed inlet gas calculation unit 219 to calculate at least the flow rate of the second mixed inlet gas G112A, which is a mixture of the second inlet gas unreacted portion Gr112 and the second inlet gas product portion GP112. The furnace reaction calculation device 20 can use the second mixed bed layer calculation unit 220 to calculate at least 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 portion SP2. As a result, the furnace reaction calculation device 20 can accurately calculate the amount of movement of the second inlet gas G112 and the amount of movement of the second mixed bed layer S22 to the discharge end 14B.

The reactor reaction calculation device 20 can be equipped with a first bed layer quantity correction unit 204. This allows the reactor reaction calculation device 20 to subtract the amount of second substance M2 present in the preliminary corrected first bed layer S11B transferred to the second bed layer S21, and add the amount of third substance M3 present in the second bed layer S21 transferred to the preliminary corrected first bed layer S11B. Therefore, the reactor reaction calculation device 20 can more accurately calculate the flow rate of the corrected first bed layer S11C used in the equilibrium reaction calculation in the first bed layer equilibrium reaction calculation unit 214-1, thereby further improving the calculation accuracy of the equilibrium reaction of the corrected first bed layer S11C in the first bed layer S11.

The reactor reaction calculation device 20 can be equipped with a second bed layer quantity correction unit 205. This allows the reactor reaction calculation device 20 to subtract the amount of third substance M3 present in the second bed layer S21 transferred to the corrected first bed layer S11C, and add the amount of second substance M2 present in the preliminary corrected first bed layer S11B transferred to the second bed layer S21. Therefore, the reactor reaction calculation device 20 can accurately determine the flow rate and other parameters of the corrected second bed layer S21A used in the equilibrium reaction calculation in the second bed layer equilibrium reaction calculation unit 214-2, thereby further improving the calculation accuracy of the equilibrium reaction of the corrected second bed layer S21A in the second bed layer S21.

The reactor reaction calculation device 20 can include a gas reaction amount calculation unit 207 and a first substance reaction amount calculation unit 208. As a result, the reactor reaction calculation device 20 can calculate the gas reaction amount GR1 that contributes to the equilibrium reaction from the second gas phase G2, which includes the first gas phase G1, in the gas reaction amount calculation unit 207, and can calculate the first substance reaction amount MR1 that contributes to the equilibrium reaction from the first substance M1 present in the gas region in the first substance reaction amount calculation unit 208. Therefore, the reactor reaction calculation device 20 can calculate the reaction amounts to be used in the gas region equilibrium reaction calculation unit 213 from the second gas phase G2 and the first substance M1 present in the gas region, thereby reliably performing equilibrium reaction calculations in the gas region using the necessary reaction amounts.

The furnace reaction calculation device 20 may include a mixed gas phase calculation unit 215 and a first mixed substance calculation unit 216. The mixed gas phase calculation unit 215 of the furnace reaction calculation device 20 can calculate at least the flow rate of the third gas phase G3, which is a mixture of the unreacted gas portion Gr1 and the gas product portion GP1. The first mixed substance calculation unit 216 of the furnace reaction calculation device 20 can calculate at least the flow rate of the first mixed substance M11, which is a mixture of the unreacted first substance portion Mr1 and the first substance product portion MP1. This allows the furnace reaction calculation device 20 to more accurately calculate the amount of movement of the first gas phase G1 and the first substance M1 to the charging end 14A.

The furnace reaction calculation device 20 may include a first mixture substance quantity correction unit 223. This allows the furnace reaction calculation device 20 to include the fifth substance M5 contained in the first mixture substance M11 present in the gas region in the first bed layer S11A, and to include the fourth substance M4 present in the first bed layer S11A in the first mixture substance M11 present in the gas region. Therefore, the furnace reaction calculation device 20 can take into account the amount of the fifth substance M5 contained in the first mixture substance M11 that moves to the bed layer and the amount of the fourth substance M4 contained in the first bed layer S11A that moves to the first mixture substance M11, thereby accurately calculating the amount of the first mixture substance M11 present in region A that moves to region (A-1).

