The novel process of hydrogen-based shaft furnaces(HSFs)has attracted considerable attention because of their significant reduction of CO_(2)emissions.In this study,the interaction of H_(2)and CO with Fe_(tet1)-and Fe...The novel process of hydrogen-based shaft furnaces(HSFs)has attracted considerable attention because of their significant reduction of CO_(2)emissions.In this study,the interaction of H_(2)and CO with Fe_(tet1)-and Fe_(oct2)-terminated Fe_(3)O_(4)(111)surfaces under HSF conditions,including their adsorption and reduction behaviors,was investigated using the density functional theory method.The results indicated that the H_(2)molecule adsorbed onto the Fe_(tet1)-terminated surface with an adsorption energy(AE)of-1.36 eV,whereas the CO molecule preferentially adsorbed on the Fe_(oct2)-terminated surface with an AE of-1.56 eV.Both H_(2)and CO can readily undergo reduction on the Fe_(tet1)-terminated surface(corresponding to energy barriers of 0.83 eV and 2.23 eV,respectively),but kinetically the reaction of H2is more favorable than that of CO.With regard to the thermodynamics at 400-1400 K,the H_(2)was easy to be adsorbed,while the CO would like to react on the Fe_(tet1)-terminated surface.These thermodynamically tendencies were reversed on the Fe_(oct2)-terminated surface.The thermodynamic disadvantage of the reaction of H_(2)on the Fe_(tet1)-terminated surface was offset by an increase in the temperature.Furthermore,the adsorption of H2 and CO on the Fe_(tet1)-terminated surface was competitive,whereas the adsorption of them on the Fe_(oct2)-terminated surface was synergistic.Therefore,iron ores with a higher proportion of Fe_(tet1)-terminated surface can be applied for the HSF process.In conjunction with the increases in the reduction temperature and the ratio of H_(2)in the reducing gas would promote efficient HSF smelting.These observations provide effective guidance for optimizing the practical operation parameters and advancing the development of the HSF process.展开更多
Sinter is the core raw material for blast furnaces.Flue pressure,which is an important state parameter,affects sinter quality.In this paper,flue pressure prediction and optimization were studied based on the shapley a...Sinter is the core raw material for blast furnaces.Flue pressure,which is an important state parameter,affects sinter quality.In this paper,flue pressure prediction and optimization were studied based on the shapley additive explanation(SHAP)to predict the flue pressure and take targeted adjustment measures.First,the sintering process data were collected and processed.A flue pressure prediction model was then constructed after comparing different feature selection methods and model algorithms using SHAP+extremely random-ized trees(ET).The prediction accuracy of the model within the error range of±0.25 kPa was 92.63%.SHAP analysis was employed to improve the interpretability of the prediction model.The effects of various sintering operation parameters on flue pressure,the relation-ship between the numerical range of key operation parameters and flue pressure,the effect of operation parameter combinations on flue pressure,and the prediction process of the flue pressure prediction model on a single sample were analyzed.A flue pressure optimization module was also constructed and analyzed when the prediction satisfied the judgment conditions.The operating parameter combination was then pushed.The flue pressure was increased by 5.87%during the verification process,achieving a good optimization effect.展开更多
The operation furnace profile for the high heat load zone was one of the important factors affecting the stable and high-quality production of the blast furnace,but it was difficult to monitor directly.To address this...The operation furnace profile for the high heat load zone was one of the important factors affecting the stable and high-quality production of the blast furnace,but it was difficult to monitor directly.To address this issue,an online calculation model for the operation furnace profile was proposed based on a dual-driven approach combining data and mechanisms,by integrating mechanism experiment,numerical simulation,and machine learning.The experimentally determined slag layer hanging temperature was 1130℃,and the thermal conductivity ranged from 1.32 to 1.96 m^(2)℃^(-1).Based on the 3D slag-hanging numerical simulation model,a database was constructed,containing 2294 sets of mechanism cases for the slag layer.The fusion of data modeling,heat transfer theory,and expert experience enabled the online calculation of key input variables for the operation furnace profile,particularly the quantification of the“black-box”variable of gas temperature.Simulated data were used as inputs,and light gradient boosting machine was applied to construct the online calculation model for the operation furnace profile.This model facilitated the online calculation of the slag layer thickness and other key indices.The coefficient of determination of the model exceeded 0.98,indicating high accuracy.A slag layer state judgment model was constructed,categorizing states as shedding,too thin,normal,and too thick.Real-time data were applied,and the average slag thickness in the high heat load area of the test data ranged from 40 to 80 mm,which was consistent with field experience.The absolute value of the Pearson correlation coefficient between slag layer thickness,thermocouple temperature,and heat load data was above 0.85,indicating that the calculated results closely aligned with the actual trends.A 3D visual online monitoring system for the operation furnace profile was created,and it has been successfully implemented at the blast furnace site.展开更多
Blast furnace(BF)operation state was difficult to characterize,measure,and predict.To solve this problem,an intelligent evaluation and advanced prediction method of BF operation state based on industry big data and ma...Blast furnace(BF)operation state was difficult to characterize,measure,and predict.To solve this problem,an intelligent evaluation and advanced prediction method of BF operation state based on industry big data and machine learning was proposed.Based on the criteria of high productivity,low consumption,high quality,smooth running and long life,five BF parameters were extracted according to production experience and metallurgy process.Using the unsupervised learning,a 4-grade evaluation rule was established to realize the intelligent rating of BF operation state.Based on Kendall and maximal information coefficient,70 BF parameters with the most characteristic power of BF operation state were determined.The weights of BF parameters were calculated by applying the criteria importance through intercriteria correlation and the grey correlation degree.The weights of raw material,fuel,gas distribution,cooling stave,BF hearth,and iron and slag were 0.241,0.213,0.140,0.098,0.117 and 0.191,respectively.The weight of data interval was calculated by using the grading algorithm and the monotonicity,and then,the intelligent scoring mechanism based on the multiple weights was formed.It was beneficial to qualitatively and quantitatively characterizing the“black box”BF operation state.Furthermore,combining the algorithm and the evaluation mechanism,a graded prediction model of BF operation state was developed and proposed.It was shown that,compared with the conventional prediction model,the mean absolute error and mean square error of the graded prediction model were reduced by 0.35 and 1.29,respectively,while the explained variation was increased by 14.56%,the hit rate was increased by 5.1%within the error of 3%,and the average hit rate was more than 90.6%.It could be applied to reliably predict the score of BF operation state in the next hour and accurately provide the support for the practical controlling of the running BF.展开更多
The sticking behavior of pellets affects the continuity of production in hydrogen-based shaft furnace.The coupling influences of V_(2)O_(5) and reduction temperature on reduction sticking behavior and mechanism evolut...The sticking behavior of pellets affects the continuity of production in hydrogen-based shaft furnace.The coupling influences of V_(2)O_(5) and reduction temperature on reduction sticking behavior and mechanism evolution of pellets under hydrogen atmosphere are investigated.The increase in V_(2)O_(5) addition aggravated the reduction sticking behavior,which is attributed to the combined functions of the development of unique interwoven structure in the metallic iron interconnections at the reduction sticking interface and the deterioration of reduction swelling behavior of pellets.In addition,the strength of metallic iron interconnections enhanced and reduction sticking behavior aggravated with the increase in reduction temperature.Importantly,compared to other reduction temperatures,the reduction sticking behavior of pellets was most significantly aggravated with the increase in V_(2)O_(5) addition at 1000℃.And the values of sticking index increased from 10.22%to 15.36% as the V_(2)O_(5) addition increased from 0 to 1.00 wt.%at 1000℃.展开更多
