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1
Kassim, D. A., A. K. Tarakanov, V. P. Lyalyuk, P. I. Otorvin, and A. A. Gusev. "Влияние качества агломерата и кокса на технико-экономические показатели доменной плавки." Metallurgicheskaya i gornorudnaya promyshlennost, №4, 2018, no. 4 (August 2018): 17–24. http://dx.doi.org/10.33101/s004-0244074.
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Purpose: Compare the results of blast furnace smelting efficiency, when chang-ing the qualitative characteristics of the sinter and coke, and the calculated param-eters of the blowing regime of melting. Methodology: Analysis of technical and economic performance of blast furnaces during periods of work on the agglomerate with different metallurgical characteris-tics and different diameter of the tuyeres. Findings: The experience of blast furnaces with a volume of 2,700 and 2,000 m3 confirmed a known fact of the dependence of furnace efficiency and coke consump-tion not only through the quality of charge materials, but also through the distribu-tion of the gas flow along the furnace section. Originality: The technological analysis of the results of the operation of blast furnaces with the volume of 2700 and 2000 m3 with a change of the quality of the sinter and pellets in combination with the change of the blowing regime parame-ters was performed. On the basis of the performed analysis, it was confirmed the expediency of increasing the gas permeability of the charge by improving the quali-ty of the raw materials while increasing the total mechanical energy of the com-bined gas-blast and hearth-gas, which are responsible for the length of the com-bustion zone and the depth of penetration of the gas flow to the center of the blast furnace. Practical value: Alternation of tuyeres of different diameters along with the im-provement of the quality characteristics of charge materials, additionally contrib-utes to the enhancement of the positive effect due to the expansion of the combus-tion zones in the furnace hearth. And if in this case the total mechanical energy of the mountain gas rises and the depth of penetration of the furnace gas to the fur-nace axis increases, the effect of using high-quality raw materials can be maxim-ized. Keywords: agglomerate, coke, blowing, tuyeres, gas permeability, quality, total energy.
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Mirkovic, Tatjana, Hauke Bartusch, Pavel Ivashechkin, and Thorsten Hauck. "Monitoring the Blast furnace working state by a combination of innovative measurement techniques." Metallurgical and Materials Engineering 27, no. 4 (December 21, 2021): 411–23. http://dx.doi.org/10.30544/757.
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At blast furnace B at Salzgitter Flachstahl a series of innovative measuring techniques are installed to monitor the processes at the blast furnace top, making this furnace one of the best equipped furnaces in Europe. These techniques comprise full 2D measurement of the temperature profile of the top gas shortly above the burden surface, 3D radar scan of the whole burden surface and online measurement of the dust concentration in the top gas. After more than 5 years’ experience with most of these techniques, they enable to better understand the complex chemical and physical interrelations occurring in the BF stack between the ascending process gas and the descending solid burden. A couple of examples of incidents that were monitored are presented in this article, including influences of charging programmes on top gas temperature profiles and influences of disturbed gas solids interaction on the BF working state. The new measuring techniques with tailor-made data processing enable the operators to gain a better picture of the processes currently occurring in the blast furnace, consequently supporting them in keeping the blast furnace operation as stable and efficient as possible.
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Hu, Bin Sheng, Yong Liang Gui, Hua Lou Guo, and Chun Yan Song. "Behaviors of Chlorine in Smelting Process of Blast Furnace." Advanced Materials Research 396-398 (November 2011): 152–56. http://dx.doi.org/10.4028/www.scientific.net/amr.396-398.152.
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The existence forms of chlorine entered into blast furnace are chloride created by Cl- and metal cation or organic speciation absorbed in specular coal or structure macromolecule of coal. The chlorine entered into blast furnace merges with blast furnace gas in the form of HCl after conducted a series of chemical reactions. With the increasing of HCl content in blast furnace gas, the coke reactivity decreases and the coke post reaction strength increases, and the reduction process of iron ore is restrained and the low temperature reduction degradation property increases. However, the corrosion of gas pipeline and TRT blade is aggravated by the HCl in blast furnace gas, and then blast furnace gas conveying process and normal operation of TRT unit are affected.
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Golovchenko, Anatoliy, Roman Dychkovskyi, Yuliya Pazynich, Cáceres Cabana Edgar, Natalia Howaniec, Bartłomiej Jura, and Adam Smolinski. "Some Aspects of the Control for the Radial Distribution of Burden Material and Gas Flow in the Blast Furnace." Energies 13, no. 4 (February 19, 2020): 923. http://dx.doi.org/10.3390/en13040923.
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The paper presents an experimental study on the formation process of burden surface texture on the blast furnace throat and its influence on the radial distribution of gas flow. The study was performed with the application of blast furnaces equipped with a bell-type charging device using radio-isotope means for the control of burden surface texture (profile) and burden surface level, i.e., gamma locators for burden surface texture. The study was carried out under the conditions of an operating blast furnace in an iron and steel plant using a unique GEOTAPS system for automated control of geometric and temperature parameters of burden material surface on the blast furnace throat. The influence of the surface texture on the gas flow distribution was also investigated. The possibility of a self-stabilization effect for burden surface texture and gas flow in an operating blast furnace under suitable conditions was experimentally proven. As a result of the experimental study performed, four ways of energy-saving technology implementation were determined for the control of blast furnace melting based on the data on the burden surface texture and previously unknown regularities of surface layer formation of burden material on the throat of an operating blast furnace with a bell-type charging device. The main idea of the paper is the development of automated control for the radial distribution of burden material and gas flow using actual or predicted surface texture parameters as important intermediate factors that both describe the process and have a significant simultaneous influence on it.
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Spirin, Nikolay, Oleg Onorin, and Alexander Istomin. "Prediction of Blast Furnace Thermal State in Real-Time Operation." Solid State Phenomena 299 (January 2020): 518–23. http://dx.doi.org/10.4028/www.scientific.net/ssp.299.518.
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The paper gives a general description of the dynamic model of the blast-furnace process that enables to calculate transition processes of the blast furnace thermal state, evaluated by the content of silicon in hot metal. It provides calculation results of the transition processes to be subjected to changes in control actions: ore load from the top and oxygen concentration in blast, natural gas flow rate and hot blast temperature from the bottom. Specific features of these transition processes during blast-furnace smelting are analyzed. The paper shows that the dynamic characteristics of blast furnaces change are subjected to control actions and depend significantly on properties of melted raw materials and operating parameters of blast furnaces. The oscillatory transition process in the blast furnace is observed in the case after disturbance it has an opposite influence on the thermal state of the lower and uppers stages of heat exchange. The paper presents prediction results of the silicon content in hot metal. It gives practical recommendations for selection of control actions.
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Rogozhnikov, S. P., and I. S. Rogozhnikov. "Effect of the natural gas hydrogen on variation of the heat and reducing processes along the blast furnace radius." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 76, no. 1 (February 7, 2020): 41–49. http://dx.doi.org/10.32339/0135-5910-2020-1-41-49.
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The expenses for the blast furnace coke are one of most significant part of the hot metal cost. To save the coke, various technologies are used, capable to replace the coke by cheaper additional fuel (AF), in particular by natural gas (NG). The injection of considerable volumes of NG results in an increase of hydrogen share in the blast furnace gases and in a significant variation in the blast furnace technology. Study of peculiarities of such variations is necessary to use the NG more effectively. Based on the mathematical model of the blast furnace process, estimation of the effect of natural gas hydrogen on changes in the heat and reducing processes along the blast furnace radius was accomplished. A formula was elaborated, confirmed by practice, for calculating the degree of hydrogen usage ηН2 along the radius of the furnace. It was determined, that the reducing action of hydrogen along the furnace radius takes place unevenly –decreasing from the periphery to the axial zone of the blast furnace. To estimate the quantitative relations of the reducing action of hydrogen, parameters of the PAO “MMK” and PAO “ArcelorMittal Krivoy Rog” blast furnaces for a long period of operation were analyzed. It was determined, that in the axial and intermediate zones of a blast furnace, values of criterion RН2, designating the oxygen share in the burden removed by hydrogen, are in the range of 0.11–0.16 and weakly depend on the NG consumption. In the peripheral zone near the walls, the value of R Н 2 sharply increases to 0.22–0.27. In this zone of the blast furnace the quantity the burden oxygen, removed by hydrogen, accounts for 80–85%. Therefore, hydrogen accomplished the heat and reducing processes mainly in the peripheral zone of the furnace. At the NG consumption increase, the ore load should be increased for the peripheral zone, near the walls individually accounting hydrogen action along the furnace radius. This will make possible to increase the degree of hydrogen usage and decrease the coke consumption.