The reactor reaction calculation device 20 may include a first bed layer reserve quantity correction unit 203. This allows the reactor reaction calculation device 20 to include the fifth substance M5 contained in the first mixture M11 present in the gas region in the first bed layer S11A, and to include the fourth substance M4 present in the first bed layer S11A in the first mixture M11 present in the gas region. Therefore, the reactor reaction calculation device 20 can take into account the amount of the fifth substance M5 contained in the first mixture M11 transferred to the bed layer and the amount of the fourth substance M4 contained in the first bed layer S11A transferred to the first mixture M11, thereby accurately calculating the amount used for the equilibrium reaction in the first bed layer S11A present in region A. Therefore, the reactor reaction calculation device 20 can accurately determine the first bed layer reaction amount SR1 used in the first bed layer equilibrium reaction calculation unit 214-1, thereby enabling more accurate first bed layer equilibrium reaction calculations.

The furnace reaction calculation device 20 can be equipped with an inflow gas summing unit 221. This allows the furnace reaction calculation device 20 to calculate the mixed inflow gas G12, which is the sum of the first mixed inflow gas G111A and the second mixed inflow gas G112A. As a result, the furnace reaction calculation device 20 can move gas components present in the bed layer to the gas region. As a result, the furnace reaction calculation device 20 can move gas components present in the bed layer to the gas region and then to region (A-1).

The reactor reaction calculation device 20 can be equipped with a gas amount summing unit 222. This allows the reactor reaction calculation device 20 to mix the mixed inflow gas G12 generated in the bed layer into the third gas phase G3, thereby allowing the gas components present in the bed layer to be included in the third gas phase G3. Therefore, the reactor reaction calculation device 20 can reliably move the gas components present in region A to region (A-1).

The furnace reaction calculation device 20 may be equipped with a bed layer distribution unit 224. This allows the furnace reaction calculation device 20 to separate 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 region 1, which includes the charging end 14A, to region A, thereby more accurately calculating the mass flow rates used for the equilibrium reactions of the first bed layer S11 and the second bed layer S21 in region A. 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.

The furnace reaction calculation device 20 includes a distribution unit 201, which can distribute the gas phase and bed layer contained in the combustion material 230 introduced during the movement of the raw ore into the added gas phase AS11 and added bed layer AG11 at a mass flow rate. The furnace reaction calculation device 20 distributes the combustion material 230 introduced midway through the rotary kiln 1 into the first gas phase G1 and the first bed layer S1, treating each as separate fuels, and can treat the added gas phase AG11 as a component that constitutes the second gas phase G2, and the added bed layer AS11 as a component that constitutes the first bed layer S11. As a result, the furnace reaction calculation device 20 calculates the gas reaction amount GR11 from the second gas phase G2 and the first bed layer reaction amount SR11 from the modified first bed layer S11C, allowing the first bed layer equilibrium reaction calculation unit 214-1 to calculate the equilibrium reaction based on the reaction amounts required for the equilibrium reaction from the first inflow gas G111 and the modified first bed layer S11C. Therefore, the furnace reaction calculation device 20 can analyze the behavior of materials in the rotary kiln 1 taking into account the combustion material 230 that is added midway through the rotary kiln 1, allowing for highly accurate calculations of furnace reactions even when the combustion material 230 is used.

In this way, the furnace reaction calculation device 20 can accurately calculate the equilibrium reactions that occur in the furnace, taking into account that the bed layers in the rotary kiln 1 exhibit multiple different types of reaction behavior. Therefore, by applying the furnace reaction calculation device 20 to the entire area within the rotary kiln 1, it is possible to accurately calculate the entire reaction process within the rotary kiln 1.

The following describes the case where the furnace reaction calculation device 20 is applied to the entire rotary kiln 1. For example, as shown in Figure 10, when the rotary kiln 1 is divided into multiple regions and the reaction process in one region A is assumed to be a unit operation model, the furnace reaction calculation device 20 can model the reaction process within the rotary kiln 1 by combining unit operation models. The furnace reaction calculation device 20 then repeatedly performs calculations in multiple regions within the rotary kiln 1 along the flow of raw ore or combustion gas (including the assumed flow) (see arrows in Figure 6). 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 11 shows a flowchart for applying the furnace reaction calculation device 20 to the entire rotary kiln 1. As shown in Figure 11, the furnace reaction calculation device 20 models the reaction process that occurs in the rotary kiln 1 by combining multiple unit operation models (modeling process: step S21).