The comprehensive status of blast furnaces was one of the most important factors affecting their economy,quality,and longev-ity.The blast furnace comprehensive status had the nature of“black box,”and it was“unpredi...The comprehensive status of blast furnaces was one of the most important factors affecting their economy,quality,and longev-ity.The blast furnace comprehensive status had the nature of“black box,”and it was“unpredictable.”In this study,a blast furnace com-prehensive status score and prediction method based on a cascade system and a combined model were proposed to address this issue.A dual cascade evaluation system was developed by integrating subjective and objective weighting methods.The analytic hierarchy process,coefficient of variation,entropy weight method,and impart combinatorial games were jointly employed to determine the optimal weight distribution across indicators.Categorized statuses(raw material,gas flow,furnace body,furnace cylinder,and iron-slag)were evaluated.Based on the five categories of the status data,the second cascade was applied to upgrade the quantitative evaluation of the comprehens-ive status.The weights of the different categories were 0.22,0.15,0.22,0.21,and 0.20,respectively.According to the data analysis,the results of the comprehensive status score closely matched the on-site production logs.Based on the blast furnace smelting period,the maximal information coefficient method was applied to the 100 parameters that were most relevant to the comprehensive status.A com-bined prediction model for a comprehensive status score was designed using bidirectional long short-term memory(BiLSTM)and categorical boosting(CatBoost).The test results indicated that the combined model reduced the mean absolute error by an average of 0.275 and increased the hit rate by an average of 5.65 percentage points compared to BiLSTM or CatBoost alone.When the er-ror range was±2.5,the combined model predicted a hit rate of 91.66%for the next hour’s comprehensive status score,and its high accur-acy was deemed satisfactory for the field.SHapley Additive exPlanations(SHAP)and regression fitting were applied to analyze the lin-ear quantitative relationship between the key variables and the comprehensive status score.When the furnace bottom center temperature was increased by 10℃,the comprehensive status score increased by 0.44.This method contributes to a more precise management and control of the comprehensive status of the blast furnace on-site.展开更多
Hydrogen metallurgy is a technology that applies hydrogen instead of carbon as a reduction agent to reduce CO2 emission,and the use of hydrogen is beneficial to promoting the sustainable development of the steel indus...Hydrogen metallurgy is a technology that applies hydrogen instead of carbon as a reduction agent to reduce CO2 emission,and the use of hydrogen is beneficial to promoting the sustainable development of the steel industry.Hydrogen metallurgy has numerous applications,such as H2reduction ironmaking in Japan,ULCORED and hydrogen-based steelmaking in Europe;hydrogen flash ironmaking technology in the US;HYBRIT in the Nordics;Midrex H2TM by Midrex Technologies,Inc.(United States);H2FUTURE by Voestalpine(Austria);and SALCOS by Salzgitter AG(Germany).Hydrogen-rich blast furnaces(BFs)with COG injection are common in China.Running BFs have been industrially tested by AnSteel,XuSteel,and BenSteel.In a currently under construction pilot plant of a coal gasification–gas-based shaft furnace with an annual output of 10000 t direct reduction iron(DRI),a reducing gas composed of 57 vol%H2 and 38 vol%CO is prepared via the Ende method.The life cycle of the coal gasification–gas-based shaft furnace–electric furnace short process(30 wt%DRI+70 wt%scrap)is assessed with 1 t of molten steel as a functional unit.This plant has a total energy consumption per ton of steel of 263.67 kg standard coal and a CO2 emission per ton of steel of 829.89 kg,which are superior to those of a traditional BF converter process.Considering domestic materials and fuels,hydrogen production and storage,and hydrogen reduction characteristics,we believe that a hydrogen-rich shaft furnace will be suitable in China.Hydrogen production and storage with an economic and large-scale industrialization will promote the further development of a full hydrogen shaft furnace.展开更多
Hydrogen-based shaft furnace process is gaining more and more attention due to its low carbon emission, and the reduction behavior of iron bearing burdens significantly affects its operation. In this work, the effects...Hydrogen-based shaft furnace process is gaining more and more attention due to its low carbon emission, and the reduction behavior of iron bearing burdens significantly affects its operation. In this work, the effects of reduction degree, temperature, and atmosphere on the swelling behavior of pellet has been studied thoroughly under typical hydrogen metallurgy conditions. The results show that the pellets swelled rapidly in the early reduction stage, then reached a maximum reduction swelling index (RSI) at approximately 40%reduction degree. The crystalline transformation of the iron oxides during the reduction process was the main reason of pellets swelling. The RSI increased significantly with increasing temperature in the range of 850-1050℃, the maximum RSI increased from 6.66%to 25.0%in the gas composition of 100%H_(2). With the temperature increased, the pellets suffered more thermal stress resulting in an increase of the volume. The maximum RSI decreased from 19.78%to 17.35%with the volume proportion of H_(2) in the atmosphere increased from 55%to 100%at the temperature of 950℃.The metallic iron tended to precipitate in a lamellar structure rather than whiskers. Consequently, the inside of the pellets became regular, so the RSI decreased. Overall, controlling a reasonable temperature and increasing the H_(2) proportion is an effective way to decrease the RSI of pellets.展开更多
Blast furnace (BF) ironmaking is the most typical “black box” process, and its complexity and uncertainty bring forth great challenges for furnace condition judgment and BF operation. Rich data resources for BF iron...Blast furnace (BF) ironmaking is the most typical “black box” process, and its complexity and uncertainty bring forth great challenges for furnace condition judgment and BF operation. Rich data resources for BF ironmaking are available, and the rapid development of data science and intelligent technology will provide an effective means to solve the uncertainty problem in the BF ironmaking process. This work focused on the application of artificial intelligence technology in BF ironmaking. The current intelligent BF ironmaking technology was summarized and analyzed from five aspects. These aspects include BF data management, the analyses of time delay and correlation, the prediction of BF key variables, the evaluation of BF status, and the multi-objective intelligent optimization of BF operations. Solutions and suggestions were offered for the problems in the current progress, and some outlooks for future prospects and technological breakthroughs were added. To effectively improve the BF data quality, we comprehensively considered the data problems and the characteristics of algorithms and selected the data processing method scientifically. For analyzing important BF characteristics, the effect of the delay was eliminated to ensure an accurate logical relationship between the BF parameters and economic indicators. As for BF parameter prediction and BF status evaluation,a BF intelligence model that integrates data information and process mechanism was built to effectively achieve the accurate prediction of BF key indexes and the scientific evaluation of BF status. During the optimization of BF parameters, low risk, low cost, and high return were used as the optimization criteria, and while pursuing the optimization effect, the feasibility and site operation cost were considered comprehensively.This work will help increase the process operator’s overall awareness and understanding of intelligent BF technology. Additionally, combining big data technology with the process will improve the practicality of data models in actual production and promote the application of intelligent technology in BF ironmaking.展开更多