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Sibagatullin, Salavat K., Aleksandr S. Kharchenko, and Marina V. Potapova. "Neural Network Modeling of Coefficient of Burden Resistance to the Gas Movement in the Lower Part of the Blast Furnace in Conditions of Operation with Coke Nut." Materials Science Forum 870 (September 2016): 487–91. http://dx.doi.org/10.4028/www.scientific.net/msf.870.487.
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A mathematical model based on the use of artificial neural networks for forecast of resistance coefficient of burden to the gas at the bottom of the blast furnace with using of coke nut by processing of data array for the OJSC "MMK" blast furnaces (capacity of 1370 m3), equipped with a chute-type bell-less charging device has been created. This test has shown the adequacy of the model to real data. Influence of such factors as characteristics of blast (oxygen content, temperature, natural gas and water steam consumption), iron ore (raw material consumption per time unit, FeO, MgO, Al2O3 content, fraction, basicity), coke (wearability (M10), impact strength (M25), coke strength reactivity (CSR), coke reactivity index (CRI)) on gas dynamics variation at the lower part of the black furnace have been determined. Average relative prediction error does not exceed 0.28 %, the maximum of the sample is 2.82 %. The oxygen content in the blast has the biggest effect on the burden resistance coefficient. When oxygen concentration is more than 25.2 %, the increase of natural gas consumption improves gas-dynamic conditions in the lower part of blast furnace. With the decrease of oxygen content in the blast, the influence of natural gas consumption on coefficient of burden resistance varies in the opposite direction. The reduction of coke wearability (M10) by 0.05 % abs. or the increase of coke strength reactivity (CSR) by 0.14 % abs. has compensated negative effect of coke nut (consumption 4 kg/t of iron) on blast furnace operation.
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Spirin, N. A., O. P. Onorin, A. S. Istomin, and I. A. Gurin. "Study of transient processes in a blast furnace based on the heat exchange scheme analysis." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 76, no. 2 (March 19, 2020): 132–38. http://dx.doi.org/10.32339/0135-5910-2020-2-132-138.
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A blast furnace is a complicated metallurgical facility, which is characterized by considerable delay and inertia in the flow of heat and mass exchange. Therefore, the analysis of transient processes based on modern ideas about heat transfer is an important issue in solving technological problems of blast furnace smelting managing. A two-stage heat transfer scheme along the height of a blast furnace of modern technology presented. When studying the thermal state of a blast furnace as a control object, it is advisable to divide it into two thermal zones - the upper zone and the lower zone. The border between the zones is located in the upper part of the mixed reduction region, between the start level of coke carbon gasification and the horizon below which iron oxides are directly reduced. It was shown, that the upper and lower thermal zones have fundamental differences in heat exchange conditions and are interconnected through the index of iron direct reduction degree. The transient processes of silicon variation in the hot metal studied at variation of iron ore load, natural gas flow rate, temperature and humidity of the hot blast, oxygen content in the hot blast and slag basicity. It was shown that the oscillatory transition process is observed in case, after applying the perturbation, it will have the opposite effect on the thermal conditions of the lower and the upper stages of heat exchange in the blast furnace. The iron ore load, hot blast humidity and slag basicity were found to be the most predictable input parameters affecting the concentration of silicon in hot metal. Change in oxygen concentration in hot blast and natural gas consumption have an alternating character of influence on thermal conditions of the blast-furnace hearth. At that, the characteristics of the transient processes of blast furnaces through various channels of action vary and depend significantly on the properties of the smelted raw materials, design and operational parameters of the furnaces
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Meng, Jia Le, Hui Qing Tang, and Zhan Cheng Guo. "Comprehensive Mathematical Model of Full Oxygen Blast Furnace with Top Recycle Gas Heated by Gasifier." Applied Mechanics and Materials 268-270 (December 2012): 356–64. http://dx.doi.org/10.4028/www.scientific.net/amm.268-270.356.
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A comprehensive mathematical model of full oxygen blast furnace with top recycle gas heated by gasifier was established. The model consists of the calculation equations for gas composition of four zones (hearth, belly, lower shaft, top) in the blast furnace, the thermo-chemical balance model of blast furnace, the energy balance model of hot stand-by zone of blast furnace, the shaft efficiency model of blast furnace, the calculation equations for gas composition of gasifier and the thermo-chemical balance model of gasifier. By using this model, the new process was calculated. The results show that coke rate and coal rate of the new process are 200 kg/thm and 190 kg/thm respectively, fuel rate is decreased by 24.7% compared with that of conventional blast furnace. In addition, theoretical combustion temperature decreases with increasing hearth-recycle gas quantity. Increasing of hearth-recycle gas quantity by 10 m3/thm decreases theoretical combustion temperature by 11.6 K. Furthermore, the model could be applied to calculate the operating parameters when the raw materials and fuel conditions are different, and the changing laws of operating parameters under the same raw materials and fuel conditions could also be studied with this model.
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Karakash, Y., and T. Baranova. "Basic areas of the secondary energy resources use in the blast-furnace ironmaking and application of heat pumps." Modern Problems of Metalurgy 1, no. 21 (March 16, 2018): 7–11. http://dx.doi.org/10.34185/1991-7848.2018.01.02.
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Under the present-day conditions of blast-furnace shop operation, the use of low-potential SERs seems to be the most promising measure with regard to reduction of cast-iron production cost. Proposed measures on improvement of blast-furnace gas calorific power due to the reduction of its moisture content allow the blast-furnace air temperature increase and coke consumption reduction. Also proposed is partial transfer of excess heat from the blast-furnace gas to combustion air by means of the system of heat pumps, which allows increase in calorimetric combustion temperature.In this paper, main parameters are calculated of the heat pump system operation under the conditions of blast-furnace shop at the increased top gas temperature. This paper presents heat pump system operating efficiency and determines conversion factor for the specific conditions (COP).
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Bailera, Manuel, Takao Nakagaki, and Ryoma Kataoka. "Revisiting the Rist diagram for predicting operating conditions in blast furnaces with multiple injections." Open Research Europe 1 (November 29, 2021): 141. http://dx.doi.org/10.12688/openreseurope.14275.1.
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Background: The Rist diagram is useful for predicting changes in blast furnaces when the operating conditions are modified. In this paper, we revisit this methodology to provide a general model with additions and corrections. The reason for this is to study a new concept proposal that combines oxygen blast furnaces with Power to Gas technology. The latter produces synthetic methane by using renewable electricity and CO2 to partly replace the fossil input in the blast furnace. Carbon is thus continuously recycled in a closed loop and geological storage is avoided. Methods: The new model is validated with three data sets corresponding to (1) an air-blown blast furnace without auxiliary injections, (2) an air-blown blast furnace with pulverized coal injection and (3) an oxygen blast furnace with top gas recycling and pulverized coal injection. The error is below 8% in all cases. Results: Assuming a 280 tHM/h oxygen blast furnace that produces 1154 kgCO2/tHM, we can reduce the CO2 emissions between 6.1% and 7.4% by coupling a 150 MW Power to Gas plant. This produces 21.8 kg/tHM of synthetic methane that replaces 22.8 kg/tHM of coke or 30.2 kg/tHM of coal. The gross energy penalization of the CO2 avoidance is 27.1 MJ/kgCO2 when coke is replaced and 22.4 MJ/kgCO2 when coal is replaced. Considering the energy content of the saved fossil fuel, and the electricity no longer consumed in the air separation unit thanks to the O2 coming from the electrolyzer, the net energy penalizations are 23.1 MJ/kgCO2 and 17.9 MJ/kgCO2, respectively. Discussion: The proposed integration has energy penalizations greater than conventional amine carbon capture (typically 3.7 – 4.8 MJ/kgCO2), but in return it could reduce the economic costs thanks to diminishing the coke/coal consumption, reducing the electricity consumption in the air separation unit, and eliminating the requirement of geological storage.
