The so-called close-coupled gas atomization process involves melting a metal and using a high-pressure gas jet positioned close to the melt stream to rapidly break it into fine,spherical powder particles.This techniqu...The so-called close-coupled gas atomization process involves melting a metal and using a high-pressure gas jet positioned close to the melt stream to rapidly break it into fine,spherical powder particles.This technique,adapted for blast furnace slag granulation using a circular seam nozzle,typically aims to produce solid slag particles sized 30–140μm,thereby allowing the utilization of slag as a resource.This study explores the atomization dynamics of liquid blast furnace slag,focusing on the effects of atomization pressure.Primary atomization is simulated using a combination of the Volume of Fluid(VOF)method and the Shear Stress Transport k-ωturbulence model,while secondary atomization is analyzed through the Discrete Phase Model(DPM).The results reveal that primary atomization progresses in three stages:the slag column transforms into an umbrella-shaped liquid film,whose leading edge fragments into particles while forming a cavity-like structure,which is eventually torn into ligaments.This primary deformation is driven by the interplay of airflow velocity in the recirculation zone and the guide tube outlet pressure(Fp).Increasing the atomization pressure amplifies airflow velocity,recirculation zone size,expansion and shock waves,though the guide tube outlet pressure variations remain irregular.Notably,at 4.5 MPa,the primary deformation is most pronounced.Secondary atomization yields finer slag particles as a result of more vigorous primary atomization.For this pressure,the smallest average particle size and the highest yield of particles within the target range(30–140μm)are achieved.展开更多
Large quantities of blast furnace(BF) slag and CO_2 are discharged annually from iron and steel industries, along with a large amount of waste heat.The mineral carbonation of BF slag can not only reduce emissions of s...Large quantities of blast furnace(BF) slag and CO_2 are discharged annually from iron and steel industries, along with a large amount of waste heat.The mineral carbonation of BF slag can not only reduce emissions of solid waste but also realize the in-situ fixation of CO_2 with low energy consumption if integrated with the waste heat utilization.In this study, based on our previous works, Aspen Plus was employed to simulate and optimize the carbonation process and integrate the process energy.The effects of gehlenite extraction, MgSO_4 carbonation,and aluminum ammonium sulfate crystallization were studied systematically.The simulation results demonstrate that 2.57 kg of BF slag can sequester 1 kg of CO_2, requiring 5.34 MJ of energy(3.3 MJ heat and 2.04 MJ electricity), and this energy includes the capture of CO_2 from industrial flue gases.Approximately 60 kg net CO_2 emission reduction could be achieved for the disposal of one ton of BF slag.In addition, the by-product,aluminum ammonium sulfate, is a high value-added product.Preliminary economic analysis indicates that the profit for the whole process is 1127 CNY per ton of BF slag processed.展开更多
Effect of distribution of iron concentrates between pelletized and matrix feed on the preparation of blast furnace burdens from two different kinds of fine iron concentrates (magnetite and hematite) by composite agglo...Effect of distribution of iron concentrates between pelletized and matrix feed on the preparation of blast furnace burdens from two different kinds of fine iron concentrates (magnetite and hematite) by composite agglomeration process (CAP) was explored. It was found that when the mass ratio of iron concentrate A (magnetite) to iron concentrate B (hematite) in the mixed feed was constant, the proportion of iron concentrate A in the pelletized and matrix feed significantly affected the quality of CAP products. Particularly, as the proportion of iron concentrate A in the pelletized feed increased from 0 to 100%, the yield decreased from 82.11% to 79.19% and the tumbler index decreased from 71.33% to 68.27%. The mineralization characterization results indicated that when 100% iron concentrate A was used as the pelletized feed, the crystallization styles of the outer layer and the inner layer of the pellet were different, and a lot of pores exist around hematite and magnetite phases in the pelletized part, with the weak connection of pelletized and matrix part, resulting in poor strength of agglomeration product.展开更多
