The article "Data-driven soft sensors in blast furnace ironmaking:a survey,"written by Yueyang LUO,Xinmin ZHANG,Manabu KANO,Long DENG,Chunjie YANG,and Zhihuan SONG,was originally published electronically on ...The article "Data-driven soft sensors in blast furnace ironmaking:a survey,"written by Yueyang LUO,Xinmin ZHANG,Manabu KANO,Long DENG,Chunjie YANG,and Zhihuan SONG,was originally published electronically on the publisher's Internet portal on Mar.27,2023 without open access.展开更多
The blast furnace ironmaking process is a crucial step in the steel industry.Effectively modelling the blast furnaces is significant in ensuring smooth operation and accelerating the digitalisation transformation of b...The blast furnace ironmaking process is a crucial step in the steel industry.Effectively modelling the blast furnaces is significant in ensuring smooth operation and accelerating the digitalisation transformation of blast furnaces.The authors focus on the mechanism modelling of the blast furnace operation process,using a digital twin model development platform to simulate the main reaction processes inside the blast furnaces.Under on-site production conditions,Si,Mn and Ti contents of molten iron and the corresponding indicators for model accuracy are calculated.For Si,Mn,and Ti content,the Root Mean Square Error values are 0.0678,0.0108 and 0.0093 for dataset 1,while 0.0933,0.0120 and 0.0111 for dataset 2,respectively,indicating that the model has a small simulation error and high accuracy.By comparing the simulation results with accurate laboratory results,the model is validated to have satisfactory simulation reliability and compensates for the existing shortcomings in the blast furnace mechanism modelling field.展开更多
In principle, slag basicity can be expressed as the concentration of free oxygen （O^2-） in the slag system. This free oxygen content is equilibrated with different silicate anions in addition to other components in ...In principle, slag basicity can be expressed as the concentration of free oxygen （O^2-） in the slag system. This free oxygen content is equilibrated with different silicate anions in addition to other components in the silicate-based slags. X-ray photon spectroscopy （XPS） and scanning electron microscope equipped with energy dispersive spectrometer （SEM-EDS） were used to investigate the effect of water vapor on the free oxygen content in ironmaking slags. It was found that water in the gas atmosphere plays a significant role in the silicate anion equilibria. Water decreases the amount of free oxygen in the studied slags, with the free oxygen expressed as percentage of the total oxygen decreasing in the order of the following gas mixtures： CO＋CO2 （44%, PH2O = 0 kPa） 〉 CO＋CO2＋H2＋H2O （41%, PH2O = 10.13 kPa） 〉 H2＋H2O （37%, PH2O = 14.19 kPa）. The content of free oxygen ion affects the distribution of elements such as sulfur, phosphorus, and manganese. In addition, it affects the iron oxide content in the slag as well as the interaction between slag and furnace lining.展开更多
The mass production of steel is inevitably accompanied by large quantities of slags.The treatment of ironmaking and steelmaking slags is a great challenge in the sustainable development of the steel industry.Japan and...The mass production of steel is inevitably accompanied by large quantities of slags.The treatment of ironmaking and steelmaking slags is a great challenge in the sustainable development of the steel industry.Japan and China are two major steel producing countries that have placed a large emphasis on developing new technologies to decrease slag emission or promote slag valorization.Slags are almost completely reused or recycled in Japan.However,due to stagnant infrastructural investments,future applications of slags in conventional sectors are expected to be difficult.Exploring new functions or applications of slags has become a research priority in Japan.For example,the utilization of steelmaking slags in offshore seabeds to create marine forests is under development.China is the top steel producer in the world.The utilization ratios of ironmaking and steelmaking slags have risen steadily in recent years,driven largely by technological advances.For example,hot stage processing of slags for materials as well as heat recovery techniques has been widely applied in steel plants with good results.However,increasing the utilization ratio of basic oxygen furnace slags remains a major challenge.Technological innovations in slag recycling are crucial for the steel industries in Japan and China.Here,the current status and developing trends of utilization technologies of slags in both countries are reviewed.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
A hybrid dynamic model was proposed, which considered both the hydrokinetic and the chaotic properties of the blast furnace ironmaking process; and great emphasis was put on its mechanism. The new model took the high ...A hybrid dynamic model was proposed, which considered both the hydrokinetic and the chaotic properties of the blast furnace ironmaking process; and great emphasis was put on its mechanism. The new model took the high complexity of the blast furnace as well as the effects of main parameters of the model into account, and the predicted results were in very good agreement with actual data.展开更多
In order to achieve higher efficient cohesion match of procedure and equipment between ironmaking and steelmaking interface, the theory of multi-dimensional material flow control was applied to analyze torpedo ladle-i...In order to achieve higher efficient cohesion match of procedure and equipment between ironmaking and steelmaking interface, the theory of multi-dimensional material flow control was applied to analyze torpedo ladle-iron ladle transportation process between blast furnace and basic oxygen furnace. Moreover, basic parameters of material flow were analyzed and optimized, such as time, temperature and material quantity. Based on operating principles of material flow, control methods were optimized, such as product organization mode, scheduling discipline and scheduling plan of hot metal ladle. Finally, the material flow control technology of ironmaking and steelmaking interface was integrated. Satisfactory effects are obtained after applying the technology in practice. The total turnover number of torpedo ladle decreases from 20 to 18, the hot metal temperature of 1# BF torpedo ladle decreases from 36 °C to 19.5 °C, the hot metal temperature of 2# BF torpedo ladle decreases from 36.6 °C to 19.8 °C, the temperature drop of desulfurization hot metal decreases by 4 °C, and the temperature drop of non-desulfurization hot metal decreases by 2.8 °C. Furthermore, the ironmaking and steelmaking interface system will realize high-efficiency control by using this control technology.展开更多