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Filatov, S. V., A. I. Dagman, and V. N. Titov. "Energy efficient technology of hot metal smelting at PAO NLMK." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 75, no. 1 (February 2, 2019): 32–36. http://dx.doi.org/10.32339/0135-5910-2019-1-32-36.
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Decrease of energy expenditure for hot metal smelting is an actual task in blast furnace technology perfection. Under conditions of PAO NLMK regimes with maximum forcing of the BF process at the expense of pressure increase under furnace mouth and coke hot strength increase were chosen as one of priority ways to increase the BF operation energy efficiency. Data on blast furnaces productivity, specific coke rate, quantity of blow-in oxygen and fuel at different gas pressure levels under the furnace mouth quoted. A dependence between pulverized coal rate and total carbon consumption determined. It was shown, that application in PAO NLMK blast furnaces of coke having hot strength of 60–65% at maximum possible pressure under the furnace mouth and application of pulverized-coal fuel enabled in the period from 2012 through 2018 to decrease the coke rate by more than 100 kg. Also the total carbon consumption decreased by more than 30 kg per hot metal ton and to increase smelting products chemical composition stability.
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Semenov, Yu S., A. L. Podkorytov, V. V. Gorupakha, I. Yu Semion, A. Yu Orobtsev, and E. I. Shumel’chik. "Еfficiency increase of powdered coal application at hot metal production and limestone calcination under unstable technology conditions." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 76, no. 7 (August 11, 2020): 676–90. http://dx.doi.org/10.32339/0135-5910-2020-7-676-690.
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Operation of Ukraine ferrous metallurgy under conditions of dependence on import and instability of energy carriers supply, shortage of investments in modernization of production equipment, make the matter of cooperation between steel-works and research organization particularly actual. Basic results of cooperation between Z.I. Nekrasov Institute of Ferrous metallurgy, NAN of Ukraine and Dnepr steel-works in 2017–2019 on blast sfurnace operation pefection and technology of powdered coal injection into rotating limestone calcination furnaces. Results of the finding of the powdered coal optimal consumption shown, which ensure a high efficiency of the coke substitution, reaching of maximum possible blast furnace productivity as well as satisfactory utilization degree of the reducing gas ability. Results of implementation of a complex of measures presented, which ensure a rational distribution of the powdered coal by BF air tuyeres for making the heat conditions of the tuyere zone even by the blast furnace circle. Efficiency of application of technology of joint injection the powdered coal and natural gas was shown, which is achieved by improving the powdered coal combustion conditions in case of increase their mixing degree. Recommendations quoted for blast furnaces starting-up after their idling for a period exceeding the permissible one, without tapping the plug hot metal. The recommendations ensure an accident-free putting a blast furnace into operation followed by reaching planned parameters. Results of usage sensors information, measuring temperature of gas flow above the charge surface presented. The results allow to prove the correction of blast furnace charging mode by an expert module, generating correction impact to support control actions by technological personal. A complex of measures formed to prevent a disturbance of a blast furnace running in case of powdered coal injection in an amount exceeding 140 kg/t of hot metal and without application of special washover materials. The results of efficiency of the mastered technology, envisaging application manganese-bearing materials at a constant base, were shown. Results of diagnostics of workability of the facility for powdered coal injection into rotating limestone calcinating furnace presented, followed by elaboration recommendation on correction parameters of injection facility operation.
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Cuervo-Piñera, Víctor, Diego Cifrián-Riesgo, Phuc-Danh Nguyen, Valerio Battaglia, Massimiliano Fantuzzi, Alessandro Della Rocca, Marco Ageno, et al. "Blast Furnace Gas Based Combustion Systems in Steel Reheating Furnaces." Energy Procedia 120 (August 2017): 357–64. http://dx.doi.org/10.1016/j.egypro.2017.07.215.
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Li, Meng, Han Wei, Yao Ge, Guocai Xiao, and Yaowei Yu. "A Mathematical Model Combined with Radar Data for Bell-Less Charging of a Blast Furnace." Processes 8, no. 2 (February 20, 2020): 239. http://dx.doi.org/10.3390/pr8020239.
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Charging directly affects the burden distribution of a blast furnace, which determines the gas distribution in the shaft of the furnace. Adjusting the charging can improve the distribution of the gas flow, increase the gas utilization efficiency of the furnace, reduce energy consumption, and prolong the life of the blast furnace. In this paper, a mathematical model of blast furnace charging was developed and applied on a steel plant in China, which includes the display of the burden profile, burden layers, descent speed of the layers, and ore/coke ratio. Furthermore, the mathematical model is developed to combine the radar data of the burden profile. The above model is currently used in Nanjing Steel as a reference for operators to adjust the charging. The model is being tested with a radar system on the blast furnace.
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Bezhan, V. A., V. M. Zhytarenko, and P. Dalakov. "Energy Characteristics of Medium Pressure Steam Boilers." Journal of Engineering Sciences 7, no. 2 (2020): F8—`F14. http://dx.doi.org/10.21272/jes.2020.7(2).f2.
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The object of this study is the thermal and energy characteristics of medium pressure boilers of СНPP-1, four boilers CKTI-75/39F-2-4 and two boilers TP-150-2. All boilers operate on a common steam collector of 32 atm, at 420 °С. Fuel is a mixture of blast furnace gas and natural gas in the ratio of 0.7-0.9 volume particles. The characteristics of the blast furnace gas are not constant: the elemental composition, humidity, and dustiness of blast furnace gas change significantly. Analysis of operation of CHPP-1 medium pressure boilers of OJSC “Mariupol Metallurgical Combinat named after P. G. Ilyich” was carried out on the basis of the technical documentation and materials obtained during the ecological and thermal-technical tests of the boilers CKTI-75/39F-2-4 No. 7–9, and TP-150 No. 11, 12 of SU “Promavtomatika”. The main purpose of the analysis is to identify patterns that affect the operational characteristics of boilers, especially the efficiency. The analysis revealed the nature of the overall dependence of the efficiency on the load, as well as the dependence of the efficiency of the boilers on the load at different thermal parts of the blast furnace gas. After carrying out the balance tests, the dependencies of the exhaust gas temperature on the boiler load at different thermal parts of the blast furnace gas were established. Keywords: medium pressure boiler, thermal efficiency, blast furnace gas, heat losses.
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Hu, Yichao, Yinxuan Qiu, Jian Chen, Liangyuan Hao, Thomas Edward Rufford, Victor Rudolph, and Geoff Wang. "Integrating a Top-Gas Recycling and CO2 Electrolysis Process for H2-Rich Gas Injection and Reduce CO2 Emissions from an Ironmaking Blast Furnace." Materials 15, no. 6 (March 8, 2022): 2008. http://dx.doi.org/10.3390/ma15062008.
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Introducing CO2 electrochemical conversion technology to the iron-making blast furnace not only reduces CO2 emissions, but also produces H2 as a byproduct that can be used as an auxiliary reductant to further decrease carbon consumption and emissions. With adequate H2 supply to the blast furnace, the injection of H2 is limited because of the disadvantageous thermodynamic characteristics of the H2 reduction reaction in the blast furnace. This paper presents thermodynamic analysis of H2 behaviour at different stages with the thermal requirement consideration of an iron-making blast furnace. The effect of injecting CO2 lean top gas and CO2 conversion products H2–CO gas through the raceway and/or shaft tuyeres are investigated under different operating conditions. H2 utilisation efficiency and corresponding injection volume are studied by considering different reduction stages. The relationship between H2 injection and coke rate is established. Injecting 7.9–10.9 m3/tHM of H2 saved 1 kg/tHM coke rate, depending on injection position. Compared with the traditional blast furnace, injecting 80 m3/tHM of H2 with a medium oxygen enrichment rate (9%) and integrating CO2 capture and conversion reduces CO2 emissions from 534 to 278 m3/tHM. However, increasing the hydrogen injection amount causes this iron-making process to consume more energy than a traditional blast furnace does.
