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Influence of Hydrogen-Based Direct Reduction Shaft Furnace Interior Structure on Shaft Furnace Performance
Qingbin Xue1, Haotian Liao1, Jianliang Zhang1,2
1School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, 30 Xueyuan Rd., Haidian District, Beijing 100083, China.
Materials (Basel, Switzerland)
|October 29, 2025
Summary
A diverter device improves particle flow in shaft furnaces for hydrogen-based direct reduction of iron ore. Optimized diverter design enhances efficiency and reduces CO2 emissions in steelmaking.
Area of Science:
- Materials Science
- Chemical Engineering
- Process Engineering
Background:
- Hydrogen-based direct reduction is key for decarbonizing steelmaking.
- Uniform particle flow in shaft furnaces is critical for process efficiency.
- Current designs may not optimize granular flow dynamics.
Purpose of the Study:
- To investigate the impact of a diverter device on granular flow in a full-scale shaft furnace.
- To analyze how diverter geometry affects particle velocity, residence time, and energy dissipation.
- To provide design insights for optimizing shaft furnaces in hydrogen-based direct reduction.
Main Methods:
- Developed a three-dimensional Discrete Element Method (DEM) model of a full-scale shaft furnace.
- Systematically varied diverter radial width and top/bottom diameters.
- Analyzed particle descent velocity, residence time, compressive force distribution, and collision energy dissipation.
Main Results:
- The diverter effectively suppressed funnel flow and improved radial flow uniformity.
- Residence time was prolonged with the introduction of the diverter.
- A smaller central diameter diverter demonstrated optimal performance: faster, uniform descent, reduced force concentration, and lower energy dissipation.
Conclusions:
- Diverter design is crucial for regulating particle dynamics in shaft furnaces.
- Optimized diverter configurations can significantly enhance the efficiency of hydrogen-based direct reduction.
- Findings offer theoretical guidance for improving shaft furnace design for sustainable steelmaking.
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