The one-ladle technology requires an efficient ironmaking and steelmaking interface. The scheduling of the hot metal ladle in the steel plant determines the overall operational efficiency of the interface. Considering...The one-ladle technology requires an efficient ironmaking and steelmaking interface. The scheduling of the hot metal ladle in the steel plant determines the overall operational efficiency of the interface. Considering the strong uncertainties of real-world production environments, this work studies the dynamic scheduling problem of hot metal ladles and develops a data-driven three-layer approach to solve this problem. A dynamic scheduling optimization model of the hot metal ladle operation with a minimum average turnover time as the optimization objective is also constructed. Furthermore, the intelligent perception of industrial scenes and autonomous identification of disturbances, adaptive configuration of dynamic scheduling strategies, and real-time adjustment of schedules can be realized. The upper layer generates a demand-oriented prescheduling scheme for hot metal ladles. The middle layer adaptively adjusts this scheme to obtain an executable schedule according to the actual supply–demand relationship. In the lower layer, three types of dynamic scheduling strategies are designed according to the characteristics of the dynamic disturbance in the model:real-time flexible fine-tuning, local machine adjustment, and global rescheduling. Case test using 24 h production data on a certain day during the system operation of a steel plant shows that the method and system can effectively reduce the fluctuation and operation time of the hot metal ladle and improve the stability of the ironmaking and steelmaking interface production rhythm. The data-driven dynamic scheduling strategy is feasible and effective, and the proposed method can improve the operation efficiency of hot metal ladles.展开更多
Ironmaking at Baosteel has focused on blast furnaces over the last 30 years. After passing through the stages of ＂learning＂, ＂tracking＂, ＂usage＂, ＂experimentation＂, ＂innovation＂ and ＂development＂, Baosteel...Ironmaking at Baosteel has focused on blast furnaces over the last 30 years. After passing through the stages of ＂learning＂, ＂tracking＂, ＂usage＂, ＂experimentation＂, ＂innovation＂ and ＂development＂, Baosteel ＇ s production capacity has grown steadily and its standard of technology is increasing. Remarkable progress has been made in the technologies of blending stack, thick layer sintering, low silicon and high anhydroferrite sintering, coal blending, and the high productivity with high pulverized coal injection （PCI） rate and long campaign of the blast furnaces. The entire ironmaking process is developing in the direction of high efficiency, low energy consumption, clean production, and environmental protection because the zero discharge of solid waste and industrial sewage has been achieved. After 20 years of development, Baosteel has become a modernized iron producer with an annual capacity of 28.85 Mt of sinter,7.26 Mt of coke and 22.50 Mt of hot metal （Pugang Corex furnace output included）, and its main economic and technological indices have reached a world-class level.展开更多
Gallium is a valuable rare metal which is mainly being used in the production of GaAs. The demand for gallium is increasing but production is limited since gallium is extracted only as a by-product of bauxite processi...Gallium is a valuable rare metal which is mainly being used in the production of GaAs. The demand for gallium is increasing but production is limited since gallium is extracted only as a by-product of bauxite processing. On the other hand coal, ironmaking coke and iron ore gangue contain traces of gallium. However little is known about the behaviour of gallium in ironmaking. The aim of the study is to clarify the distribution of gallium between hot metal, slag and top gas by means of laboratory experiments. It was found that Ga2O3 is not stable in blast furnace slags and that gallium is retained in hot metal. Vacuum distillation experiments with hot metal showed that gallium is not transferred to the gas phase. Data on the input and output of gallium at two industrial blast furnaces, as well as chemical analyses of the gallium content of several cokes are presented, too.展开更多
In the prevailing incineration processes of municipal solid waste,the presence of polyvinyl chloride(PVC)may cause environmental problems.The energy-intensive ironmaking sector in the iron and steel industry operates ...In the prevailing incineration processes of municipal solid waste,the presence of polyvinyl chloride(PVC)may cause environmental problems.The energy-intensive ironmaking sector in the iron and steel industry operates at high temperature and under high reduction potential with the function of energy conversion,which can provide a potential path for the collaborative utilization of waste plastics in large quantities and low cost.The gasification of the char formed from PVC when processed in the ironmaking sector is significant for the development of the related technologies.Thus,the gasification experiment of PVC char and traditional carbonaceous materials was performed by thermogravimetric analysis.The results indicated that the gasification ability decreased in the sequence of PVC char>anthracite coal>coke>graphite.Then,kinetics were also analyzed by Coats-Redfern and Doyle approximations.The PVC char showed the best gasification ability with the smallest activation energy,ranging from 87.18 to 117.52 kJ/mol,and the smaller graphitization degree of PVC char compared with other carbonaceous materials should be the main reason for its excellent gasification reactivity.展开更多