The reactor reaction calculation device 20 shown in Figure 2 above is applied to the unit operation model. For each unit operation model, the gas mixture amount calculation unit 202, inlet gas distribution unit 206, gas region equilibrium reaction calculation unit 213, first bed layer equilibrium reaction calculation unit 214-1, second bed layer equilibrium reaction calculation unit 214-2, 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 into the unit operation model.

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

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

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

If calculations have been completed up to the final unit operation model (Step S23: Yes), the reactor reaction calculation device 20 determines whether a previous calculation value for the unit operation model is available (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 S24) 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).

Convergence conditions include, for example, the difference between the calculated value and the previous calculated value being within a few degrees Celsius (e.g., 1°C).

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 terminates 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 calculations have not been completed up to the final unit operation model (step S23: No), the reactor reaction calculation device 20 moves on 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 proceeds to the first unit operation model (step S28).

The furnace reaction calculation device 20 therefore models the reaction process occurring in the rotary kiln 1 using a combination of multiple unit operation models, and performs calculations based on the values set for each unit operation model in accordance with the connection order of the unit operation models. In this embodiment, calculations for each unit operation model are performed sequentially from the charging end 14A toward the discharge end 14B of the rotary kiln 1, and then from the discharge end 14B toward the charging end 14A (see Figure 6). This series of operations is then repeated until the calculated values in a specified region A satisfy a specified convergence condition. As a result, calculation results are derived for the flow rates of combustion gas and raw ore in each region within the rotary kiln 1. This enables more accurate analysis of the behavior of each substance that constitutes the combustion gas and raw ore throughout the entire kiln body 11 of the rotary kiln 1.

In this way, the furnace reaction calculation device 20 can accurately calculate the reactions within the reactor, taking into account the fact that the bed layers within the reactor exhibit two different types of reaction behavior, throughout the entire reaction process within the rotary kiln 1. This allows for more accurate analysis of the behavior of each substance within the rotary kiln 1 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 impact 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 Figure 1 midway does not necessarily have to contain both volatile matter and a bed layer, and may contain other substances such as ash in addition to the volatile matter and bed layer.

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

Although the embodiments have been described above, they are presented as examples and do not limit the present invention. The embodiments can be implemented in a variety of other forms, and various combinations, omissions, substitutions, modifications, etc. are possible without departing from the spirit of the invention. These embodiments and their variations are included within the scope and spirit of the invention, as well as within the scope of the inventions and their equivalents as set forth in the claims.

DESCRIPTION OF SYMBOLS 1 Rotary kiln 11 Kiln body 16 Burner 20 Calculation device for furnace reaction 201 Distribution section of combustion material (distribution section)
202 Gas mixture amount calculation unit 203 First bed layer preliminary material amount correction unit 204 First bed layer material amount correction unit 205 Second bed layer material amount correction unit 206 Inflow gas distribution unit 207 Gas reaction amount calculation unit 208 First material reaction amount calculation unit
209 First bed layer reaction amount calculation unit 210 First inflow gas reaction amount calculation unit 211 Second bed layer reaction amount calculation unit 212 Second inflow gas reaction amount calculation unit 213 Gas region equilibrium reaction calculation unit 214-1 First bed layer equilibrium reaction calculation unit 214-2 Second bed layer equilibrium reaction calculation unit 215 Mixed gas phase calculation unit 216 First mixed substance calculation unit 217 First mixed inflow gas calculation unit 218 First mixed bed layer calculation unit
219 Second mixed inlet gas calculation unit 220 Second mixed bed layer calculation unit 221 Inlet gas summing unit 222 Gas amount summing unit 223 First mixed substance amount correction unit 224 Bed layer distribution unit G1 First gas phase G2 Second gas phase G3 Third gas phase G3' Third mixed gas phase G11 Inlet gas G111 First inlet gas G112 Second inlet gas G111A First mixed inlet gas G112A Second mixed inlet gas G12 Mixed inlet gas S1 Bed layer S11, S11A First bed layer S11B Preliminary corrected first bed layer S11C Corrected first bed layer S12 First mixed bed layer S21 Second bed layer S21A Corrected second bed layer S22 Second mixed bed layer M1 First substance M2 Second substance M3 Third substance M4 Fourth substance M5 Fifth substance M11 First mixed substance M12 First modified mixed substance GR1 Reacted gas fraction Gr1 Unreacted gas fraction GP1 Gas product fraction MR1 Reacted first substance fraction Mr1 Unreacted first substance fraction MP1 First substance product fraction GR111 Reacted first inlet gas fraction Gr111 Unreacted first inlet gas fraction GP111 Product first inlet gas fraction GR112 Reacted second inlet gas fraction Gr112 Unreacted second inlet gas fraction GP112 Product second inlet gas fraction SR1 Reacted first bed layer fraction Sr1 Unreacted first bed layer fraction SP1 Product first bed layer fraction SR2 Reacted second bed layer fraction Sr2 Unreacted second bed layer fraction SP2 Product second bed layer fraction