The effects of MgO/Al2 O3 ratio on the viscous behaviors of MgO-Al2 O3-TiO2-CaO-SiO2 systems were investigated by the rotating cylinder method.Raman spectroscopy was used to analyze the structural characteristics of s...The effects of MgO/Al2 O3 ratio on the viscous behaviors of MgO-Al2 O3-TiO2-CaO-SiO2 systems were investigated by the rotating cylinder method.Raman spectroscopy was used to analyze the structural characteristics of slag and Factsage 7.0 was adopted to demonstrate the liquidus temperature of slag.The results show that the viscosity and activation energy for viscous flow decrease when the MgO/Al2O3 ratio increases from 0.82 to 1.36.The break point temperature and liquidus temperature of slag initially decrease and subsequently increase.The complex viscous structures are gradually depolymerized to simple structural units.In conclusion,with the increase of MgO/Al2O3 ratio,the degree of polymerization of slag decreases,which improves the fluidity of slag.The variations of liquidus temperature of slag lead to the same changes of break point temperature.展开更多
Smelting separations of Hongge vanadium-bearing titanomagnetite metallized pellets（HVTMP）prepared by gas-based direct reduction were investigated,and the effects of smelting parameters on the slag/metal separation b...Smelting separations of Hongge vanadium-bearing titanomagnetite metallized pellets（HVTMP）prepared by gas-based direct reduction were investigated,and the effects of smelting parameters on the slag/metal separation behaviors were analyzed.Relevant mechanisms were elucidated using X-ray diffraction analysis,FACTSAGE 7.0 calculations,and scanning electron microscopy observations.The results show that,when the smelting temperature,time,and C/O ratio are increased,the recoveries of V and Cr of HVTMP in pig iron are improved,the recovery of Fe initially increases and subsequently decreases,and the recovery of Ti O_2 in slag decreases.When the smelting Ca O/Si O_2 ratio is increased,the recoveries of Fe,V,and Cr in pig iron increase and the recovery of Ti O_2 in slag initially increases and subsequently decreases.The appropriate smelting separation parameters for HVTMP are as follows：smelting temperature of 1873 K;smelting time of 30–50 min;C/O ratio of 1.25;and Ca O/Si O_2 ratio of 0.50.With these optimized parameters（smelting time：30 min）,the recoveries of Fe,V,Cr,and Ti O_2 are 99.5%,91.24%,92.41%,and 94.86%,respectively.展开更多
A new process for preparing high-purity iron(HPI)was proposed,and it was investigated by laboratory experiments and pilot tests.The results show that under conditions of a reduced temperature of 1075°C,reduced ti...A new process for preparing high-purity iron(HPI)was proposed,and it was investigated by laboratory experiments and pilot tests.The results show that under conditions of a reduced temperature of 1075°C,reduced time of 5 h,and CaO content of 2.5wt%,a DRI with a metallization rate of 96.5%was obtained through coal-based direct reduction of ultra-high-grade iron concentrate.Then,an HPI with a Fe purity of 99.95%and C,Si,Mn,and P contents as low as 0.0008wt%,0.0006wt%,0.0014wt%,and 0.0015wt%,respectively,was prepared by smelting separation of the DRI using a smelting temperature of 1625°C,smelting time of 45 min,and CaO content of 9.3wt%.The product of the pilot test with a scale of 0.01 Mt/a had a lower impurity content than the Chinese industry standard.An HPI with a Fe purity of 99.98wt%can be produced through the direct reduction?smelting separation of ultra-high-grade iron concentrate at relatively low cost.The proposed process shows a promising prospect for application in the future.展开更多
The optimized use of MgO flux in the agglomeration of high-chromium vanadium-titanium magnetite was investigated system- atically through sinter and pellet experiments. MgO was added in the form of magnesite. When the...The optimized use of MgO flux in the agglomeration of high-chromium vanadium-titanium magnetite was investigated system- atically through sinter and pellet experiments. MgO was added in the form of magnesite. When the content of MgO in the sinter was in- creased from 1.95wt% to 2.63wt%, the low-temperature reduction degradation index increased from 80.57% to 82.71%. When the content of MgO in the pellet was increased from 1.14wt% to 2.40wt%, the reduction swelling index decreased from 15.2% to 8.6%; however, the com- pressive strength of the oxidized pellet decreased dramatically and it was 1985 N with an MgO content of 1.14wt%. This compressive strength does not satisfy the requirements for blast-furnace production. When all of the aforementioned results were taken into account, the sinter with a high MgO content （2.63wt%） matching the pellet with a low MgO content （less than 1.14wt%） was the rational burden structure for smelting high-chromium vanadium-titanium magnetite in blast furnaces.展开更多
In order to clarify the slag system of high Cr2O3 vanadium-titanium magnetite smelting in BF （blast furnace）, the melting properties of slag samples prepared by analytically pure reagents were measured. By means of ...In order to clarify the slag system of high Cr2O3 vanadium-titanium magnetite smelting in BF （blast furnace）, the melting properties of slag samples prepared by analytically pure reagents were measured. By means of orthogonal test synthetic weighted score method, the optimal slag for high Cr2O3 vanadium-titanium magnetite was obtained, which contained 10% MgO, 8% TiO2 and 15% Al2O3, with the binary basicity being 1.15. In addition, the effects of basicity, MgO, TiO2 and A12 03 on slag melting properties were investigated by single factor test, and the results showed that, with increasing the basicity or TiO2 content, melting temperature （Tin） increased, whereas initial vis- cosity （r/0） and high temperature viscosity （r/h） decreased. With increasing the MgO content, Tm decreased firstly and then increased. With increasing the Al2 O3 content, Tm increased, and η0 and r/h decreased firstly and then increased.展开更多
The prediction and control of furnace heat indicators are of great importance for improving the heat levels and conditions of the complex and difficult-to-operate hour-class delay blast furnace(BF)system.In this work,...The prediction and control of furnace heat indicators are of great importance for improving the heat levels and conditions of the complex and difficult-to-operate hour-class delay blast furnace(BF)system.In this work,a prediction and feedback model of furnace heat indicators based on the fusion of data-driven and BF ironmaking processes was proposed.The data on raw and fuel materials,process op-eration,smelting state,and slag and iron discharge during the whole BF process comprised 171 variables with 9223 groups of data and were comprehensively analyzed.A novel method for the delay analysis of furnace heat indicators was established.The extracted delay variables were found to play an important role in modeling.The method that combined the genetic algorithm and stacking efficiently im-proved performance compared with the traditional machine learning algorithm in improving the hit ratio of the furnace heat prediction model.The hit ratio for predicting the temperature of hot metal in the error range of±10℃ was 92.4%,and that for the chemical heat of hot metal in the error range of±0.1wt%was 93.3%.On the basis of the furnace heat prediction model and expert experience,a feedback model of furnace heat operation was established to obtain quantitative operation suggestions for stabilizing BF heat levels.These sugges-tions were highly accepted by BF operators.Finally,the comprehensive and dynamic model proposed in this work was successfully ap-plied in a practical BF system.It improved the BF temperature level remarkably,increasing the furnace temperature stability rate from 54.9%to 84.9%.This improvement achieved considerable economic benefits.展开更多
The technology of coal gasification in shaft furnace is an effective way to develop direct reduction iron in China. In order to clarify the process of the reduction of oxidized pellets in shaft furnace by carbon monox...The technology of coal gasification in shaft furnace is an effective way to develop direct reduction iron in China. In order to clarify the process of the reduction of oxidized pellets in shaft furnace by carbon monoxide or hydrogen in two ways, i.e. thermodynamics and kinetics, the gas utilization and reaction mechanism were studied by theoretical computations and isothermal thermogravimetric experiment. The results showed that the gas utilization increased with the rise of temperature when xH2/xco≥1 and with the increase of xco/（xH2 ＋xco） when temperature is less than 1073 K. The water-gas shift reaction restrains efficient utilization of gas, particularly in high tem- perature and hydrogen-rich gas. The gas utilization dropped with increase of carburization quantity of direct reduction iron （DRI） and oxygen potential of atmosphere. With the increase of both temperature and content of H2 in inlet gas, the reaction rate increased. At 100% Hz atmosphere, the interfacial chemical reaction is the dominant reaction re- stricted step. For the H2-CO mixture atmosphere, the reduction process is controlled by both interfacial chemical reaction and internal diffusion展开更多