The blast furnace is the oldest metallurgical process in commercial use.It has gone through great improvements during the last decades and new important modifications are still foreseen.The huge amount of coal and cok...The blast furnace is the oldest metallurgical process in commercial use.It has gone through great improvements during the last decades and new important modifications are still foreseen.The huge amount of coal and coke needed for reduction of iron ore is resulting in emissions of carbon dioxide that have to be strongly reduced to meet the requirement of minimizing the carbon footprint.All residuals from iron- and steelmaking also need to be taken care of to meet the requirement of zero waste.This paper deals with several potential improvements of the blast furnace process being developed in the LKAB Experimental Blast Furnace in Lulea, Sweden over the last decade,including operation at ultra low slag volume,injection of BF flue dust,injection of BOF slag,and the oxygen blast furnace.展开更多
Since China’s Reform and Opening-up,the innovation and development of refractories for ironmaking industry in Sinosteel Luonai were narrated,including silica materials,Al_(2)O_(3)-SiO_(2) refractories and non-oxide c...Since China’s Reform and Opening-up,the innovation and development of refractories for ironmaking industry in Sinosteel Luonai were narrated,including silica materials,Al_(2)O_(3)-SiO_(2) refractories and non-oxide composites;and the development direction of refractories for ironmaking industry was prospected.展开更多
As a new type of ironmaking raw materials,carbon composite iron ore hot briquette(CCB) is the product of fine iron ore and fine coal by hot briquetting process.On basis of experimental research on the manufacturing an...As a new type of ironmaking raw materials,carbon composite iron ore hot briquette(CCB) is the product of fine iron ore and fine coal by hot briquetting process.On basis of experimental research on the manufacturing and metallurgical properties of CCB,this study focused on the application of CCB to blast furnace ironmaking and newly-developed shaft furnace smelting reduction processes.Firstly,the metallurgical properties of CCB are experimentally tested and compared with the common iron-bearing burdens.Then,the effects of charging CCB on blast furnace operation are numerically analyzed by means of multi-fluid blast furnace model,and the flowchart and pilot test of CCB-Shaft furnace smelting reduction process are briefly introduced.展开更多
The utilization of iron coke provides a green pathway for low-carbon ironmaking.To uncover the influence mechanism of iron ore on the behavior and kinetics of iron coke gasification,the effect of iron ore on the micro...The utilization of iron coke provides a green pathway for low-carbon ironmaking.To uncover the influence mechanism of iron ore on the behavior and kinetics of iron coke gasification,the effect of iron ore on the microstructure of iron coke was investigated.Furthermore,a comparative study of the gasification reactions between iron coke and coke was conducted through non-isothermal thermogravimetric method.The findings indicate that compared to coke,iron coke exhibits an augmentation in micropores and specific surface area,and the micropores further extend and interconnect.This provides more adsorption sites for CO_(2) molecules during the gasification process,resulting in a reduction in the initial gasification temperature of iron coke.Accelerating the heating rate in non-isothermal gasification can enhance the reactivity of iron coke.The metallic iron reduced from iron ore is embedded in the carbon matrix,reducing the orderliness of the carbon structure,which is primarily responsible for the heightened reactivity of the carbon atoms.The kinetic study indicates that the random pore model can effectively represent the gasification process of iron coke due to its rich pore structure.Moreover,as the proportion of iron ore increases,the activation energy for the carbon gasification gradually decreases,from 246.2 kJ/mol for coke to 192.5 kJ/mol for iron coke 15wt%.展开更多
Against the background of“carbon peak and carbon neutrality,”it is of great practical significance to develop non-blast furnace ironmaking technology for the sustainable development of steel industry.Carbon-bearing ...Against the background of“carbon peak and carbon neutrality,”it is of great practical significance to develop non-blast furnace ironmaking technology for the sustainable development of steel industry.Carbon-bearing iron ore pellet is an innovative burden of direct reduction ironmaking due to its excellent self-reducing property,and the thermal strength of pellet is a crucial metallurgical property that affects its wide application.The carbon-bearing iron ore pellet without binders(CIPWB)was prepared using iron concentrate and anthracite,and the effects of reducing agent addition amount,size of pellet,reduction temperature and time on the thermal compressive strength of CIPWB during the reduction process were studied.Simultaneously,the mechanism of the thermal strength evolution of CIPWB was revealed.The results showed that during the low-temperature reduction process(300-500℃),the thermal compressive strength of CIPWB linearly increases with increasing the size of pellet,while it gradually decreases with increasing the anthracite ratio.When the CIPWB with 8%anthracite is reduced at 300℃for 60 min,the thermal strength of pellet is enhanced from 13.24 to 31.88 N as the size of pellet increases from 8.04 to 12.78 mm.Meanwhile,as the temperature is 500℃,with increasing the anthracite ratio from 2%to 8%,the thermal compressive strength of pellet under reduction for 60 min remarkably decreases from 41.47 to 8.94 N.Furthermore,in the high-temperature reduction process(600-1150℃),the thermal compressive strength of CIPWB firstly increases and then reduces with increasing the temperature,while it as well as the temperature corresponding to the maximum strength decreases with increasing the anthracite ratio.With adding 18%anthracite,the thermal compressive strength of pellet reaches the maximum value at 800℃,namely 35.00 N,and obtains the minimum value at 1050℃,namely 8.60 N.The thermal compressive strength of CIPWB significantly depends on the temperature,reducing agent dosage,and pellet size.展开更多