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Barbasova, T. A. "A MULTILEVEL RESOURCE-SAVING BLAST FURNACE PROCESS CONTROL." Bulletin of the South Ural State University. Ser. Computer Technologies, Automatic Control & Radioelectronics 21, no. 1 (February 2021): 136–46. http://dx.doi.org/10.14529/ctcr210112.
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A multilevel resource-saving blast furnace process control is considered. The resource-saving control is provided for operating, adaptation, technical and economic control in the automated systems of blast-furnace processes. It is proposed to form optimal operation modes of blast furnace heating, metal charge structures, natural gas and oxygen consumption. Decisions are made using Kohonen neural networks taking into account current and planned parameters of coke quality, iron ore, raw materials and blast. At the level of operating control, the work suggests a model predictive control to improve the resource conservation indicators. The method is based on decomposition of the general problem of the process dynamics identification on particular problems: dynamic synchronization and identification of process transfer functions. At the level of adaptive control, optimal operating modes of blast furnaces are expedient to be developed with respect to blast furnace heating, structure of metal charge, natural gas and oxygen rate considering the current and planned parameters of coke, blasting. The blast furnace operating modes are suggested to be determined based on Kohonen neural networks. In evaluating the efficiency of introducing the model predictive control, the existing actual statistics of scatter of BF mode parameters should be based upon. The fact is that the introduction of model predictive control assumes no radical change of the BF melt technology. Like in all the control systems, the BF process is considered as the set control object with all its characteristics. Changing process settings, raw material content does not introduce any cardinal variation in the scatter of process characteristics. However, in this case a transient process occurs which is necessary for the control system to identify the changing conditions. The transient process is inherent to all the control systems and the blast furnace process is not an exclusion. As a result of transient process, the control system is set to the optimal mode.
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Udjianto, Tjatur, and Teguh Sasono. "Pemanfaatan Gas Buang Blast Furnace Plant Menggunakan Top-Gas Recovery Turbine (TRT) Sebagai Upaya Penghematan Energi." Jurnal Teknik Energi 10, no. 1 (January 3, 2021): 14–18. http://dx.doi.org/10.35313/energi.v10i1.2313.
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Energi telah menjadi kebutuhan mendasar dan sebagai salah satu komponen biaya di dalam industri salah satunya pabrik baja terpadu. Salah satu upaya untuk untuk mengurangi biaya produksi tanpa mempengaruhi hasil atau kualitas produksi adalah dengan memanfaatkan gas buang yang dihasilkan dari proses yang terdapat di pabrik baja terpadu. Salah satu gas buang yang dihasilkan adalah blast furnace gas (BFG) yang dihasilkan dari proses di Blast Furnace Plant. Salah satu cara untuk menurunkan konsumsi energi Listrik Khususnya di Blast furnace plant adalah dengan diaplikasikannya Top-gas Recovery Turbine (TRT). TRT merupakan suatu sistem yang dapat membangkitkan energi listrik dengan memanfaatkan gas buang yang dihasilkan dari bagian atas (top) Blast furnace yang dialirkan melalui Gas cleaning plant untuk selanjutnya memutarkan turbin-generator. Dengan adanya sistem TRT ini, BFG dapat dimanfaatkan secara maksimal dan dapat menambah pasokan listrik sehingga bisa mengurangi biaya energi listrik. Berdasarkan hasil perhitungan kapasitas terpasang TRT adalah sebesar 18 MW. Energi listrik yang dihasilkan adalah sebesar 117.121,5 MWh. Estimasi jumlah penghematan biaya listrik adalah sebesar 120,12 milyar/tahun. Dengan adanya TRT pengurangan emisi CO2 dalam satu tahun adalah sebesar 84,064 ton- CO2.
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Hu, Bin Sheng, Xiao Guang Liu, Yong Liang Gui, and Kai Lv. "Thermodynamic Calculation of Hydrogen Chloride Generation in Blast Furnace Smelting Process." Advanced Materials Research 1033-1034 (October 2014): 1300–1304. http://dx.doi.org/10.4028/www.scientific.net/amr.1033-1034.1300.
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The generating pathways of hydrogen chloride in blast furnace smelting process may have two pathways: 1.sodium chloride and water react with phosphorus pentaoxide forming hydrogen chloride gas.2. Sodium chloride and water react with sulfur dioxide and nitrogen dioxide forming hydrogen chloride gas. Based on Thermodynamic calculation of hydrogen chloride generation in blast furnace smelting process, hydrogen chloride gas is generated in the upper part of blast furnace shaft ,the generating temperature main range from 300°C too 800°C.
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Hu, Bin Sheng, Bo Zhang, Yong Liang Gui, and Hua Lou Guo. "Study on Separation of Chlorine in Coal in Combustion Process of Pulverized Coal Injection into B.F." Applied Mechanics and Materials 675-677 (October 2014): 578–82. http://dx.doi.org/10.4028/www.scientific.net/amm.675-677.578.
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In the combustion process of pulverized coal injection into blast furnace, the chlorine goes into the unburned pulverized coal is about 17%, the chlorine in the unburned coal keeps original state; The chlorine goes into the blast furnace gas is about 83%, and these chlorine stay as Hcl gas. Changes in air temperature and oxygen rate had no significant effect on the decomposition of chlorine in coal, resulting the rate of Cl into the blast furnace gas is difficult to increase significantly.
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Levytska, Olena Hryhoriivna, Yulia Vladimirovna Voytenko, and Anastasiia Oleksiivna Orishechok. "COMPARATIVE ASSESSMENT OF GASEOUS FUEL EMISSION." Bulletin of the National Technical University "KhPI". Series: Chemistry, Chemical Technology and Ecology, no. 1(5) (May 15, 2021): 83–91. http://dx.doi.org/10.20998/2079-0821.2021.01.13.
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The work presents estimated comparative assessment of emissions release in combustion products during work of high–power steam boilers with the use of traditional fuel – natural gas and alternative fuels – blast–furnace and coke–oven gases generated in the process of technological cycle at iron and steel and coke–chemical enterprises. Calculation algorithm is shown and formulas for assessment of carbon content in exhaust gases are defined, conclusions on ecological efficiency of gaseous fuels are given.
The purpose of the work was to evaluate the emissions of harmful substances generated during the combustion of natural, blast furnace and coke oven gases, justification of the calculation of carbon content of a given chemical composition and determine the optimal environmental impact of analogues of natural gas.
The comparative estimation of pollutant emissions into atmospheric air during combustion of natural, coke oven and blast furnace gases revealed:
– high sulfur dioxide emissions from combustion of blast furnace and coke oven gases due to the presence of sulfur compounds in the composition of these gases;
– relatively high emissions of nitrogen compounds for natural and coke oven gases and relatively low emissions for blast furnace gas;
– сarbon emissions are high for all types of fuels which have been considered, most carbon dioxide gets into the air when burning natural gas, least – when burning blast furnace gas;
– significantly higher methane emissions are observed during the combustion of natural and coke oven gases, respectively, smaller – for blast–furnace gas combustion;
– coke oven and natural gases are characterized by low mercury emissions.
Comparative assessment of the calculated values of hazardous substances emissions in the combustion products in the process of combustion of natural, coke–oven and blast–furnace gases shows that even at lower working heat of combustion values the coke–oven and blast–furnace gases can compete with natural gas.
For the first time, a comparative characterization of the emissions of harmful substances in the combustion of natural, coke oven and blast furnace gases is presented, and it is shown that the gases used in coke and metallurgical industries, which are used as analogues of natural, are logical to use, but require the installation of treatment systems. The paper defines a formula for calculating the carbon content in natural gas from the Urengoy–Uzhhorod gas pipeline. The provided calculations and the introduction of simplified formulas serve as an example for the calculation of emission factors and emissions in assessing the level of safety of existing equipment and can be used in the development of permit documents of enterprises that carry out emissions of harmful substances to the environment.