The core of the long-life copper stave was to ensure the stability of the slag layer,and the uniform distribution of the slag layer was beneficial to restrict the generation of the overthick slag layer.A novel model f...The core of the long-life copper stave was to ensure the stability of the slag layer,and the uniform distribution of the slag layer was beneficial to restrict the generation of the overthick slag layer.A novel model for calculating the thickness and distribution of the slag layer in the part of copper stave was established based on the finite element theory through the ANSYS birth-death element technology.The distribution and thickness of the slag layer on the hot surface of copper stave were calculated and analyzed when the gas temperature and slag properties tended to be changed,which was applied to characterize the slag-hanging capability of copper stave with the changes of furnace conditions.It was shown that the thickness of hot surface slag layer in the part of copper stave decreased obviously while the temperature of stave body raised rapidly with increasing gas temperature.When the gas temperature was 1400℃,the inlaid slag layer was gradually melted,and the maximum temperature of the stave body was closed to 120℃.The change of gas temperature was very sensitive to the adherent dross capability of copper stave which would be enhanced by the promotion of slag-hanging temperature.However,when the slag-hanging temperature was 1150℃and the gas temperature was lower than 1250℃,the overlhick slag layer was easily formed on the hot surface of the copper stave,and its stability was poor.The improvement in the thermal conductivity of slag could be conducive to the formation of the uniform and stable slag layer on the hot surface of copper stave,especially in the dovetail groove.When the thermal conductivity of the slag was greater than 1.8 W m^(-2)℃^(-1),the inlaid slag layer in the dovetail groove was not melted,although the gas temperature reached 1500℃.展开更多
The effects of MgO and TiO_2 on the viscosity, activation energy for viscous flow, and break-point temperature of titanium-bearing slag were studied. The correlation between viscosity and slag structure was analyzed b...The effects of MgO and TiO_2 on the viscosity, activation energy for viscous flow, and break-point temperature of titanium-bearing slag were studied. The correlation between viscosity and slag structure was analyzed by Fourier transform infrared（FTIR） spectroscopy. Subsequently, main phases in the slag and their content changes were investigated by X-ray diffraction and Factsage 6.4 software package. The results show that the viscosity decreases when the MgO content increases from 10.00wt% to 14.00wt%. Moreover, the break-point temperature increases, and the activation energy for viscous flow initially increases and subsequently decreases. In addition, with increasing TiO_2 content from 5.00wt% to 9.00wt%, the viscosity decreases, and the break-point temperature and activation energy for viscous flow initially decrease and subsequently increase. FTIR analyses reveal that the polymerization degree of complex viscous units in titanium-bearing slag decreases with increasing MgO and TiO_2 contents. The mechanism of viscosity variation was elucidated. The basic phase in experimental slags is melilite. Besides, as the MgO content increases, the amount of magnesia–alumina spinel in the slag increases. Similarly, the sum of pyroxene and perovskite phases in the slag increases with increasing TiO_2 content.展开更多
The effects of MgO/Al_(2)O_(3)and CaO/SiO_(2)ratios on the viscosity,break-point temperature,and viscous activation energy of a high titanium-bearing slag were studied.The results showed that both the viscosity and th...The effects of MgO/Al_(2)O_(3)and CaO/SiO_(2)ratios on the viscosity,break-point temperature,and viscous activation energy of a high titanium-bearing slag were studied.The results showed that both the viscosity and the break-point temperature of the slag decreased with the MgO/Al_(2)O_(3)ratio increasing from 0.50 to 0.65,the viscous activation energy decreased gradually,and the thermal stability became better.In addition,with an increase in CaO/SiO_(2)ratio from 1.12 to 1.22,the main viscous units in the slag depolymerized and the viscosity of slag decreased.However,the break-point temperature of slag showed an increasing tendency.The viscous activation energy decreased gradually and the thermal stability became better.The basic phase in the experimental high titanium-bearing slag was pyroxene,and its amount increased with increasing the MgO/Al_(2)O_(3)ratio while decreased with increasing the CaO/SiO_(2)ratio.展开更多
Blast furnace （BF） ironmaking is dominant for reducing pollution emission and energy consumption in iron and steel industry, Under the increasingly strict environmental pressure, some innovative tech nologies of BF ...Blast furnace （BF） ironmaking is dominant for reducing pollution emission and energy consumption in iron and steel industry, Under the increasingly strict environmental pressure, some innovative tech nologies of BF ironmaking for environmental protection have been developed and applied in actual op- erating facilities. The current state of BF ironmaking in Europe, America, Japan, and China were briefly overviewed. Moreover, some innovative BF ironmaking technologies aiming at environmental harmony and operation intellectualization in the world, such as waste gas recycling sintering, BF op eration with coke oven gas injection, ferro coke, lime coating coke, BF visualization and intellectuali zation, were roundly summarized. Finally, some discussion on the technologies was carried out and the development trends of BF ironmaking were pointed out. The review could provide references and supports for the progress of environment friendly technologies of BF ironmaking, thereby promoting their practical applications and achieving sustainable development of BF ironmaking, especially for Chinese ironmaking industry.展开更多
基金financially supported by the Key Program of National Natural Science Foundation of China(No.U23A20608)the Liaoning Province Science and Technology Plan Joint Program(Key Research and Development Program Project),China(No.2023JH2/101800058)+3 种基金the Science&Technology Plan Project of Hebei Province,China(No.23314601L)the Project of Hydrogen-Based Shaft Furnace Reduction-Electric Furnace Melting And Separation Technology Research and Application for High-Titanium Magnetite Iron Ore(No.HG2023239)the General Program of National Natural Science Foundation of China(No.52274253)the Special Project for Major Scientific and Technological Achievements Transformation in Hebei Province,China(No.23284101Z)。
文摘The novel process of hydrogen-based shaft furnaces(HSFs)has attracted considerable attention because of their significant reduction of CO_(2)emissions.In this study,the interaction of H_(2)and CO with Fe_(tet1)-and Fe_(oct2)-terminated Fe_(3)O_(4)(111)surfaces under HSF conditions,including their adsorption and reduction behaviors,was investigated using the density functional theory method.The results indicated that the H_(2)molecule adsorbed onto the Fe_(tet1)-terminated surface with an adsorption energy(AE)of-1.36 eV,whereas the CO molecule preferentially adsorbed on the Fe_(oct2)-terminated surface with an AE of-1.56 eV.Both H_(2)and CO can readily undergo reduction on the Fe_(tet1)-terminated surface(corresponding to energy barriers of 0.83 eV and 2.23 eV,respectively),but kinetically the reaction of H2is more favorable than that of CO.With regard to the thermodynamics at 400-1400 K,the H_(2)was easy to be adsorbed,while the CO would like to react on the Fe_(tet1)-terminated surface.These thermodynamically tendencies were reversed on the Fe_(oct2)-terminated surface.The thermodynamic disadvantage of the reaction of H_(2)on the Fe_(tet1)-terminated surface was offset by an increase in the temperature.Furthermore,the adsorption of H2 and CO on the Fe_(tet1)-terminated surface was competitive,whereas the adsorption of them on the Fe_(oct2)-terminated surface was synergistic.Therefore,iron ores with a higher proportion of Fe_(tet1)-terminated surface can be applied for the HSF process.In conjunction with the increases in the reduction temperature and the ratio of H_(2)in the reducing gas would promote efficient HSF smelting.These observations provide effective guidance for optimizing the practical operation parameters and advancing the development of the HSF process.