The steel industry’s transition to hydrogen-based ironmaking necessitates a deeper understanding of magnetite ore reduction,a crucial yet underexplored pathway for decarbonization.This study systematically investigat...The steel industry’s transition to hydrogen-based ironmaking necessitates a deeper understanding of magnetite ore reduction,a crucial yet underexplored pathway for decarbonization.This study systematically investigates the combined effects of particle size and gangue composition on hydrogen-based reduction behavior of four industrial magnetite ore concentrates with varying CaO and MgO con-tents.Thermogravimetric analysis at 973 K,interrupted reduction experiments,and post-reduction characterization steps are used to eval-uate reduction extent and phase transformations across different particle size fractions and bulk ores.The finer fractions generally exhibit faster and more complete reduction.However,this trend is overridden by gangue effects in certain ores.Magnetite ores with MgO as gangue tend to form magnesio-wustite solid solution(Mg,Fe)O during reduction,resulting in dense microstructures that impede hydrogen diffusion and limit reduction progress.In contrast,magnetite ores with CaO as gangue facilitate the formation of intermediate calcium fer-rites,which promote porous morphology and enhanced reducibility.Notably,even the finer particles of ore containing MgO show a lower reduction degree than the coarser particles of the ore containing CaO as gangue.This highlights the dominant role of gangue composition in governing reduction kinetics,intermediate phase formation and final product morphology.These findings contribute to the growing knowledge necessary to enable fossil-free ironmaking by emphasizing the importance of considering both granulometric characteristics and heterogeneity when evaluating magnetite ores for hydrogen-based reduction.展开更多
Sintering is the process that emits the most pollutants in ironmaking,including CO,SO_(2),NO_(x),and dioxins.Flue gas circulation sintering technology can not only reduce the emissions of various pollutants but also d...Sintering is the process that emits the most pollutants in ironmaking,including CO,SO_(2),NO_(x),and dioxins.Flue gas circulation sintering technology can not only reduce the emissions of various pollutants but also decrease the consumption of solid fuels.Therefore,it is necessary to summarize and discuss the research status of flue gas circulation technology.Firstly,the research status,advantages,and disadvantages of five typical flue gas circulation processes and their effects on the emission of different pollutants were analyzed.Then,the impact of O_(2),CO,SO_(2),and temperature in the circulating gas during the sintering flue gas circulation process on the quality of sinter and their reasonable ranges was summarized,and the formation mechanisms of CO_(x),NO_(x),SO_(2),and dioxins during the sintering process were discussed.Furthermore,the optimization and improvement of flue gas circulation technology in recent years were introduced.Finally,issues related to element enrichment,equipment improvements,and fine particulate matter emissions in the flue gas circulation process were reviewed,providing a reference for the optimal application of flue gas circulation sintering technology in the future.展开更多
From the perspective of facilitating the design of fluidized hydrogen reduction reactors for iron ore powder and maintaining stable operation,the operational conditions and bubble behavior in stable state fluidization...From the perspective of facilitating the design of fluidized hydrogen reduction reactors for iron ore powder and maintaining stable operation,the operational conditions and bubble behavior in stable state fluidization of multi-particle size systems were investigated through cold-state experiments.To facilitate the identification of bubble behavior,a two-dimensional bubbling bed cold-state experiment was carried out using iron ore powder with a narrow particle size distribution and glass beads.Initially,the multi-stage fluidization characteristics of iron ore powder were examined.Then,using Geldart B-type glass beads to simulate a multi-particle size composition system,the particle size range and superficial gas velocity range for stable operation of the multi-particle composition system were explored.When the mass percentage of 150-μm glass beads was 15%,the stable fluidization operational gas velocity range was found to be(1.05-1.21)umf,where umf is the minimum fluidization velocity;when the content was 20%,the stable fluidized superficial gas velocity range was(1.09-1.26)umf.Under stable fluidization operating conditions,the dynamic behavior of bubbles(average equivalent diameter,rising velocity,and lateral migration velocity)was studied,and the quantitative relationship between the average equivalent diameter of bubbles and bed height in multi-particle size systems under stable fluidization conditions was also corrected.Additionally,the correlation between bubble rising velocity and bubble average equivalent diameter was established.展开更多
The iron and steel industries generate large amounts of unavoidable CO_(2)emissions as well as considerable quantities of slags.More than one-half of the emitted CO_(2)is produced in blast furnaces during ironmaking,a...The iron and steel industries generate large amounts of unavoidable CO_(2)emissions as well as considerable quantities of slags.More than one-half of the emitted CO_(2)is produced in blast furnaces during ironmaking,and thus it is meaningful to use blast furnace slags to capture CO_(2)while addressing the byproducts and flue gas of ironmaking.Mineral carbonation of slags is a promising route to achieve carbon neutrality and effective slag utilization.To exploit slag more effectively and capture CO_(2)in flue gas,an in-depth investigation into the carbonation of blast furnace slags generated with different cooling methods was conducted.The effects of the solid–liquid ratio and introduced CO_(2)concentration on carbonation were determined.The CO_(2)uptake capacity of air-cooled slag(0.04 g/g)was greater than that of water-quenched slag.The CO_(2)uptake capacities of the two slags were comparable with those of slags in previous works,indicating the potential of the two slags for CO_(2)sequestration and utilization even with low-energy input and this fact suggests that this process is feasible.展开更多
文摘The article "Data-driven soft sensors in blast furnace ironmaking:a survey,"written by Yueyang LUO,Xinmin ZHANG,Manabu KANO,Long DENG,Chunjie YANG,and Zhihuan SONG,was originally published electronically on the publisher's Internet portal on Mar.27,2023 without open access.
