Model-Based Optimization of Industrial Gas-Solid Reactors

Heterogeneous non-catalytic gas-solid reactors are essential in the production of chemicals, metals, and metal oxides, and their optimization is critical for industrial processes involving multicomponent solid mixtures. This paper discusses the significance of modeling the physico-chemical phenomena occurring in these reactors, such as gas flow through porous media, heat transfer, moisture management, and solid reactions. A variety of reactors, including rotary drum reactors and moving bed reactors, are highlighted along with case studies focusing on the production of direct reduced iron in rotary kilns and the induration of wet iron ore pellets in packed bed reactors. General features of the mathematical models utilized for simulating these non-catalytic reactors are described. The study emphasizes the need for effective model-based optimization methodologies to enhance production efficiency in the iron and steel industry, considering the complexities of heterogeneous raw materials and variations in their characteristics. This comprehensive review aims to provide insights into the modeling and optimization processes that can improve reactor performance and industrial outcomes.