基金supported by the General Program of the National Natural Science Foundation of China(No.52274326)the China Baowu Low Carbon Metallurgy Innovation Foundation(No.BWLCF202109)the Seventh Batch of Ten Thousand Talents Plan of China(No.ZX20220553).
文摘Sinter is the core raw material for blast furnaces.Flue pressure,which is an important state parameter,affects sinter quality.In this paper,flue pressure prediction and optimization were studied based on the shapley additive explanation(SHAP)to predict the flue pressure and take targeted adjustment measures.First,the sintering process data were collected and processed.A flue pressure prediction model was then constructed after comparing different feature selection methods and model algorithms using SHAP+extremely random-ized trees(ET).The prediction accuracy of the model within the error range of±0.25 kPa was 92.63%.SHAP analysis was employed to improve the interpretability of the prediction model.The effects of various sintering operation parameters on flue pressure,the relation-ship between the numerical range of key operation parameters and flue pressure,the effect of operation parameter combinations on flue pressure,and the prediction process of the flue pressure prediction model on a single sample were analyzed.A flue pressure optimization module was also constructed and analyzed when the prediction satisfied the judgment conditions.The operating parameter combination was then pushed.The flue pressure was increased by 5.87%during the verification process,achieving a good optimization effect.
基金financially supported by the National Natural Science Foundation of China(Grant Nos.52404343 and 52274326)the Fundamental Research Funds for the Central Universities(Grant Nos.N2425031 and N25BJD007)+1 种基金the China Postdoctoral Science Foundation(Grant No.2024M760370)the Liaoning Province Science and Technology Plan Joint Program(Key Research and Development Program Project)(Grant No.2023JH2/101800058).
文摘The operation furnace profile for the high heat load zone was one of the important factors affecting the stable and high-quality production of the blast furnace,but it was difficult to monitor directly.To address this issue,an online calculation model for the operation furnace profile was proposed based on a dual-driven approach combining data and mechanisms,by integrating mechanism experiment,numerical simulation,and machine learning.The experimentally determined slag layer hanging temperature was 1130℃,and the thermal conductivity ranged from 1.32 to 1.96 m^(2)℃^(-1).Based on the 3D slag-hanging numerical simulation model,a database was constructed,containing 2294 sets of mechanism cases for the slag layer.The fusion of data modeling,heat transfer theory,and expert experience enabled the online calculation of key input variables for the operation furnace profile,particularly the quantification of the“black-box”variable of gas temperature.Simulated data were used as inputs,and light gradient boosting machine was applied to construct the online calculation model for the operation furnace profile.This model facilitated the online calculation of the slag layer thickness and other key indices.The coefficient of determination of the model exceeded 0.98,indicating high accuracy.A slag layer state judgment model was constructed,categorizing states as shedding,too thin,normal,and too thick.Real-time data were applied,and the average slag thickness in the high heat load area of the test data ranged from 40 to 80 mm,which was consistent with field experience.The absolute value of the Pearson correlation coefficient between slag layer thickness,thermocouple temperature,and heat load data was above 0.85,indicating that the calculated results closely aligned with the actual trends.A 3D visual online monitoring system for the operation furnace profile was created,and it has been successfully implemented at the blast furnace site.
基金supported by the National Natural Science Foundation of China(Nos.52404343,52274326,and 52404341)the Fundamental Research Funds for the Central Universities(N2425031,N25BJD007)+1 种基金the China Postdoctoral Science Foundation(2024M760370)the Liaoning Province Science and Technology Plan Joint Program(Key Research and Development Program Project)(2023JH2/101800058).
文摘Blast furnace(BF)operation state was difficult to characterize,measure,and predict.To solve this problem,an intelligent evaluation and advanced prediction method of BF operation state based on industry big data and machine learning was proposed.Based on the criteria of high productivity,low consumption,high quality,smooth running and long life,five BF parameters were extracted according to production experience and metallurgy process.Using the unsupervised learning,a 4-grade evaluation rule was established to realize the intelligent rating of BF operation state.Based on Kendall and maximal information coefficient,70 BF parameters with the most characteristic power of BF operation state were determined.The weights of BF parameters were calculated by applying the criteria importance through intercriteria correlation and the grey correlation degree.The weights of raw material,fuel,gas distribution,cooling stave,BF hearth,and iron and slag were 0.241,0.213,0.140,0.098,0.117 and 0.191,respectively.The weight of data interval was calculated by using the grading algorithm and the monotonicity,and then,the intelligent scoring mechanism based on the multiple weights was formed.It was beneficial to qualitatively and quantitatively characterizing the“black box”BF operation state.Furthermore,combining the algorithm and the evaluation mechanism,a graded prediction model of BF operation state was developed and proposed.It was shown that,compared with the conventional prediction model,the mean absolute error and mean square error of the graded prediction model were reduced by 0.35 and 1.29,respectively,while the explained variation was increased by 14.56%,the hit rate was increased by 5.1%within the error of 3%,and the average hit rate was more than 90.6%.It could be applied to reliably predict the score of BF operation state in the next hour and accurately provide the support for the practical controlling of the running BF.
基金supported by the authors are especially grateful to the National Natural Science Foundation of China(Grant No.51904063)the Key Program of National Natural Science Foundation of China(No.U23A20608)+6 种基金Fundamental Research Funds for the Central Universities(N2025023,N2225046)Postdoctoral Followship Program of CPSF(GZC20230392)Science&Technology Plan Project of Liaoning Province(2022JH24/10200027)Science&Technology Plan Project of Hebei Province(23314601L)Science and Technology Program of Liaoning of China(2023JH2/101700304)China Postdoctoral Science Foundation(2023M740551)Liaoning Province Science and Technology Plan Joint Program(Key Research and Development Program Project)(2023JH2/101800058).