基金National Natural Science Foundation of China,Grant/Award Numbers:61933015,62394341Postdoctoral Fellowship Program of CPSF,Grant/Award Number:GZC20232288。
文摘The blast furnace ironmaking process is a crucial step in the steel industry.Effectively modelling the blast furnaces is significant in ensuring smooth operation and accelerating the digitalisation transformation of blast furnaces.The authors focus on the mechanism modelling of the blast furnace operation process,using a digital twin model development platform to simulate the main reaction processes inside the blast furnaces.Under on-site production conditions,Si,Mn and Ti contents of molten iron and the corresponding indicators for model accuracy are calculated.For Si,Mn,and Ti content,the Root Mean Square Error values are 0.0678,0.0108 and 0.0093 for dataset 1,while 0.0933,0.0120 and 0.0111 for dataset 2,respectively,indicating that the model has a small simulation error and high accuracy.By comparing the simulation results with accurate laboratory results,the model is validated to have satisfactory simulation reliability and compensates for the existing shortcomings in the blast furnace mechanism modelling field.
基金the financial support from American Iron and Steel Institute(AISI) through a Research Service Agreement with the University of Utah under AISI’s CO2 Breakthrough Programthe U.S.Department of Energy under Award Number DE-EE0005751
文摘In principle, slag basicity can be expressed as the concentration of free oxygen （O^2-） in the slag system. This free oxygen content is equilibrated with different silicate anions in addition to other components in the silicate-based slags. X-ray photon spectroscopy （XPS） and scanning electron microscope equipped with energy dispersive spectrometer （SEM-EDS） were used to investigate the effect of water vapor on the free oxygen content in ironmaking slags. It was found that water in the gas atmosphere plays a significant role in the silicate anion equilibria. Water decreases the amount of free oxygen in the studied slags, with the free oxygen expressed as percentage of the total oxygen decreasing in the order of the following gas mixtures： CO＋CO2 （44%, PH2O = 0 kPa） 〉 CO＋CO2＋H2＋H2O （41%, PH2O = 10.13 kPa） 〉 H2＋H2O （37%, PH2O = 14.19 kPa）. The content of free oxygen ion affects the distribution of elements such as sulfur, phosphorus, and manganese. In addition, it affects the iron oxide content in the slag as well as the interaction between slag and furnace lining.
文摘The mass production of steel is inevitably accompanied by large quantities of slags.The treatment of ironmaking and steelmaking slags is a great challenge in the sustainable development of the steel industry.Japan and China are two major steel producing countries that have placed a large emphasis on developing new technologies to decrease slag emission or promote slag valorization.Slags are almost completely reused or recycled in Japan.However,due to stagnant infrastructural investments,future applications of slags in conventional sectors are expected to be difficult.Exploring new functions or applications of slags has become a research priority in Japan.For example,the utilization of steelmaking slags in offshore seabeds to create marine forests is under development.China is the top steel producer in the world.The utilization ratios of ironmaking and steelmaking slags have risen steadily in recent years,driven largely by technological advances.For example,hot stage processing of slags for materials as well as heat recovery techniques has been widely applied in steel plants with good results.However,increasing the utilization ratio of basic oxygen furnace slags remains a major challenge.Technological innovations in slag recycling are crucial for the steel industries in Japan and China.Here,the current status and developing trends of utilization technologies of slags in both countries are reviewed.
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Item Sponsored by National Basic Research Programof China (2005EC000166) Ningbo Natural Science Foundation ofChina (2006A610032)
文摘A hybrid dynamic model was proposed, which considered both the hydrokinetic and the chaotic properties of the blast furnace ironmaking process; and great emphasis was put on its mechanism. The new model took the high complexity of the blast furnace as well as the effects of main parameters of the model into account, and the predicted results were in very good agreement with actual data.
