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<p>This study analyzes the main components, migration, transformation, and deposition mechanisms of flue gas during the coal-fired grate rotary kiln process. The results indicate that during pellet oxidation, significant amounts of gases such as SO<sub>2</sub>, NaF, KF, Na<sub>2</sub>O, and K<sub>2</sub>O enter the flue gas. These gas phases are primarily adsorbed by the preheated pellets and condense on the grate bar's surface throughout the flue gas circulation process, resulting in the formation of sulfates (CaSO<sub>4</sub>, MgSO<sub>4</sub>, Na<sub>2</sub>SO<sub>4</sub>, Fe<sub>2</sub>(SO<sub>4</sub>)<sub>3</sub>, K<sub>2</sub>SO<sub>4</sub>), alkali metal ferrites (NaFeO<sub>2</sub>), and fluorides (NaF and KF). Additionally, some harmful gas phases are adsorbed by particulate dust in the flue gas, forming sulfates and fluorides that also precipitate on the surfaces of the preheated pellets and grate bars. The sulfates and fluorides present on the grate bars facilitate the oxidation of Cr–Fe alloys, leading to the formation of Cr–Fe oxide powders that subsequently detach from the grate bars. This process results in a larger area of voids at the bottom of the chain grate machine due to the corrosion of the grate bars, which disrupts the trajectory of the fuel gas and further affects heat distribution.</p> Graphical Abstract <p></p>

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Comprehensive Analysis of Waste Heat Recovery from Coal-Fired Rotary Kiln Flue Gas in Iron Pellet Production: Transport, Enrichment, and Detrimental Effects of Harmful Elements

  • 期刊论文

  • 发表日期：

    2025年3月19日

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  • Ke Ma,
  • Jing Yi,
  • Kun Lin,
  • Zijian Su,
  • Xiaoguang Bai,
  • Guowei Fu,
  • Tao Jiang,
  • Yuanbo Zhang

摘要

This study analyzes the main components, migration, transformation, and deposition mechanisms of flue gas during the coal-fired grate rotary kiln process. The results indicate that during pellet oxidation, significant amounts of gases such as SO2, NaF, KF, Na2O, and K2O enter the flue gas. These gas phases are primarily adsorbed by the preheated pellets and condense on the grate bar's surface throughout the flue gas circulation process, resulting in the formation of sulfates (CaSO4, MgSO4, Na2SO4, Fe2(SO4)3, K2SO4), alkali metal ferrites (NaFeO2), and fluorides (NaF and KF). Additionally, some harmful gas phases are adsorbed by particulate dust in the flue gas, forming sulfates and fluorides that also precipitate on the surfaces of the preheated pellets and grate bars. The sulfates and fluorides present on the grate bars facilitate the oxidation of Cr–Fe alloys, leading to the formation of Cr–Fe oxide powders that subsequently detach from the grate bars. This process results in a larger area of voids at the bottom of the chain grate machine due to the corrosion of the grate bars, which disrupts the trajectory of the fuel gas and further affects heat distribution.

Graphical Abstract