文摘The sticking behavior of pellets affects the continuity of production in hydrogen-based shaft furnace.The coupling influences of V_(2)O_(5) and reduction temperature on reduction sticking behavior and mechanism evolution of pellets under hydrogen atmosphere are investigated.The increase in V_(2)O_(5) addition aggravated the reduction sticking behavior,which is attributed to the combined functions of the development of unique interwoven structure in the metallic iron interconnections at the reduction sticking interface and the deterioration of reduction swelling behavior of pellets.In addition,the strength of metallic iron interconnections enhanced and reduction sticking behavior aggravated with the increase in reduction temperature.Importantly,compared to other reduction temperatures,the reduction sticking behavior of pellets was most significantly aggravated with the increase in V_(2)O_(5) addition at 1000℃.And the values of sticking index increased from 10.22%to 15.36% as the V_(2)O_(5) addition increased from 0 to 1.00 wt.%at 1000℃.
基金supported by the Youth Program of National Natural Science Foundation of China(No.52404343)the General Program of National Natural Science Foundation of China(No.52274326)+2 种基金the Fundamental Research Funds for the Central Universities,China(No.N2425031)the Seventh Batch of Ten Thousand Talents Plan of China(No.ZX20220553)the Liaoning Province Science and Technology Plan Joint Program,China(Key Research and Development Program Project)(No.2023JH2/101800058).
文摘The comprehensive status of blast furnaces was one of the most important factors affecting their economy,quality,and longev-ity.The blast furnace comprehensive status had the nature of“black box,”and it was“unpredictable.”In this study,a blast furnace com-prehensive status score and prediction method based on a cascade system and a combined model were proposed to address this issue.A dual cascade evaluation system was developed by integrating subjective and objective weighting methods.The analytic hierarchy process,coefficient of variation,entropy weight method,and impart combinatorial games were jointly employed to determine the optimal weight distribution across indicators.Categorized statuses(raw material,gas flow,furnace body,furnace cylinder,and iron-slag)were evaluated.Based on the five categories of the status data,the second cascade was applied to upgrade the quantitative evaluation of the comprehens-ive status.The weights of the different categories were 0.22,0.15,0.22,0.21,and 0.20,respectively.According to the data analysis,the results of the comprehensive status score closely matched the on-site production logs.Based on the blast furnace smelting period,the maximal information coefficient method was applied to the 100 parameters that were most relevant to the comprehensive status.A com-bined prediction model for a comprehensive status score was designed using bidirectional long short-term memory(BiLSTM)and categorical boosting(CatBoost).The test results indicated that the combined model reduced the mean absolute error by an average of 0.275 and increased the hit rate by an average of 5.65 percentage points compared to BiLSTM or CatBoost alone.When the er-ror range was±2.5,the combined model predicted a hit rate of 91.66%for the next hour’s comprehensive status score,and its high accur-acy was deemed satisfactory for the field.SHapley Additive exPlanations(SHAP)and regression fitting were applied to analyze the lin-ear quantitative relationship between the key variables and the comprehensive status score.When the furnace bottom center temperature was increased by 10℃,the comprehensive status score increased by 0.44.This method contributes to a more precise management and control of the comprehensive status of the blast furnace on-site.
基金the National Natural Science Foundation of China(No.51904063)the Fundamental Research Funds for the Central Universities(Nos.N2025023,N172503016,N172502005,and N172506011)+1 种基金the China Postdoctoral Science Foundation(No.2018M640259)the Xingliao Talent Plan(No.XLYC1902118)。
文摘Hydrogen metallurgy is a technology that applies hydrogen instead of carbon as a reduction agent to reduce CO2 emission,and the use of hydrogen is beneficial to promoting the sustainable development of the steel industry.Hydrogen metallurgy has numerous applications,such as H2reduction ironmaking in Japan,ULCORED and hydrogen-based steelmaking in Europe;hydrogen flash ironmaking technology in the US;HYBRIT in the Nordics;Midrex H2TM by Midrex Technologies,Inc.(United States);H2FUTURE by Voestalpine(Austria);and SALCOS by Salzgitter AG(Germany).Hydrogen-rich blast furnaces(BFs)with COG injection are common in China.Running BFs have been industrially tested by AnSteel,XuSteel,and BenSteel.In a currently under construction pilot plant of a coal gasification–gas-based shaft furnace with an annual output of 10000 t direct reduction iron(DRI),a reducing gas composed of 57 vol%H2 and 38 vol%CO is prepared via the Ende method.The life cycle of the coal gasification–gas-based shaft furnace–electric furnace short process(30 wt%DRI+70 wt%scrap)is assessed with 1 t of molten steel as a functional unit.This plant has a total energy consumption per ton of steel of 263.67 kg standard coal and a CO2 emission per ton of steel of 829.89 kg,which are superior to those of a traditional BF converter process.Considering domestic materials and fuels,hydrogen production and storage,and hydrogen reduction characteristics,we believe that a hydrogen-rich shaft furnace will be suitable in China.Hydrogen production and storage with an economic and large-scale industrialization will promote the further development of a full hydrogen shaft furnace.
基金financially supported by the National Natural Science Foundation of China (No.51904063)the China Postdoctoral Science Foundation (No.2018M640259)+2 种基金the Fundamental Research Funds for the Central Universities(No.N2025023)the Key research and development project of Hebei Province (No.21314001D)the Plan of Xingliao Talents,China (No.XLYC1902118)。
文摘Hydrogen-based shaft furnace process is gaining more and more attention due to its low carbon emission, and the reduction behavior of iron bearing burdens significantly affects its operation. In this work, the effects of reduction degree, temperature, and atmosphere on the swelling behavior of pellet has been studied thoroughly under typical hydrogen metallurgy conditions. The results show that the pellets swelled rapidly in the early reduction stage, then reached a maximum reduction swelling index (RSI) at approximately 40%reduction degree. The crystalline transformation of the iron oxides during the reduction process was the main reason of pellets swelling. The RSI increased significantly with increasing temperature in the range of 850-1050℃, the maximum RSI increased from 6.66%to 25.0%in the gas composition of 100%H_(2). With the temperature increased, the pellets suffered more thermal stress resulting in an increase of the volume. The maximum RSI decreased from 19.78%to 17.35%with the volume proportion of H_(2) in the atmosphere increased from 55%to 100%at the temperature of 950℃.The metallic iron tended to precipitate in a lamellar structure rather than whiskers. Consequently, the inside of the pellets became regular, so the RSI decreased. Overall, controlling a reasonable temperature and increasing the H_(2) proportion is an effective way to decrease the RSI of pellets.
基金financially supported by the General Program of the National Natural Science Foundation of China(No.52274326)the Fundamental Research Funds for the Central Universities (Nos.2125018 and 2225008)China Baowu Low Carbon Metallurgy Innovation Foundation(BWLCF202109)。
文摘Blast furnace (BF) ironmaking is the most typical “black box” process, and its complexity and uncertainty bring forth great challenges for furnace condition judgment and BF operation. Rich data resources for BF ironmaking are available, and the rapid development of data science and intelligent technology will provide an effective means to solve the uncertainty problem in the BF ironmaking process. This work focused on the application of artificial intelligence technology in BF ironmaking. The current intelligent BF ironmaking technology was summarized and analyzed from five aspects. These aspects include BF data management, the analyses of time delay and correlation, the prediction of BF key variables, the evaluation of BF status, and the multi-objective intelligent optimization of BF operations. Solutions and suggestions were offered for the problems in the current progress, and some outlooks for future prospects and technological breakthroughs were added. To effectively improve the BF data quality, we comprehensively considered the data problems and the characteristics of algorithms and selected the data processing method scientifically. For analyzing important BF characteristics, the effect of the delay was eliminated to ensure an accurate logical relationship between the BF parameters and economic indicators. As for BF parameter prediction and BF status evaluation,a BF intelligence model that integrates data information and process mechanism was built to effectively achieve the accurate prediction of BF key indexes and the scientific evaluation of BF status. During the optimization of BF parameters, low risk, low cost, and high return were used as the optimization criteria, and while pursuing the optimization effect, the feasibility and site operation cost were considered comprehensively.This work will help increase the process operator’s overall awareness and understanding of intelligent BF technology. Additionally, combining big data technology with the process will improve the practicality of data models in actual production and promote the application of intelligent technology in BF ironmaking.