基金Project(2011FZ056)supported by the Applied Basic Research Plan Program of Yunnan Province,China
文摘In order to achieve higher efficient cohesion match of procedure and equipment between ironmaking and steelmaking interface, the theory of multi-dimensional material flow control was applied to analyze torpedo ladle-iron ladle transportation process between blast furnace and basic oxygen furnace. Moreover, basic parameters of material flow were analyzed and optimized, such as time, temperature and material quantity. Based on operating principles of material flow, control methods were optimized, such as product organization mode, scheduling discipline and scheduling plan of hot metal ladle. Finally, the material flow control technology of ironmaking and steelmaking interface was integrated. Satisfactory effects are obtained after applying the technology in practice. The total turnover number of torpedo ladle decreases from 20 to 18, the hot metal temperature of 1# BF torpedo ladle decreases from 36 °C to 19.5 °C, the hot metal temperature of 2# BF torpedo ladle decreases from 36.6 °C to 19.8 °C, the temperature drop of desulfurization hot metal decreases by 4 °C, and the temperature drop of non-desulfurization hot metal decreases by 2.8 °C. Furthermore, the ironmaking and steelmaking interface system will realize high-efficiency control by using this control technology.
基金financially supported by the National Natural Science Foundation of China (No.51734004)the Key Program of the National Key R&D Program of China(No.2017YFB0304002)。
文摘The one-ladle technology requires an efficient ironmaking and steelmaking interface. The scheduling of the hot metal ladle in the steel plant determines the overall operational efficiency of the interface. Considering the strong uncertainties of real-world production environments, this work studies the dynamic scheduling problem of hot metal ladles and develops a data-driven three-layer approach to solve this problem. A dynamic scheduling optimization model of the hot metal ladle operation with a minimum average turnover time as the optimization objective is also constructed. Furthermore, the intelligent perception of industrial scenes and autonomous identification of disturbances, adaptive configuration of dynamic scheduling strategies, and real-time adjustment of schedules can be realized. The upper layer generates a demand-oriented prescheduling scheme for hot metal ladles. The middle layer adaptively adjusts this scheme to obtain an executable schedule according to the actual supply–demand relationship. In the lower layer, three types of dynamic scheduling strategies are designed according to the characteristics of the dynamic disturbance in the model:real-time flexible fine-tuning, local machine adjustment, and global rescheduling. Case test using 24 h production data on a certain day during the system operation of a steel plant shows that the method and system can effectively reduce the fluctuation and operation time of the hot metal ladle and improve the stability of the ironmaking and steelmaking interface production rhythm. The data-driven dynamic scheduling strategy is feasible and effective, and the proposed method can improve the operation efficiency of hot metal ladles.
文摘Ironmaking at Baosteel has focused on blast furnaces over the last 30 years. After passing through the stages of ＂learning＂, ＂tracking＂, ＂usage＂, ＂experimentation＂, ＂innovation＂ and ＂development＂, Baosteel ＇ s production capacity has grown steadily and its standard of technology is increasing. Remarkable progress has been made in the technologies of blending stack, thick layer sintering, low silicon and high anhydroferrite sintering, coal blending, and the high productivity with high pulverized coal injection （PCI） rate and long campaign of the blast furnaces. The entire ironmaking process is developing in the direction of high efficiency, low energy consumption, clean production, and environmental protection because the zero discharge of solid waste and industrial sewage has been achieved. After 20 years of development, Baosteel has become a modernized iron producer with an annual capacity of 28.85 Mt of sinter,7.26 Mt of coke and 22.50 Mt of hot metal （Pugang Corex furnace output included）, and its main economic and technological indices have reached a world-class level.
基金The financial support of the EU-sponsored TACIS Project "Joint Education in Natural Resources Management" is gratefully acknowledged.
文摘Gallium is a valuable rare metal which is mainly being used in the production of GaAs. The demand for gallium is increasing but production is limited since gallium is extracted only as a by-product of bauxite processing. On the other hand coal, ironmaking coke and iron ore gangue contain traces of gallium. However little is known about the behaviour of gallium in ironmaking. The aim of the study is to clarify the distribution of gallium between hot metal, slag and top gas by means of laboratory experiments. It was found that Ga2O3 is not stable in blast furnace slags and that gallium is retained in hot metal. Vacuum distillation experiments with hot metal showed that gallium is not transferred to the gas phase. Data on the input and output of gallium at two industrial blast furnaces, as well as chemical analyses of the gallium content of several cokes are presented, too.
基金The work was supported by the National Natural Science Foundation of China(Nos.51804024 and U1960205)the Fundamental Research Funds for the Central Universities(No.FRF-IC-20-09)The authors also thank for the financial support from the State Key Laboratory of Advanced Metallurgy,University of Science and Technology Beijing,China(No.41621002).
文摘In the prevailing incineration processes of municipal solid waste,the presence of polyvinyl chloride(PVC)may cause environmental problems.The energy-intensive ironmaking sector in the iron and steel industry operates at high temperature and under high reduction potential with the function of energy conversion,which can provide a potential path for the collaborative utilization of waste plastics in large quantities and low cost.The gasification of the char formed from PVC when processed in the ironmaking sector is significant for the development of the related technologies.Thus,the gasification experiment of PVC char and traditional carbonaceous materials was performed by thermogravimetric analysis.The results indicated that the gasification ability decreased in the sequence of PVC char>anthracite coal>coke>graphite.Then,kinetics were also analyzed by Coats-Redfern and Doyle approximations.The PVC char showed the best gasification ability with the smallest activation energy,ranging from 87.18 to 117.52 kJ/mol,and the smaller graphitization degree of PVC char compared with other carbonaceous materials should be the main reason for its excellent gasification reactivity.