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Semenov, Yu S., Е. І. Shumelchik, and V. V. Horupakha. "Development and implementation of the new approaches to diagnostics and management of the blast furnace smelting." Fundamental and applied problems of ferrous metallurgy, no. 33 (2019): 61–77. http://dx.doi.org/10.52150/2522-9117-2019-33-61-77.
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The article presents a brief description of the results of blast furnace production research carried out at the Yenakiieve Iron & Steel Works and the Dneprovsky Iron & Steel Integrated Works in 2011–2019. For the conditions of transition modes of blast furnace to ensure its stability in changing the qualitative and quantitative composition of the components of the charge materials, as well as in the change of fuel additives in the blast, the complex use of information of modern means of automated control is proved: stationary thermosets and thermocouples to the lining. New approaches to the choice of rational charging programs using the principle of variable maximum ore loading along the radius of the furnace within the charging cycle for working conditions on a charge of low quality have been developed. The implementation of such a charging program over the next three years has allowed to ensure a stable and economical course of melting, and its adaptation to the technology of using pulverized coal has allowed to reduce the gas flow temperature of the peripheral zone throughout the height of the blast furnace, as well as to preserve the cooling system during the development of lining-free. Expert module of adjustment of the program of charging using the established rational ranges of change of temperature indices of gas flow distribution along the radius of the furnace under different technological conditions of blast furnace has been developed and implemented on three blast furnaces. The method of reasonable choice of location of closed air tuyeres or air tuyeres of different diameter was developed and tested using information on change of lining temperatures on height and circumference of blast furnace. The method of equalizing the raceway adiabatic flame temperature around the blast furnace circumference by creating a non-uniform flow rate of pulverized coal in the air tuyeres has been improved and implemented. The basic technological requirements for blast furnace blasting after its long stop without release of "gantry" cast iron and scraping of materials from the furnace, the use of which before and in the blast furnace blasting of the Yenakiieve Iron & Steel Works and the Dneprovsky Iron & Steel Integrated Works after a long-lasting set-up were developed economic indicators, while ensuring the preservation of refractory lining, structures and equipment.
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Kou, Zhou, Wang, Hong, Yao, Xu, and Wu. "Numerical Simulation of Effects of Different Operational Parameters on the Carbon Solution Loss Ratio of Coke inside Blast Furnace." Processes 7, no. 8 (August 9, 2019): 528. http://dx.doi.org/10.3390/pr7080528.
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Carbon solution loss reaction of coke gasification is one of the most important reasons for coke deterioration and degradation in a blast furnace. It also affects the permeability of gas and fluids, as well as stable working conditions. In this paper, a three dimensional model is established based on the operational parameters of blast furnace B in Bayi Steel. The model is then used to calculate the effects of oxygen enrichment, coke oven gas injection, and steel scrap charging on the carbon solution loss ratio of coke in the blast furnace. Results show that the carbon solution loss ratio of coke gasification for blast furnace B is almost 20% since the results of a model are probably only indicative. The oxygen enrichment and the addition of steel scrap can reduce the carbon solution loss ratio with little effect on the working condition. However, coke oven gas injection increases the carbon solution loss ratio. Therefore, coke oven gas should not be injected into the blast furnace unless the quality of the coke is improved.
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Horupakha, V. V., Yu S. Semenov, E. I. Schumelchyk, S. V. Vashchenko, and E. D. Vyshinskaya. "Influence of transition modes of blast-furnace smelting to change the temperature of the cooling-system plates." Metallurgicheskaya i gornorudnaya promyshlennost, №6, 2018, no. 6 (2018): 3–9. http://dx.doi.org/10.33101/s065456789.
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Purpose. Estimation of the influence of non-stationary blast-furnace smelting on the thermal state of the cooling system. Methodology. Analysis of changes in the meanings of thermocouples installed in the body of the cooling system plates, under different operating conditions of the blast furnace. Results. The study of the influence of transitional modes of blast-furnace smelting on the temperature change of the cooling-system plates at the joint use of natural gas and coal-pulverized fuel, under conditions of a low-intensity blast furnace operation and using pulverized coal with a consumption of more than 110 kg/ton of pig iron. Findings. The peculiarities of the influence of transitional modes of blast-furnace smelting on the thermal state of the cooling system are established: incl. with various fuel additives for blasting and with the operation of the furnace with reduced intensity. Practical value. The results presented in the article can be used in the design of the cooling system, as well as in the selection of rational operating modes of the blast furnace. Keywords. blast furnace, PCI technology, natural gas, cooling-system plates, thermocouple.
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Semenov, Yu S., E. I. Shumelchik, V. V. Horupakha, S. V. Vashchenko, O. Yu Khudyakov, K. P. Ermolina, I. Yu Semion, and I. V. Chychov. "INTRODUCTION OF DECISION SUPPORT SYSTEMS FOR BLAST SMELTING CONTROL IN THE CONDITIONS OF METALLURGICAL PRODUCTION OF PRJSC "DNIPROVSKYI COKE PLANT"." Fundamental and applied problems of ferrous metallurgy, no. 35 (2021): 78–94. http://dx.doi.org/10.52150/2522-9117-2021-35-78-94.
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The aim of the work is to increase the level of automation of blast furnace production through the development and implementation of new systems to support decision-making on the management of blast furnace smelting in changing technological and fuel conditions. The article presents a description of three decision support systems (DSS) in the mode of an adviser to the technological personnel of blast furnaces, which were implemented by the Iron and Steel Institute or underwent pilot testing as part of the automated control system of the blast furnace shop of the metallurgical production of PrJSC "Dniprovskyi Coke Plant" (Kamianske). The first DSS for managing the thermal state was implemented in 2021, it includes the entire list of information necessary for personnel in a convenient and compact form, generates recommendations in case of technology deviations and, in case of incorrect actions of the personnel, signals the need for correct actions. The main recommendations of the system are to correct the raceway adiabatic flame temperature, coke consumption when its characteristics and ore load change. Using the system allows both reducing the specific coke consumption and preventing unplanned downtime. The second DSS for controlling the distribution of fuel additives over air tuyeres is based on information on thermal loads determined on water-cooled elements of tuyere tools. The main recommendations of the system are to adjust the amount of injected pulverized coal fuel on individual tuyeres in order to ensure a uniform distribution of the raceway adiabatic flame temperature around the circumference of the blast furnace and, as a result, the energy efficiency of blast furnace smelting. The third DSS for adjusting the parameters of the charging mode is based on information from the means of controlling the temperatures of the gas flow above the surface of the charge in the blast furnace. The functioning of this system is based on determining the reference curves for the distribution of the gas flow along the furnace radii, corresponding to the minimum consumption of coke and maximum productivity, and on the search for solutions by direct and iterative optimization methods, which allow, by adjusting the loading parameters, to ensure a rational distribution of charge materials and gas flow in the furnace.
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Nielson, Samuel, Tyamo Okosun, Bradley Damstedt, Megha Jampani, and Chenn Q. Zhou. "Tuyere-Level Syngas Injection in the Blast Furnace: A Computational Fluid Dynamics Investigation." Processes 9, no. 8 (August 20, 2021): 1447. http://dx.doi.org/10.3390/pr9081447.
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With the recent push towards high injection rate blast furnace operation for economic and environmental reasons, it has become desirable in North America to better understand the impacts of alternate injected gas fuels in comparison to the well-documented limitations of natural gas. The quenching effects of gas injection on the furnace present a functional limit on the maximum stable injection rate which can be utilized. With this in mind, researchers at Purdue University Northwest’s Center for Innovation through Visualization and Simulation utilized previously developed computational fluid dynamics (CFD) models of the blast furnace to explore the impacts of replacing natural gas with syngas in a blast furnace with a single auxiliary fuel supply. Simulations predicted that the syngas injection can indeed reduce coke consumption in the blast furnace at similar injection rates to natural gas while maintaining stable raceway flame and reducing gas temperatures. The coke rates predicted by modeling using similar injection rates indicated an improvement of 8 to 15 kg/thm compared to baseline conditions when using the syngas of various feedstocks. Additionally, syngas injection scenarios typically produced higher raceway flame temperatures than comparable natural gas injection cases, indicating potential headroom for reducing oxygen enrichment in the hot blast or providing an even higher total injection rate.