Claims (13)

A calculation device for calculating a reaction in a furnace, in which raw material ore is supplied from one end of a reactor and moved toward the other end of the reactor, and the raw material ore is brought into countercurrent contact with combustion gas supplied from the other end, thereby drying and reducing the raw material ore,
a gas mixing amount calculation unit that calculates the flow rate of an inflow gas that moves from the gas region in the reactor to a bed layer that is the raw material ore, among the first gas phase that is the combustion gas flowing through the gas region in the reactor;
an inflow gas distribution unit that distributes the inflow gas into a first inflow gas and a second inflow gas;
a first bed layer reaction amount calculation unit that calculates, using a first reaction rate equation, a first bed layer reaction amount that contributes to an equilibrium state with the first inflow gas in one of two types of distributed bed layers among the bed layers distributed according to reaction rate-dependent conditions of the solid material and the liquid material contained in the bed layer, thereby determining a first bed layer reaction amount that contributes to the equilibrium reaction of the first bed layer;
a second bed layer reaction amount calculation unit that calculates a second bed layer reaction amount that contributes to an equilibrium state with the second inflow gas in the other second bed layer of the two types of distributed bed layers using a second reaction rate equation different from the first reaction rate equation, and obtains a second bed layer reaction amount that contributes to the equilibrium reaction in the second bed layer;
a first bed layer equilibrium reaction calculation unit that calculates an equilibrium reaction between the first bed layer reaction component and the first inflow gas;
a second bed layer equilibrium reaction calculation unit that calculates an equilibrium reaction between the second bed layer reaction component and the second inflow gas;
a gas region equilibrium reaction calculation unit that calculates an equilibrium reaction between the first gas phase and a first substance including at least one of a solid substance and a liquid substance present in the gas region based on a Gibbs energy minimization method;
a first inflow gas reaction amount calculation unit that calculates a gas reaction amount that contributes to an equilibrium state of the first inflow gas with the first bed layer, and obtains a first inflow gas reaction amount that contributes to the equilibrium reaction of the first inflow gas;
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, which is an unreacted portion other than the first inflow gas reacted portion generated in the first inflow gas reaction amount calculation unit, and a first inflow gas product portion generated by the reaction of 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 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, which is an 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 second inflow gas reaction amount calculation unit that calculates a gas reaction amount that contributes to an equilibrium state of the second inflow gas with the second bed layer, and obtains a second inflow gas reaction amount that contributes to the equilibrium reaction of the second inflow gas;
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, which is an unreacted portion other than the second inflow gas reacted 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 reacted portion and the second inflow gas reacted portion in the second bed layer equilibrium reaction calculation unit;
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, which is an 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;
Equipped with
the reaction rate-causing condition is both one or more properties of the solid substance contained in the bed layer selected from the group consisting of particle size, specific gravity, type, and segregation, and one or more properties of the liquid substance contained in the bed layer selected from the group consisting of specific gravity, type, and segregation,
The reactor is divided into a plurality of regions, and when the reaction process in one region is assumed to be a unit operation model, the reactor calculation device is applied to each of the unit operation models, models the reaction process in the reactor by combining the unit operation models, and repeatedly calculates the unit operation models in the plurality of regions in the reactor along the flow of the raw material ore or the flow of the combustion gas, until the difference between the calculated value of the temperature of the first gas phase and the first bed layer in a predetermined region and the previous calculated value in that region satisfies a predetermined convergence condition. a first bed layer material quantity correcting unit that corrects the material quantity of the first bed layer by subtracting a movement amount of a second material, including at least one of a solid material and a liquid material, contained in the first bed layer from the movement amount of the second material to calculate a corrected first bed layer;
2. The apparatus for calculating a reactor reaction according to claim 1, wherein the first bed layer reaction amount calculation unit uses the modified first bed layer as the first bed layer. a second bed layer material quantity correcting unit that corrects the material quantity of the second bed layer by subtracting the amount of a third substance, including at least one of a solid substance and a liquid substance, contained in the second bed layer from the amount of movement of the third substance to the first bed layer, and calculates a corrected second bed layer;