文摘The blast furnace is the oldest metallurgical process in commercial use.It has gone through great improvements during the last decades and new important modifications are still foreseen.The huge amount of coal and coke needed for reduction of iron ore is resulting in emissions of carbon dioxide that have to be strongly reduced to meet the requirement of minimizing the carbon footprint.All residuals from iron- and steelmaking also need to be taken care of to meet the requirement of zero waste.This paper deals with several potential improvements of the blast furnace process being developed in the LKAB Experimental Blast Furnace in Lulea, Sweden over the last decade,including operation at ultra low slag volume,injection of BF flue dust,injection of BOF slag,and the oxygen blast furnace.
文摘Since China’s Reform and Opening-up,the innovation and development of refractories for ironmaking industry in Sinosteel Luonai were narrated,including silica materials,Al_(2)O_(3)-SiO_(2) refractories and non-oxide composites;and the development direction of refractories for ironmaking industry was prospected.
文摘As a new type of ironmaking raw materials,carbon composite iron ore hot briquette(CCB) is the product of fine iron ore and fine coal by hot briquetting process.On basis of experimental research on the manufacturing and metallurgical properties of CCB,this study focused on the application of CCB to blast furnace ironmaking and newly-developed shaft furnace smelting reduction processes.Firstly,the metallurgical properties of CCB are experimentally tested and compared with the common iron-bearing burdens.Then,the effects of charging CCB on blast furnace operation are numerically analyzed by means of multi-fluid blast furnace model,and the flowchart and pilot test of CCB-Shaft furnace smelting reduction process are briefly introduced.
基金financially supported by the National Science Foundation of China(Nos.51974212 and 52274316)the China Baowu Low Carbon Metallurgy Innovation Foundation(No.BWLCF202116)+1 种基金the Science and Technology Major Project of Wuhan(No.2023020302020572)the Foundation of Key Laboratory for Ferrous Metallurgy and Resources Utilization of Ministry of Education(No.FMRUlab23-04)。
文摘The utilization of iron coke provides a green pathway for low-carbon ironmaking.To uncover the influence mechanism of iron ore on the behavior and kinetics of iron coke gasification,the effect of iron ore on the microstructure of iron coke was investigated.Furthermore,a comparative study of the gasification reactions between iron coke and coke was conducted through non-isothermal thermogravimetric method.The findings indicate that compared to coke,iron coke exhibits an augmentation in micropores and specific surface area,and the micropores further extend and interconnect.This provides more adsorption sites for CO_(2) molecules during the gasification process,resulting in a reduction in the initial gasification temperature of iron coke.Accelerating the heating rate in non-isothermal gasification can enhance the reactivity of iron coke.The metallic iron reduced from iron ore is embedded in the carbon matrix,reducing the orderliness of the carbon structure,which is primarily responsible for the heightened reactivity of the carbon atoms.The kinetic study indicates that the random pore model can effectively represent the gasification process of iron coke due to its rich pore structure.Moreover,as the proportion of iron ore increases,the activation energy for the carbon gasification gradually decreases,from 246.2 kJ/mol for coke to 192.5 kJ/mol for iron coke 15wt%.
基金support of the National Natural Science Foundation of China(52074080,52004001,and 51574002).
文摘Against the background of“carbon peak and carbon neutrality,”it is of great practical significance to develop non-blast furnace ironmaking technology for the sustainable development of steel industry.Carbon-bearing iron ore pellet is an innovative burden of direct reduction ironmaking due to its excellent self-reducing property,and the thermal strength of pellet is a crucial metallurgical property that affects its wide application.The carbon-bearing iron ore pellet without binders(CIPWB)was prepared using iron concentrate and anthracite,and the effects of reducing agent addition amount,size of pellet,reduction temperature and time on the thermal compressive strength of CIPWB during the reduction process were studied.Simultaneously,the mechanism of the thermal strength evolution of CIPWB was revealed.The results showed that during the low-temperature reduction process(300-500℃),the thermal compressive strength of CIPWB linearly increases with increasing the size of pellet,while it gradually decreases with increasing the anthracite ratio.When the CIPWB with 8%anthracite is reduced at 300℃for 60 min,the thermal strength of pellet is enhanced from 13.24 to 31.88 N as the size of pellet increases from 8.04 to 12.78 mm.Meanwhile,as the temperature is 500℃,with increasing the anthracite ratio from 2%to 8%,the thermal compressive strength of pellet under reduction for 60 min remarkably decreases from 41.47 to 8.94 N.Furthermore,in the high-temperature reduction process(600-1150℃),the thermal compressive strength of CIPWB firstly increases and then reduces with increasing the temperature,while it as well as the temperature corresponding to the maximum strength decreases with increasing the anthracite ratio.With adding 18%anthracite,the thermal compressive strength of pellet reaches the maximum value at 800℃,namely 35.00 N,and obtains the minimum value at 1050℃,namely 8.60 N.The thermal compressive strength of CIPWB significantly depends on the temperature,reducing agent dosage,and pellet size.