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Yur'ev, Boris, Vladimir A. Gol'tsev, and Vyacheslav Dudko. "Efficiency Upgrading for Blast Furnace Smelting through Use of Iron Ore Raw Materials with Various Fluxing Degree." Solid State Phenomena 299 (January 2020): 681–86. http://dx.doi.org/10.4028/www.scientific.net/ssp.299.681.
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Firing of various basicity pellets and sintering of Kachkanar concentrates were evaluated on a pilot plant. Mineral analysis was carried out for fired pellets and those reduced in a derivatograph in gas with composition close to that of blast furnace gas. Structure and metallurgical property dependence of pellets and agglomerate on their basicity was studied. Failure mechanism of fluxed pellets was considered. Blast furnace smelting process was developed for Kachkanar iron ore raw material with various fluxing degree, consisting of low-basic pellets, and high basic agglomerate characterized by low failure characteristics at reduction and ensuring high gas permeability in blast furnace top. Optimal values of agglomerate basicity, carbon content in burden and ferrous oxide in agglomerate, ensuring its high reducibility and adequate reduction degree index, were determined. Optimal ratio of pellets and agglomerate in a blast furnace, which implementation contributes to improved furnace performance, was detected.
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Liu, Yong Qi, Xiao Yan Wang, Guang Fei Zhu, Rui Xiang Liu, and Zhen Qiang Gao. "Simulation on the Combustion Property of Blast-Furnace Gas Engine by GT-POWER." Advanced Materials Research 156-157 (October 2010): 965–68. http://dx.doi.org/10.4028/www.scientific.net/amr.156-157.965.
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Blast-furnace gas produced from the process of iron making effectively can be used as fuel for engines to generate electricity for most middle and small steel enterprises. The effects of different component of blast-furnace gas, compressive ratio and ignition timing on combustion property of blast-furnace gas are simulated by GT-POWER software in this paper. The results show that flame speed and combustion rate will increase with the proportion of carbon monoxide and hydrogen increasing. There will be an optimized compression ratio value, under which the burning velocity is maximum. Within a certain scope, increasing ignition timing angle appropriately can improve property of combustion. A comparison of simulation and experiment result shows that the predictions give good results. All these results can help to optimize the parameters that affect the combustion, and provide certain reference for the further study blast-furnace gas engine.
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Muramatsu, Atsushi, Hirotaka Sato, Tomohiro Akiyama, and Jun-ichiro Yagi. "Methanol Synthesis from Blast Furnace Off Gas." ISIJ International 33, no. 11 (1993): 1144–49. http://dx.doi.org/10.2355/isijinternational.33.1144.
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Lyalyuk, V. P., and A. K. Tarakanov. "Gas-Dynamic Assessment of Blast-Furnace Smelting." Steel in Translation 49, no. 8 (August 2019): 535–42. http://dx.doi.org/10.3103/s0967091219080096.
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Liu, Hui, Wen Zhong Chen, and Ben Wen Li. "Sensitivity Analysis of Blast Furnace Gas Combustion." Advanced Materials Research 268-270 (July 2011): 172–77. http://dx.doi.org/10.4028/www.scientific.net/amr.268-270.172.
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Simplification of the detail reaction mechanism is critical to the numerical simulation of BFG (Blast Furnace Gas) combustion. The software CHEMKIN was used for solving a one-dimensional mathematical model of steady-state premixing combustion. By analyzing the effects of BFG’s basic species on the burning rate, the simplified reaction mechanism was obtained. Compared the results of simplified mechanism with that of detail mechanism, the consumed time of the former was less than 1 second but that of the latter was about 18 seconds. The differences between the molar fractions of BFG species which were computed by the two mechanisms were less than 0.4%. Therefore the reliability of the simplified reaction mechanism is verified.
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Danloy, G., J. Mignon, and L. Bonte. "Blast furnace model for gas flow control." Revue de Métallurgie 96, no. 6 (June 1999): 715–20. http://dx.doi.org/10.1051/metal/199996060715.
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Meng, Jia Le, Jian Hua Shao, and Ai Min Zhao. "Multi-Fluid Mathematical Model for Blast Furnace and its Parallel Solution." Applied Mechanics and Materials 675-677 (October 2014): 1463–72. http://dx.doi.org/10.4028/www.scientific.net/amm.675-677.1463.
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Developing blast furnace model is benefit to understand, control and improve blast furnace iron making process. Multi-fluid blast furnace model was established on computational fluid dynamics, reaction kinetics, transport phenomena and other theories. In the model, complicated motion and heat transfer between phases of gas, liquid and solid were considered and numerous reactions in blast furnace were simplified. Because there were so many equations in the model and there were strong coupling relationships between phases, parallel computing technology using computer group was adopted to solve the model to accelerate convergence velocity of iteration. The model can provide versatile information, it is a useful tool to simulate blast furnace operation.
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Panic, B. "3D Model Studies on the Effect of Bed and Powder Type Upon Radial Static Pressure and Powder Distribution in Metallurgical Shaft Furnaces." Archives of Metallurgy and Materials 62, no. 3 (September 26, 2017): 1449–52. http://dx.doi.org/10.1515/amm-2017-0224.
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AbstractThe flow of gases in metallurgical shaft furnaces has a decisive influence on the course and process efficiency. Radial changes in porosity of the bed cause uneven flow of gas along the radius of the reactor, which sometimes is deliberate and intentional. However, holdup of solid particles in descending packed beds of metallurgical shaft furnaces can lead to unintentional changes in porosity of the bed along the radial reactor. Unintentional changes in porosity often disrupt the flow of gas causing poor performance of the furnace. Such disruptions of flow may occur in the blast furnace due to high level of powder content in gas caused by large amount of coal dust/powder insufflated as fuel substitute. The paper describes the model test results of radial distribution of static pressure and powder hold up within metallurgical reactor. The measurements were carried out with the use of 3D physical model of two-phase flow gas-powder in the moving (descending) packed bed. Sinter or blast furnace pellets were used as packed bed while carbon powder or iron powder were used as the powder. Wide diversity within both static pressure distribution and powder distribution along the radius of the reactor were observed once the change in the type of powder occurred.
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Zhang, Fu Ming. "Research and Application of the New Technologies on Blast Furnace at Shougang Qiangang Plant." Advanced Materials Research 402 (November 2011): 151–55. http://dx.doi.org/10.4028/www.scientific.net/amr.402.151.
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In recent years great progress is made in technical equipment of large blast furnace in China. A series of new process, technologies and equipment, integrated and developed on our own, are applied on newly built large blast furnaces and have been proved to be highly effective. After more than 20 years’ development and innovation of the bell-less top equipment designed and developed on our own, it has reached the advanced level in the world in terms of equipment reliability and service life; fully-dry impulse bag filter dedusting technology of BF gas, which is also developed on our own, has gained technical breakthroughs in terms of optimized system design, gas temperature control, pneumatic conveying of dedusting fines; the integrated innovative high-efficiency long-life high-temperature technology, through applying high-temperature preheating technology of combustion air, improving heat transfer efficiency of hot blast stove and optimizing structure of the hot blast stove system, enables the blast temperature to reach 1250°C with BF gas as fuel.
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Octaviano, Yoska, Yusep Mujalis, Benny Siantury, Tono Sukarnoto, and Rianti Dewi Sulamet. "PERANCANGAN COWPER GUNA PEMANFAATAN GAS BUANG PELEBURAN LOGAM." POROS 12, no. 2 (November 1, 2014): 138. http://dx.doi.org/10.24912/poros.v12i2.566.