3. The apparatus for calculating a reactor reaction according to claim 1, wherein the second bed layer reaction amount calculation unit uses the modified second bed layer as the second bed layer. a gas reaction amount calculation unit that calculates a gas reaction amount that contributes to an equilibrium state between the first gas phase and the first substance, and obtains a 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 the 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 reactor reaction calculation device according to any one of claims 1 to 3, comprising: The unreacted amount of gas other than the reacted amount of gas generated in the gas reaction amount calculation unit is defined as the unreacted amount of gas,
The unreacted amount of the first substance other than the reacted amount of the first substance generated in the first substance reaction amount calculation unit is defined as the unreacted amount of the first substance,
a mixed gas phase calculation unit that calculates at least a flow rate of a mixed gas phase obtained by mixing the unreacted gas and a gas product generated by the reaction of the gas reactant with the first substance reactant in the gas region equilibrium reaction calculation unit;
a first mixed substance calculation unit that calculates at least a flow rate of a first mixed substance obtained by mixing the unreacted portion of the first substance and a first substance product portion generated by the reaction of the gas reactant and the first substance reactant in the gas region equilibrium reaction calculation unit;
The reactor reaction calculation device according to claim 4, comprising: The reactor reaction calculation device of claim 5 further comprises a first mixture substance quantity correction unit that corrects the quantity of the first mixture substance and calculates a first corrected mixture substance, taking into account the amount of movement of a fourth substance, including at least one of a solid substance or a liquid substance contained in the first bed layer, to the gas region and the amount of movement of a fifth substance, including at least one of a solid substance or a liquid substance contained in the first mixture generated by the first mixture substance calculation unit, to the first bed layer. The reactor reaction calculation device according to claim 5 or 6, 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 fourth substance, including at least one of a solid substance or a liquid substance, contained in the first bed layer to the gas region, and the amount of movement of a fifth substance, including at least one of a solid substance or a liquid substance, contained in the first mixture generated by the first mixture calculation unit to the first bed layer. The reactor reaction calculation device according to any one of claims 1 to 7, further comprising an inflow gas combining unit that mixes a first inflow gas product resulting from the reaction of the first bed layer reaction component with the first inflow gas in the first bed layer equilibrium reaction calculation unit, and a second inflow gas product resulting from the reaction of the second bed layer reaction component with the second inflow gas in the second bed layer equilibrium reaction calculation unit. The reactor reaction calculation device of claim 8, further comprising a gas quantity summing unit that mixes a mixed inflow gas generated by mixing the first inflow gas product fraction and the second inflow gas product fraction in the inflow gas summing unit with a gas product fraction generated by the reaction between the first gas phase and the first substance in the gas region equilibrium reaction calculation unit. The reactor reaction calculation device according to any one of claims 1 to 9, further comprising a bed layer distribution unit that pre-allocates the first bed layer into two types of distribution bed layers according to the reaction rate-driven conditions of the solid and liquid materials contained in the first bed layer. A distribution unit is provided which distributes the combustion material, which is introduced during the movement of the raw ore and includes at least one of a gas phase and the bed layer, to the added gas phase and the added bed layer at a mass flow rate, with the gas phase being an added gas phase and the bed layer being an added bed layer,
the gas region equilibrium reaction calculation unit calculates an equilibrium reaction between the first substance and a second gas phase including the first gas phase and the additional gas phase;
The first bed layer equilibrium reaction calculation unit calculates the equilibrium reaction between the inflow gas and a first combined distribution bed layer including the first bed layer and the additive bed layer. 12. The apparatus for calculating a furnace reaction according to claim 1, wherein the raw material ore is a nickel oxide ore containing iron and nickel as main components. A method for calculating a reaction in a reactor, in which raw material ore is supplied from one end of a reactor and moved toward the other end of the reactor, while the raw material ore is brought into countercurrent contact with combustion gas supplied from the other end, thereby drying and reducing the raw material ore,