文摘The steel industry’s transition to hydrogen-based ironmaking necessitates a deeper understanding of magnetite ore reduction,a crucial yet underexplored pathway for decarbonization.This study systematically investigates the combined effects of particle size and gangue composition on hydrogen-based reduction behavior of four industrial magnetite ore concentrates with varying CaO and MgO con-tents.Thermogravimetric analysis at 973 K,interrupted reduction experiments,and post-reduction characterization steps are used to eval-uate reduction extent and phase transformations across different particle size fractions and bulk ores.The finer fractions generally exhibit faster and more complete reduction.However,this trend is overridden by gangue effects in certain ores.Magnetite ores with MgO as gangue tend to form magnesio-wustite solid solution(Mg,Fe)O during reduction,resulting in dense microstructures that impede hydrogen diffusion and limit reduction progress.In contrast,magnetite ores with CaO as gangue facilitate the formation of intermediate calcium fer-rites,which promote porous morphology and enhanced reducibility.Notably,even the finer particles of ore containing MgO show a lower reduction degree than the coarser particles of the ore containing CaO as gangue.This highlights the dominant role of gangue composition in governing reduction kinetics,intermediate phase formation and final product morphology.These findings contribute to the growing knowledge necessary to enable fossil-free ironmaking by emphasizing the importance of considering both granulometric characteristics and heterogeneity when evaluating magnetite ores for hydrogen-based reduction.
基金the financial support provided by the National Natural Science Foundation of China(52204335,52374319,52174291)the National Youth Talent Support Program(GJRC2023008)+2 种基金the Beijing New-Star Plan of Science and Technology(Z211100002121115)the Central Universities Foundation of China(06500170)Interdisciplinary Research Project for Young Teachers of USTB(Fundamental Research Funds for the Central Universities)(FRF-IDRY-22-004).
文摘Sintering is the process that emits the most pollutants in ironmaking,including CO,SO_(2),NO_(x),and dioxins.Flue gas circulation sintering technology can not only reduce the emissions of various pollutants but also decrease the consumption of solid fuels.Therefore,it is necessary to summarize and discuss the research status of flue gas circulation technology.Firstly,the research status,advantages,and disadvantages of five typical flue gas circulation processes and their effects on the emission of different pollutants were analyzed.Then,the impact of O_(2),CO,SO_(2),and temperature in the circulating gas during the sintering flue gas circulation process on the quality of sinter and their reasonable ranges was summarized,and the formation mechanisms of CO_(x),NO_(x),SO_(2),and dioxins during the sintering process were discussed.Furthermore,the optimization and improvement of flue gas circulation technology in recent years were introduced.Finally,issues related to element enrichment,equipment improvements,and fine particulate matter emissions in the flue gas circulation process were reviewed,providing a reference for the optimal application of flue gas circulation sintering technology in the future.
基金supported by the China Baowu Low Carbon Metallurgy Innovation Foundation(No.202114)National Natural Science Foundation of China(No.51874056)Sichuan Science and Technology Program(2025ZNSFSC0378).
文摘From the perspective of facilitating the design of fluidized hydrogen reduction reactors for iron ore powder and maintaining stable operation,the operational conditions and bubble behavior in stable state fluidization of multi-particle size systems were investigated through cold-state experiments.To facilitate the identification of bubble behavior,a two-dimensional bubbling bed cold-state experiment was carried out using iron ore powder with a narrow particle size distribution and glass beads.Initially,the multi-stage fluidization characteristics of iron ore powder were examined.Then,using Geldart B-type glass beads to simulate a multi-particle size composition system,the particle size range and superficial gas velocity range for stable operation of the multi-particle composition system were explored.When the mass percentage of 150-μm glass beads was 15%,the stable fluidization operational gas velocity range was found to be(1.05-1.21)umf,where umf is the minimum fluidization velocity;when the content was 20%,the stable fluidized superficial gas velocity range was(1.09-1.26)umf.Under stable fluidization operating conditions,the dynamic behavior of bubbles(average equivalent diameter,rising velocity,and lateral migration velocity)was studied,and the quantitative relationship between the average equivalent diameter of bubbles and bed height in multi-particle size systems under stable fluidization conditions was also corrected.Additionally,the correlation between bubble rising velocity and bubble average equivalent diameter was established.
基金supported by the Science and Technology Research Partnership for Sustainable Development(SATREPS)。
文摘The iron and steel industries generate large amounts of unavoidable CO_(2)emissions as well as considerable quantities of slags.More than one-half of the emitted CO_(2)is produced in blast furnaces during ironmaking,and thus it is meaningful to use blast furnace slags to capture CO_(2)while addressing the byproducts and flue gas of ironmaking.Mineral carbonation of slags is a promising route to achieve carbon neutrality and effective slag utilization.To exploit slag more effectively and capture CO_(2)in flue gas,an in-depth investigation into the carbonation of blast furnace slags generated with different cooling methods was conducted.The effects of the solid–liquid ratio and introduced CO_(2)concentration on carbonation were determined.The CO_(2)uptake capacity of air-cooled slag(0.04 g/g)was greater than that of water-quenched slag.The CO_(2)uptake capacities of the two slags were comparable with those of slags in previous works,indicating the potential of the two slags for CO_(2)sequestration and utilization even with low-energy input and this fact suggests that this process is feasible.