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Abstract: A prototype of homemade furnace was built and the highest temperature it can reach during the trial process is approximately 400OC. Beside liquid metal, the furnace also produced exhaust gas as a side product. The exhaust gas is still hot. Hot gas can be used to improve the furnace’s temperature based on blast furnace method. To apply this method, the furnace should be companied with cowper. In designing cowper, several parameters should be notice. The parameters are hot gas temperature, air flow direction, and its movement ability with the furnace. Hot gas temperature will determine the number of heat absorber layers. The direction of the air flow will determine the cowper construction. Movement ability is associated with space. The design is made based on VDI 2221. The cowper design concept is cowper to store hot gas made of ramming refectories with its outer diameter similar to oil tank and the movement mechanism only applied for migration.
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Lyalyuk, V. P. "Analysis of the blast furnace operations with a volume of 5000 m3 on tuyeres of different diameters from the positions of full mechanical energies of flows of combined blow and hearth gas." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 76, no. 7 (August 11, 2020): 691–99. http://dx.doi.org/10.32339/0135-5910-2020-7-691-699.
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In the commissioning period of the development of pulverized coal injection technology (PCI) on a blast furnace No. 9 with a volume of 5000 m3 of PJSC “ArcelorMittal Kryvyi Rih”, frequent cases of burnout of refrigerators of the cooling system of the shoulders and air tyueres appeared due to the highly developed peripheral gas flow. An attempt to limit the gas flow at the periphery by controlling the distribution of charge materials on the top produced a short-term result. Based on the prevailing ideas, that to reduce the intensity of the peripheral gas flow, it is necessary to increase the speed of the blast and, accordingly, the kinetic energy of the blast flow, flowing out of the air tuyeres of a blast furnace, it was decided to reduce their diameter. As a result of analysis of the operation of the specified blast furnace using the technology of PCI on tuyeres with a diameter of 150 and 140 mm, increased peripheral gas flow with a smaller diameter was established. Based on the results of the analysis, conclusions were made by many researchers and it was shown that with constant kinetic energy of the blast, flowing from the tuyeres of different diameters, the dimensions of the combustion zone are always larger before the tuyeres of a larger diameter. This is explained by the fact that the kinetic energy of the gas flow is only a part of their total mechanical energy. It was shown that to analyze the change in the size of the combustion zones and the depth of penetration of the hearth gas, it is necessary to use the full mechanical energy of the flows of the combined blast on the cut of the tuyere and hearth gas. It was established that the transition to PCI in a blast furnace instead of natural gas, it always causes an increase in the peripheral gas flow. The main reason for this phenomenon is associated with a decrease in the total mechanical energy of blast and hearth gas. It was recommended on a blast furnace with a volume of 5000 m3 with a hearth diameter of 14.7 m and the PCI technology to maintain the total mechanical energy of the blast flow at least 2100–2600 kJ/s, and the full mechanical energy of the hearth gas flow at least 5100–5300 kJ/s.
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Tunckaya, Yasin. "Performance assessment of permeability index prediction in an ironmaking process via soft computing techniques." Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 231, no. 6 (June 7, 2016): 1101–13. http://dx.doi.org/10.1177/0954408916654199.
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Permeability index is a crucial productivity indicator of the lower zone in blast furnaces to maintain the operation, energy consumption, and hot liquid metal production rates during the ironmaking process. Blast furnace operation parameters such as coke-to-ore ratio, wall pressures and temperatures, flame temperature, top gas pressure, temperature and composition, hot blast pressure and temperature, sounding levels, etc. and also the level of hot liquid metal and slag in the bottom of furnace, influence the permeability phenomenon directly. Hence, fluctuations and instantenous variations of permeability index parameter should be avoided by controlling inadequate drainage cycles and operational factors to achieve more efficient and stable operation in the furnaces. In this study, permeability index parameter of the Erdemir Blast Furnace #1, located in Turkey, is modeled and experimental computing work is carried out to assess the operation performance of the furnace, depending on selected input parameters. The demanding artificial intelligence and soft computing techniques, artificial neural networks and adaptive neural fuzzy inference system, and a well-known statistical tool, autoregressive integrated moving average model are executed throughout the study using previous furnace data, received during one day of operation. Selected performance measures, coefficient of determination ( R2) and root mean squared error, are used to compare the forecasting accuracy of proposed models. Consequently, the most satisfactory forecasting model of the study, adaptive neural fuzzy inference system, is proposed to be integrated into the plant control system as an expert modeler.
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Song, Liu, Liu Xiaojie, Lyu Qing, Zhang Xusheng, and Qie Yana. "Study on the Appropriate Production Parameters of a Gas-injection Blast Furnace." High Temperature Materials and Processes 39, no. 1 (February 11, 2020): 10–25. http://dx.doi.org/10.1515/htmp-2020-0005.
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AbstractThe change regulations of the smelting parameters in a gas-injection blast furnace are investigated using theoretical calculations. The results show that when the volume of gas injected, the oxygen enrichment rate and the theoretical combustion temperature of tuyere are 600 m3/tHM, 10% and 1950~2200∘C, respectively, the conditions meet the smelting requirements of a blast furnace. With the increase of the oxygen enrichment rate, the required air volume decreases, the contents of CO and H2 in the top gas increase, and the content of CO2 first increases and then decreases.With an increase of the volume of gas injected, the coke rate decreases. In addition, when the oxygen enrichment rate and the volume of gas injected are 10% and 600 m3/tHM, respectively, the CO content of the top gas constantly increases with the increase of the coke rate, while the H2 and CO2 contents both decrease. With the increase of the H2 content in the gas, the direct reduction degree of iron gradually decreases and the volume shrinkage burden increases. Apparently, injecting gas into the blast furnace can prevent the theoretical combustion temperature from being too high and solve the contradiction between the upper cooling and lower heating of the blast furnace.
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Meng, Jia Le, Zhan Cheng Guo, and Hui Qing Tang. "Comprehensive Mathematical Model of Full Oxygen Blast Furnace and its Solution." Advanced Materials Research 567 (September 2012): 178–86. http://dx.doi.org/10.4028/www.scientific.net/amr.567.178.
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A comprehensive mathematical model of full blast furnace with top gas recycling was established. The model consists of the calculation equations for gas composition of four zones (hearth, belly, lower shaft. top) in the blast furnace, the thermo-chemical balance model, the energy balance model of hot stand-by zone of the blast furnace and the shaft efficiency model. By using the model, the new process was calculated. The results show that coke rate and coal rate of the new process are both 200 kg/thm, fuel rate is decreased by 22.8% compared with that of conventional blast furnace. In addition, theoretical combustion temperature decreases with increasing hearth-recycle gas quantity. Increasing of hearth-recycle gas quantity by 10 m3/thm decreases theoretical combustion temperature by 10.0 K. Furthermore, the model could be applied to calculate the operating parameters when the raw materials and fuel conditions are different, and the change laws of operating parameters under the same raw materials and fuel conditions could also be studied with this model.
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Sun, Ye, Ren Chen, Zuoliang Zhang, Guoxi Wu, Huishu Zhang, Lingling Li, Yan Liu, Xiaoliang Li, and Yan Huang. "Numerical Simulation of the Raceway Zone in Melter Gasifier of COREX Process." Processes 7, no. 12 (November 20, 2019): 867. http://dx.doi.org/10.3390/pr7120867.
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The physical and chemical processes in the raceway zone of the COREX melter–gasifier express are similar to those inside the blast furnace. Based on the research achievements on blast furnaces, the unsteady numerical simulation of a gas-solid two-phase in the raceway was carried out by using computational fluid software. The formation process of the raceway in the COREX melter–gasifier was simulated. The shape and size of the raceway were obtained. Then, the effect of gas flow on the depth and height of the raceway was analyzed in this paper.
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Yaroshevskii, S. I., V. V. Kochura, A. M. Kuznetsov, A. S. Khaibulaev, and Z. K. Afanas’eva. "Efficiency of injection of natural gas and pulverized coal at ironmaking." Izvestiya. Ferrous Metallurgy 62, no. 11 (December 23, 2019): 833–39. http://dx.doi.org/10.17073/0368-0797-2019-11-833-839.