a gas mixing amount calculation step of calculating a flow rate of an inflow gas, which is the combustion gas flowing through a gas region in the reactor, moving from the gas region in the reactor to a bed layer which is the raw material ore;
an inlet gas distribution step of dividing the inlet gas into a first inlet gas and a second inlet gas;
a first bed layer reaction amount calculation step of calculating, by using a first reaction rate equation, a first bed layer reaction amount contributing to an equilibrium state with the first inflow gas in one of two types of distributed bed layers distributed among the bed layers according to reaction rate-dependent conditions of the solid and liquid substances contained in the bed layer, thereby obtaining a first bed layer reaction amount contributing to the equilibrium reaction in the first bed layer;
a second bed layer reaction amount calculation step of calculating a second bed layer reaction amount contributing to an equilibrium state with the second inlet gas of the other of the two types of distributed bed layers using a second reaction rate equation different from the first reaction rate equation to obtain a second bed layer reaction amount contributing to the equilibrium reaction of the second bed layer;
a first bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the first bed layer reaction component and the first inflow gas;
a second bed layer equilibrium reaction calculation step of calculating an equilibrium reaction between the second bed layer reaction component and the second inflow gas;
a gas region equilibrium reaction calculation step of calculating an equilibrium reaction between the first gas phase and a first substance including at least one of a solid substance and a liquid substance present in the gas region based on a Gibbs energy minimization method;
a first inflow gas reaction amount calculation step of calculating a gas reaction amount contributing to an equilibrium state of the first inflow gas with the first bed layer, thereby obtaining a first inflow gas reaction amount contributing to the equilibrium reaction of the first inflow gas;
a first mixed inflow gas calculation step of calculating at least a flow rate of a first mixed inflow gas obtained by mixing a first inflow gas unreacted portion, which is an unreacted portion other than the first inflow gas reacted portion generated in the first inflow gas reaction amount calculation step, and a first inflow gas product portion generated by the reaction of the first bed layer reacted portion and the first inflow gas reacted portion in the first bed layer equilibrium reaction calculation step;
a first mixed bed layer calculation step of calculating at least a flow rate of a first mixed bed layer obtained by mixing a first bed layer unreacted portion, which is an unreacted portion other than the first bed layer reacted portion generated in the first bed layer reaction amount calculation step, and a first bed layer product portion generated by the reaction of the first bed layer reacted portion with the first inflow gas reacted portion in the first bed layer equilibrium reaction calculation step;
a second inflow gas reaction amount calculation step of calculating a gas reaction amount contributing to an equilibrium state of the second inflow gas with the second bed layer, thereby obtaining a second inflow gas reaction amount contributing to the equilibrium reaction of the second inflow gas;
a second mixed inflow gas calculation step of calculating at least the flow rate of a second mixed inflow gas obtained by mixing a second inflow gas unreacted portion, which is an unreacted portion other than the second inflow gas reacted portion generated in the second inflow gas reaction amount calculation step, and a second inflow gas product portion generated by the reaction of the second bed layer reactant and the second inflow gas reactant in the second bed layer equilibrium reaction calculation step;
a second mixed bed layer calculation step of calculating at least a flow rate of a second mixed bed layer obtained by mixing a second bed layer unreacted portion, which is an unreacted portion other than the second bed layer reacted portion generated in the second bed layer reaction amount calculation step, and a second bed layer product portion generated by the reaction of the second bed layer reacted portion with the second inflow gas reacted portion in the second bed layer equilibrium reaction calculation step;
Including,
the reaction rate-causing condition is both one or more properties of a solid substance contained in the bed layer selected from the group consisting of particle size, specific gravity, type, and segregation, and one or more properties of a liquid substance contained in the bed layer selected from the group consisting of specific gravity, type, and segregation,
The method for calculating the reaction in the reactor is applied to each unit operation model when the reactor is divided into a plurality of regions and the reaction process in one region is assumed to be a unit operation model, the reaction process in the reactor is modeled by combining the unit operation models, and calculations of the unit operation models in the plurality of regions in the reactor are repeatedly performed along the flow of the raw material ore or the flow of the combustion gas, until the difference between the calculated value of the temperature of the first gas phase and the first bed layer in a predetermined region and the previous calculated value in that region satisfies a predetermined convergence condition.