基金Projects(51574067,51904063)supported by the National Natural Science Foundation of ChinaProjects(N172503016,N172502005,N172506011)supported by Fundamental Research Funds for the Central Universities,ChinaProject(2018M640259)supported by China Postdoctoral Science Foundation
文摘The effects of MgO/Al2 O3 ratio on the viscous behaviors of MgO-Al2 O3-TiO2-CaO-SiO2 systems were investigated by the rotating cylinder method.Raman spectroscopy was used to analyze the structural characteristics of slag and Factsage 7.0 was adopted to demonstrate the liquidus temperature of slag.The results show that the viscosity and activation energy for viscous flow decrease when the MgO/Al2O3 ratio increases from 0.82 to 1.36.The break point temperature and liquidus temperature of slag initially decrease and subsequently increase.The complex viscous structures are gradually depolymerized to simple structural units.In conclusion,with the increase of MgO/Al2O3 ratio,the degree of polymerization of slag decreases,which improves the fluidity of slag.The variations of liquidus temperature of slag lead to the same changes of break point temperature.
基金financially supported by the National Natural Science Foundation of China (No.51574067)
文摘Smelting separations of Hongge vanadium-bearing titanomagnetite metallized pellets（HVTMP）prepared by gas-based direct reduction were investigated,and the effects of smelting parameters on the slag/metal separation behaviors were analyzed.Relevant mechanisms were elucidated using X-ray diffraction analysis,FACTSAGE 7.0 calculations,and scanning electron microscopy observations.The results show that,when the smelting temperature,time,and C/O ratio are increased,the recoveries of V and Cr of HVTMP in pig iron are improved,the recovery of Fe initially increases and subsequently decreases,and the recovery of Ti O_2 in slag decreases.When the smelting Ca O/Si O_2 ratio is increased,the recoveries of Fe,V,and Cr in pig iron increase and the recovery of Ti O_2 in slag initially increases and subsequently decreases.The appropriate smelting separation parameters for HVTMP are as follows：smelting temperature of 1873 K;smelting time of 30–50 min;C/O ratio of 1.25;and Ca O/Si O_2 ratio of 0.50.With these optimized parameters（smelting time：30 min）,the recoveries of Fe,V,Cr,and Ti O_2 are 99.5%,91.24%,92.41%,and 94.86%,respectively.
基金the National Natural Science Foundation of China(No.51904063)the Fundamental Research Funds for the Central Universities,China(Nos.N172503016,N172502005,and N172506011)the China Postdoctoral Science Foundation(No.2018M640259).
文摘A new process for preparing high-purity iron(HPI)was proposed,and it was investigated by laboratory experiments and pilot tests.The results show that under conditions of a reduced temperature of 1075°C,reduced time of 5 h,and CaO content of 2.5wt%,a DRI with a metallization rate of 96.5%was obtained through coal-based direct reduction of ultra-high-grade iron concentrate.Then,an HPI with a Fe purity of 99.95%and C,Si,Mn,and P contents as low as 0.0008wt%,0.0006wt%,0.0014wt%,and 0.0015wt%,respectively,was prepared by smelting separation of the DRI using a smelting temperature of 1625°C,smelting time of 45 min,and CaO content of 9.3wt%.The product of the pilot test with a scale of 0.01 Mt/a had a lower impurity content than the Chinese industry standard.An HPI with a Fe purity of 99.98wt%can be produced through the direct reduction?smelting separation of ultra-high-grade iron concentrate at relatively low cost.The proposed process shows a promising prospect for application in the future.
基金financially supported by the National Natural Science Foundation of China (Major Program, No. 51090384)the National High Technology Research and Development Program of China (Nos. 2012AA062302 and 2012AA062304)+1 种基金the Fundamental Research Funds for Central Universities (Nos. N110202001 and N130602003)the Northeastern University Cultivation Project of Excellent Doctoral Dissertation
文摘The optimized use of MgO flux in the agglomeration of high-chromium vanadium-titanium magnetite was investigated system- atically through sinter and pellet experiments. MgO was added in the form of magnesite. When the content of MgO in the sinter was in- creased from 1.95wt% to 2.63wt%, the low-temperature reduction degradation index increased from 80.57% to 82.71%. When the content of MgO in the pellet was increased from 1.14wt% to 2.40wt%, the reduction swelling index decreased from 15.2% to 8.6%; however, the com- pressive strength of the oxidized pellet decreased dramatically and it was 1985 N with an MgO content of 1.14wt%. This compressive strength does not satisfy the requirements for blast-furnace production. When all of the aforementioned results were taken into account, the sinter with a high MgO content （2.63wt%） matching the pellet with a low MgO content （less than 1.14wt%） was the rational burden structure for smelting high-chromium vanadium-titanium magnetite in blast furnaces.
基金Item Sponsored by National Natural Science Foundation of China(51090384)National High Technology Research and Development Program(863 Program)of China(2012AA062302,2012AA062304)Fundamental Research Funds for the Central Universities of China(N110202001)
文摘In order to clarify the slag system of high Cr2O3 vanadium-titanium magnetite smelting in BF （blast furnace）, the melting properties of slag samples prepared by analytically pure reagents were measured. By means of orthogonal test synthetic weighted score method, the optimal slag for high Cr2O3 vanadium-titanium magnetite was obtained, which contained 10% MgO, 8% TiO2 and 15% Al2O3, with the binary basicity being 1.15. In addition, the effects of basicity, MgO, TiO2 and A12 03 on slag melting properties were investigated by single factor test, and the results showed that, with increasing the basicity or TiO2 content, melting temperature （Tin） increased, whereas initial vis- cosity （r/0） and high temperature viscosity （r/h） decreased. With increasing the MgO content, Tm decreased firstly and then increased. With increasing the Al2 O3 content, Tm increased, and η0 and r/h decreased firstly and then increased.