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The method for calculating indicators of blast furnace smelting with replacement of part of coke with additional fuels has been developed on the basis of full and complex compensation and compensating measures. Efficiency of the use of natural gas and pulverized coal in the blast furnace conditions of the Enakievo Metallurgical Plant was calculated and it has been confirmed as rather high. Increase in the consumption of natural gas from the baseline (71.8 m3/t of iron) to 110 m3/t ensures a corresponding increase in productivity of the blast furnace to 107.6 % and a decrease in the consumption of coke to 417.3 kg/t of iron (–38.4 kg/t, –8.42 %). Replacing natural gas with pulverized coal in the amount of 160 kg/t of iron made it possible to completely remove it from the blast. At the same time, coke consumption decreased to 354.59 kg/t of iron (–101.1 kg/t; –22.18 %). Increasing the consumption of pulverized coal fuel up to 200 kg/t of iron with compensation of the blast temperature of1200 °Cand oxygen of the blast of 25 % provides an increase in the productivity of the blast furnace to 105.8 % and reduction of coke consumption to 303.8 kg/t of iron (–151.9 kg/t, –33.33 %). High efficiency of the use of pulverized coal in conditions of the Enakievo Metallurgical Plant is explained by its lower cost compared to natural gas, high carbon content in coal and a significantly lower effecton the theoretical combustion temperature and other technological parameters.
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Perpiñán, Jorge, Manuel Bailera, Luis M. Romeo, Begoña Peña, and Valerie Eveloy. "CO2 Recycling in the Iron and Steel Industry via Power-to-Gas and Oxy-Fuel Combustion." Energies 14, no. 21 (October 29, 2021): 7090. http://dx.doi.org/10.3390/en14217090.
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The iron and steel industry is the largest energy-consuming sector in the world. It is responsible for emitting 4–5% of the total anthropogenic CO2. As an energy-intensive industry, it is essential that the iron and steel sector accomplishes important carbon emission reduction. Carbon capture is one of the most promising alternatives to achieve this aim. Moreover, if carbon utilization via power-to-gas is integrated with carbon capture, there could be a significant increase in the interest of this alternative in the iron and steel sector. This paper presents several simulations to integrate oxy-fuel processes and power-to-gas in a steel plant, and compares gas productions (coke oven gas, blast furnace gas, and blast oxygen furnace gas), energy requirements, and carbon reduction with a base case in order to obtain the technical feasibility of the proposals. Two different power-to-gas technology implementations were selected, together with the oxy blast furnace and the top gas recycling technologies. These integrations are based on three strategies: (i) converting the blast furnace (BF) process into an oxy-fuel process, (ii) recirculating blast furnace gas (BFG) back to the BF itself, and (iii) using a methanation process to generate CH4 and also introduce it to the BF. Applying these improvements to the steel industry, we achieved reductions in CO2 emissions of up to 8%, and reductions in coal fuel consumption of 12.8%. On the basis of the results, we are able to conclude that the energy required to achieve the above emission savings could be as low as 4.9 MJ/kg CO2 for the second implementation. These values highlight the importance of carrying out future research in the implementation of carbon capture and power-to-gas in the industrial sector.
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Ding, Cui-Jiao, Sheng Chen, Zhan-Zeng Liu, Zhao-Hui Liu, and Lin Wang. "Numerical Simulation of Temperature Field in Blast Furnace Gas Regenerative Furnace." Journal of Computational and Theoretical Nanoscience 9, no. 9 (September 1, 2012): 1248–54. http://dx.doi.org/10.1166/jctn.2012.2180.
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Dmitriev, A. N., and Yu A. Chesnokov. "Reduction Kinetics of Iron Ore Materials by Gases." Defect and Diffusion Forum 283-286 (March 2009): 45–52. http://dx.doi.org/10.4028/www.scientific.net/ddf.283-286.45.
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The proposed balance logic-statistical model of the blast furnace process is based on the use of material and thermal balances along with calculations of heat- and mass exchange taking into account the non-uniformity of gas and burden distribution on the radius of the furnace and influence of the basic metallurgical characteristics of iron ore raw materials and coke on the indices of blast furnace operation. As a check of the applicability of the model, calculations on the most critical parameters of the blast furnace process – the smelting of ferromanganese and iron nickel with a graphical representation of heat- and mass exchange processes, dynamics of oxides reduction on the height and radius of the blast furnace have been carried out.
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Semenov, Yu S. "Elaboration and realization of new approaches to diagnostic and control of blast furnace heat." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 76, no. 2 (March 19, 2020): 123–31. http://dx.doi.org/10.32339/0135-5910-2020-2-123-131.
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Under conditions of unstable supply of quality charge materials and technological fuel, the elaboration of new effective means of blast furnace heat control becomes actual for reaching acceptable technical and economic indices of its operation. Results of the studies carried out at the BF No. 3 of Enakievo steel-works (EMZ, Ukraine) during the period from October 2011 until December 2016 presented. During the period, various fuel additives to the blast were used within a wide range of their variation, and composition of charge materials was characterized by numerous components and variable quality. In the charge content, various additives were used: iron ore, limestone, BOF slag, briquettes of pellets siftings, manganese-containing additives. The new approach to the selection of rational charging programs was justified, providing stable economic BF running under variation of heat technological conditions. For the first time the temperature indices of estimation of gas stream distribution along the furnace radius were elaborated, the rational ranges of their variation at the operation under various gas-dynamic and fuel conditions determined, requirements to the gas stream temperature distribution along the furnace radius formulated. Based on analysis of information about lining temperature along the furnace height over the five year of EMZ BF No. 3 running, its values were ascertained, showing the partial or complete lining wear in the middle and upper part of the shaft. For the lining of the furnace bottom and other parts the temperature was ascertained, showing the formation in the lower zone unstable protective scull, as well the temperature characterizing its complete absence. The influence of blast mode during addition into it an increased volume of steam, natural gas and pulverized coal on variation of distribution of peripheral gas stream temperature along the furnace height from the tuyere zone to the top studied. It became a reason for an elaboration a method of the identification of the viscous-plastic state zone border in the peripheral zone of the furnace. Regulations of the blowing-in of blast furnaces after a long time stoppage without tapping the emergency hot metal elaborated. The technology of usage manganese-containing materials in the BF charge adjusted, which demonstrated the most effective washing out of the hearth under conditions of low and unstable charge materials quality and pulverized coal injection.
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Korpa, L., and Ya Mudron’. "System for cleaning blast-furnace gas in the blast-furnace shop at the VSZh Koshitse combine." Metallurgist 50, no. 7-8 (July 2006): 379–83. http://dx.doi.org/10.1007/s11015-006-0092-8.
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Vieira, Carlos Maurício Fontes, Sergio Neves Monteiro, Mariana Miranda Abreu, Aline Vieira Riter, Fernando Vernilli, and Veronica Scarpini Candido. "Recycling of Benefited Blast Furnace Sludge into Red Clay Ceramic." Materials Science Forum 775-776 (January 2014): 607–12. http://dx.doi.org/10.4028/www.scientific.net/msf.775-776.607.
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The blast furnace sludge is a waste generated after the washing step of the blast furnace gas. The reuse of this waste in the steelmaking process itself is quite problematic. This study aims to analyze the possibility of the incorporation of a type of blast furnace sludge, benefited by a process that uses helical separators, into red ceramic. Specimens were prepared by uniaxial pressing at 20 MPa and then fired at 750°C and 950°C. The evaluated technological properties were linear shrinkage, water absorption and flexural rupture strength. The results showed that the benefited blast furnace sludge significantly influences the evaluated properties, by impairing the linear shrinkage and the water absorption but improving the mechanical strength.
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Zhang, Chongmin, Zhimin Sun, Shuwen Chen, and Baohai Wang. "Enriching blast furnace gas by removing carbon dioxide." Journal of Environmental Sciences 25 (December 2013): S196—S200. http://dx.doi.org/10.1016/s1001-0742(14)60655-0.
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