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Volume 117
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Study on the effect of two AGD beams on the abrasive wear of screw flights in a COREX shaft furnace with scaffolding at different positions
Xinlei Yin, Yi Zhong, Wenjie Rong *, Shuoning Cui, Jiashuo Li
School of Metallurgy, Northeastern University, Shenyang, 110819, China
10.1016/j.partic.2026.08.004
Volume 117, October 2026, Pages 453-462
Received 22 May 2026, Revised 19 July 2026, Accepted 6 August 2026, Available online 6 August 2026, Version of Record 21 August 2026.
E-mail: rongwenjie@smm.neu.edu.cn
Highlights

• Effects of gas distribution beams and scaffolds on burden flow and screw wear were investigated.

• Scaffolds force particle bypass, while a 45-degree beam layout causes maximum flow asymmetry.

• Adding two gas distribution beams effectively reduces screw flight wear caused by scaffolding.

• A 90-degree relative position minimizes average wear depth and provides optimal wear reduction.


Abstract

The layout of Areal Gas Distribution (AGD) beams in COREX shaft furnaces influences burden motion and screw flight abrasion. High-temperature conditions easily trigger scaffold formation, further complicating internal furnace flow when scaffolds interact with AGD beams. This work adopts the Discrete Element Method (DEM) with Hertz-Mindlin no-slip contact and Archard wear model to investigate coupled impacts of AGD beams and scaffolds at various relative positions on burden flow and screw wear. Five conditions, two AGD beams, scaffolding, and three typical relative positions (0°, 45°, and 90°) between two AGD beams and scaffolding are compared. The results demonstrate that the burden flow presents distinct zonal characteristics. Particle bypass around scaffolding is relatively symmetric at 0° and 90°, while the 45° arrangement shows the most significant asymmetry in flow and accumulation. The average wear depth under all three combined conditions is lower than that under the scaffolding condition, indicating that the adoption of two AGD beams can partly alleviate scaffolding-induced wear aggravation. The 90° case presents the minimum average wear depth and the 0° case provides a more uniform wear distribution among different flights. Furthermore, the interaction analysis based on the standard 22 full-factor fixed-effects model indicates that the 90° case has the smallest interaction deviation and the best overall wear-reduction performance.

Graphical abstract
Keywords
COREX shaft furnace; AGD beams; Scaffolding; Archard wear model; Abrasive wear of screw flights
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