An in-depth exploration of the reaction kinetics and thermo-chemical behaviors of the raceway can offer practical insights for optimizing the operations of blast furnace (BF), thus achieving a more effective iron and steel production process. In this study, the dynamic characteristics and the flow, heat and mass transfer behaviors in the BF raceway were simulated by Discrete Element Method-Computational Fluid Dynamics (DEM-CFD) method at a particulate scale. The effects of coke size distribution and blast velocity on coke combustion characteristics, thermochemical behavior (particle volume fraction, raceway size, carbon loss, and coke temperature) and microscopic properties (coordination number (CN), contact normal force, pore structure and stress) were systematically investigated. The results show that as the blast velocity decreases or the size ratio λ (the largest coke particle size divided by the smallest coke particle size) increases, the raceway size becomes smaller, resulting in a smaller area of high oxygen (O₂) concentration and low carbon monoxide (CO) concentration in the raceway, and higher CO concentration in the packed bed. For the thermal-chemical behaviors, a lower blast velocity or a higher λ value decreases the number of particles experiencing mass loss, as well as increases individual particle mass loss, the average coke temperature and its variance. For microscopic properties, the CN distribution becomes wider as λ increases. The contact normal force in the coke bed with λ > 1 is significantly higher than that of λ = 1. As λ increases or blast velocity decreases, the pore distribution curve shifts to the left and the average pore volume decreases. The stress acting on the particles in the raceway increases with the blast velocity or λ. These new understandings of the complex reactive flow behaviors in the raceway will shed light on energy utilization and process optimization.

The densification of mono-sized regular octahedral particles under vibration is simulated by a DEM model. The model is validated by physical experiments. The effects of operating parameters including vibration amplitude and frequency are investigated. The obtained packing structures are characterized, and corresponding densification mechanisms are identified. The results indicate that vibration amplitude is more critical for densification compared to frequency, where a wide range of suitable amplitudes exists to realize the dense packing structures. Ordered packing structure exists in boundary region. The central region possesses good particle position randomness and orientation randomness, and the packing density for poured packing (initial loose packing) and vibrated packing (dense packing) in the central region are 0.670 and 0.684, respectively. During densification, contacts and constraints between particles decrease, and the stress within the structure becomes larger. The typical arrangement of neighboring particles is close to but not perfect face to face (F–F) contact. Particles in the boundary region experience more rotations and can form local ordered structures. These structures prevent the relative movement of individual particles but favor their movement as a whole. Particles in the central region have relatively little movement and rotation. The ordered structures formed at boundary is difficult to extend to the central region due to the restricted change of particle contact conditions.

The packing of cohesive particles is of paramount importance in many industries because the packing structure is closely related to process performance. A general relation between packing density and interparticle force was previously proposed based on packing structures formed without dynamic fluid flows. Its universality is examined here in two different packings, formed in settling and defluidization of static and dynamic fluids, respectively. First, it is shown that the packings of the same particles formed by two different methods have different structures because of different impact-induced pressures. Nevertheless, a one-to-one relationship between packing density and structural properties still holds regardless of the different packing methods, and the force distribution in those packings obeys similar rules. Finally, the packing densities obtained by the different methods are demonstrated to be universally correlated with the ratio of the interparticle force to the effective gravity. These findings indicate that different phenomena of particulate systems at a macro- or meso-scale may share similar microscopic origins, with the interparticle force playing a crucial role.

In this paper, the transition from random to ordered packings of mono-sized cylindrical particles under 3D mechanical vibration was simulated by discrete element method (DEM). The effects of particle aspect ratio, size of the particulate system and container wall on the granular crystallization were investigated. And the mechanisms were analyzed through the characterization of the order transition process in terms of packing density, coordination number (CN), orientational ordering parameter (O), nucleation and growth of cluster and granular temperature (θ). The results show that nearly perfect crystallization of mono-sized cylindrical particles can be achieved with specific aspect ratio and proper vibration conditions in a cylindrical container. The orientational ordering parameter demonstrates that the crystallization firstly starts from the container wall and then propagates inward gradually. The lower granular temperature in a cuboid container indicates less vibration energy transferred to the granular assembly compared with that in a cylindrical container, illustrating the critical role of container shape in crystallization. The vibrated crystallization of mono-sized cylindrical particles is analogous to entropy-driven process, which can be gradually achieved by the self-assembly of particles with parallel alignments along the already formed ordered clusters (nuclei)or the container wall. These results can help design complex and ordered granular structures.