基金financially supported by the General Program of the National Natural Science Foundation of China (No. 52274326)the Fundamental Research Funds for the Central Universities (No. N2425031)+3 种基金Seventh Batch of Ten Thousand Talents Plan (No. ZX20220553)China Baowu Low Carbon Metallurgy Innovation Foundation (No. BWLCF202109)The key technology research and development and application of digital transformation throughout the iron and steel production process (No. 2023JH2/101800058)Liaoning Province Science and Technology Plan Joint Program (Key Research and Development Program Project)
文摘The prediction and control of furnace heat indicators are of great importance for improving the heat levels and conditions of the complex and difficult-to-operate hour-class delay blast furnace(BF)system.In this work,a prediction and feedback model of furnace heat indicators based on the fusion of data-driven and BF ironmaking processes was proposed.The data on raw and fuel materials,process op-eration,smelting state,and slag and iron discharge during the whole BF process comprised 171 variables with 9223 groups of data and were comprehensively analyzed.A novel method for the delay analysis of furnace heat indicators was established.The extracted delay variables were found to play an important role in modeling.The method that combined the genetic algorithm and stacking efficiently im-proved performance compared with the traditional machine learning algorithm in improving the hit ratio of the furnace heat prediction model.The hit ratio for predicting the temperature of hot metal in the error range of±10℃ was 92.4%,and that for the chemical heat of hot metal in the error range of±0.1wt%was 93.3%.On the basis of the furnace heat prediction model and expert experience,a feedback model of furnace heat operation was established to obtain quantitative operation suggestions for stabilizing BF heat levels.These sugges-tions were highly accepted by BF operators.Finally,the comprehensive and dynamic model proposed in this work was successfully ap-plied in a practical BF system.It improved the BF temperature level remarkably,increasing the furnace temperature stability rate from 54.9%to 84.9%.This improvement achieved considerable economic benefits.
基金Item Sponsored by National Natural Science Foundation of China(51090384)Fundamental Research Funds for Central Universities of China(N110202001)
文摘The technology of coal gasification in shaft furnace is an effective way to develop direct reduction iron in China. In order to clarify the process of the reduction of oxidized pellets in shaft furnace by carbon monoxide or hydrogen in two ways, i.e. thermodynamics and kinetics, the gas utilization and reaction mechanism were studied by theoretical computations and isothermal thermogravimetric experiment. The results showed that the gas utilization increased with the rise of temperature when xH2/xco≥1 and with the increase of xco/（xH2 ＋xco） when temperature is less than 1073 K. The water-gas shift reaction restrains efficient utilization of gas, particularly in high tem- perature and hydrogen-rich gas. The gas utilization dropped with increase of carburization quantity of direct reduction iron （DRI） and oxygen potential of atmosphere. With the increase of both temperature and content of H2 in inlet gas, the reaction rate increased. At 100% Hz atmosphere, the interfacial chemical reaction is the dominant reaction re- stricted step. For the H2-CO mixture atmosphere, the reduction process is controlled by both interfacial chemical reaction and internal diffusion
基金The authors were especially grateful to the National Natural Science Foundation of China(No.51904063)Fundamental Research Funds for the Central Universities(Nos.N172503016,N172502005,and N172506011)China Postdoctoral Science Foundation(No.2018M640259).
文摘The core of the long-life copper stave was to ensure the stability of the slag layer,and the uniform distribution of the slag layer was beneficial to restrict the generation of the overthick slag layer.A novel model for calculating the thickness and distribution of the slag layer in the part of copper stave was established based on the finite element theory through the ANSYS birth-death element technology.The distribution and thickness of the slag layer on the hot surface of copper stave were calculated and analyzed when the gas temperature and slag properties tended to be changed,which was applied to characterize the slag-hanging capability of copper stave with the changes of furnace conditions.It was shown that the thickness of hot surface slag layer in the part of copper stave decreased obviously while the temperature of stave body raised rapidly with increasing gas temperature.When the gas temperature was 1400℃,the inlaid slag layer was gradually melted,and the maximum temperature of the stave body was closed to 120℃.The change of gas temperature was very sensitive to the adherent dross capability of copper stave which would be enhanced by the promotion of slag-hanging temperature.However,when the slag-hanging temperature was 1150℃and the gas temperature was lower than 1250℃,the overlhick slag layer was easily formed on the hot surface of the copper stave,and its stability was poor.The improvement in the thermal conductivity of slag could be conducive to the formation of the uniform and stable slag layer on the hot surface of copper stave,especially in the dovetail groove.When the thermal conductivity of the slag was greater than 1.8 W m^(-2)℃^(-1),the inlaid slag layer in the dovetail groove was not melted,although the gas temperature reached 1500℃.
基金financial support by the Fundamental Research Funds for the Central Universities (No. N130602003)National High Technology Research and Development Program of China (No. 2012AA062302)the National Natural Science Foundation of China (No. 51574067)
文摘The effects of MgO and TiO_2 on the viscosity, activation energy for viscous flow, and break-point temperature of titanium-bearing slag were studied. The correlation between viscosity and slag structure was analyzed by Fourier transform infrared（FTIR） spectroscopy. Subsequently, main phases in the slag and their content changes were investigated by X-ray diffraction and Factsage 6.4 software package. The results show that the viscosity decreases when the MgO content increases from 10.00wt% to 14.00wt%. Moreover, the break-point temperature increases, and the activation energy for viscous flow initially increases and subsequently decreases. In addition, with increasing TiO_2 content from 5.00wt% to 9.00wt%, the viscosity decreases, and the break-point temperature and activation energy for viscous flow initially decrease and subsequently increase. FTIR analyses reveal that the polymerization degree of complex viscous units in titanium-bearing slag decreases with increasing MgO and TiO_2 contents. The mechanism of viscosity variation was elucidated. The basic phase in experimental slags is melilite. Besides, as the MgO content increases, the amount of magnesia–alumina spinel in the slag increases. Similarly, the sum of pyroxene and perovskite phases in the slag increases with increasing TiO_2 content.
基金The authors were specially grateful to the National Natural Science Foundation of China(Grant No.51904063)the Fundamental Research Funds for the Central Universities(N2025023).
文摘The effects of MgO/Al_(2)O_(3)and CaO/SiO_(2)ratios on the viscosity,break-point temperature,and viscous activation energy of a high titanium-bearing slag were studied.The results showed that both the viscosity and the break-point temperature of the slag decreased with the MgO/Al_(2)O_(3)ratio increasing from 0.50 to 0.65,the viscous activation energy decreased gradually,and the thermal stability became better.In addition,with an increase in CaO/SiO_(2)ratio from 1.12 to 1.22,the main viscous units in the slag depolymerized and the viscosity of slag decreased.However,the break-point temperature of slag showed an increasing tendency.The viscous activation energy decreased gradually and the thermal stability became better.The basic phase in the experimental high titanium-bearing slag was pyroxene,and its amount increased with increasing the MgO/Al_(2)O_(3)ratio while decreased with increasing the CaO/SiO_(2)ratio.
基金support by the National Natural Science Foundation of China(Nos.50804008and 51374058)the China Postdoctoral Science Foundation(No.2016M601321)the Fundamental Research Funds of the Central Universities of China(No.N162503003)
文摘Blast furnace （BF） ironmaking is dominant for reducing pollution emission and energy consumption in iron and steel industry, Under the increasingly strict environmental pressure, some innovative tech nologies of BF ironmaking for environmental protection have been developed and applied in actual op- erating facilities. The current state of BF ironmaking in Europe, America, Japan, and China were briefly overviewed. Moreover, some innovative BF ironmaking technologies aiming at environmental harmony and operation intellectualization in the world, such as waste gas recycling sintering, BF op eration with coke oven gas injection, ferro coke, lime coating coke, BF visualization and intellectuali zation, were roundly summarized. Finally, some discussion on the technologies was carried out and the development trends of BF ironmaking were pointed out. The review could provide references and supports for the progress of environment friendly technologies of BF ironmaking, thereby promoting their practical applications and achieving sustainable development of BF ironmaking, especially for Chinese ironmaking industry.