To reduce the fuel consumption and emissions and also enhance the molten aluminum quality, a mathematical model with user-developed melting model and burning capacity model, were established according to the features ...To reduce the fuel consumption and emissions and also enhance the molten aluminum quality, a mathematical model with user-developed melting model and burning capacity model, were established according to the features of melting process of regenerative aluminum melting furnaces. Based on validating results by heat balance test for an aluminum melting furnace, CFD （computational fluid dynamics） technique, in association with statistical experimental design were used to optimize the melting process of the aluminum melting furnace. Four important factors influencing the melting time, such as horizontal angle between burners, height-to-radius ratio, natural gas mass flow and air preheated temperature, were identified by PLACKETT-BURMAN design. A steepest descent method was undertaken to determine the optimal regions of these factors. Response surface methodology with BOX-BEHNKEN design was adopted to further investigate the mutual interactions between these variables on RSD （relative standard deviation） of aluminum temperature, RSD of furnace temperature and melting time. Multiple-response optimization by desirability function approach was used to determine the optimum melting process parameters. The results indicate that the interaction between the height-to-radius ratio and horizontal angle between burners affects the response variables significantly. The predicted results show that the minimum RSD of aluminum temperature （12.13%）, RSD of furnace temperature （18.50%） and melting time （3.9 h） could be obtained under the optimum conditions of horizontal angle between burners as 64°, height-to-radius ratio as 0.3, natural gas mass flow as 599 m3/h, and air preheated temperature as 639 ℃. These predicted values were further verified by validation experiments. The excellent correlation between the predicted and experimental values confirms the validity and practicability of this statistical optimum strategy.展开更多
In order to reduce the materials cost of COREX ironmaking process,sinter has been introduced into the composite burden in China.This work explored the reducing process of sinter in COREX shaft furnace to clarify its r...In order to reduce the materials cost of COREX ironmaking process,sinter has been introduced into the composite burden in China.This work explored the reducing process of sinter in COREX shaft furnace to clarify its reduction properties change and then the effect of sinter proportion on metallurgical performance of composite burden was investigated.The results show that the reducing process of sinter in COREX shaft furnace was basically same with that in blast furnace but sinter seems like breaking faster.Under reducing condition simulated COREX shaft furnace,sinter possessed the worst reduction degradation index(RDI)and undifferentiated reduction index(RI)compared with pellet and iron ore lumps.Macroscopic and microscopic mineralogy changes indicated that sinter presents integral cracking while pellet and lump ore present surface cracking,and no simple congruent relationship exists between cracks of the burden and its ultimate reduction degradation performance.The existence of partial metallurgical performance superposition between composite and single ferrous burden was confirmed.RDI_(+6.3)≥70%and RDI_(+3.15)≥80%were speculated as essential requirements for the composite burden containing sinter in COREX shaft furnace.展开更多
The effect of heavy metals on the properties and hydration of blast furnace slag-cement composites(BFS-CC)remain unclear.In this study,two BFS-CC(denoted as DBFS-CC and WBFS-CC)were prepared by dry and wet grinding of...The effect of heavy metals on the properties and hydration of blast furnace slag-cement composites(BFS-CC)remain unclear.In this study,two BFS-CC(denoted as DBFS-CC and WBFS-CC)were prepared by dry and wet grinding of BFS,respectively.The effect of Cu(II)on BFS-CC’s properties and hydration was investigated by adding representative copper contaminants(CuO,CuCl_(2),and CuS)to the composites.Adding 1.0wt%CuO and 0.5wt%CuS increased the 3-d compressive strength of DBFS-CC by 14.9%and 5.7%,respectively,but suppressed the 3-d strength of WBFS-CC.This trend reversed at 28-d curing,where adding 1.5wt%CuO,2.0wt%CuCl_(2),and 1.5wt%CuS enhanced the compressive strength of WBFS-CC by 23.4%,6.2%,and 13.6%,respectively,but adversely affected the strength of DBFS-CC.For 28-d hydration,adding CuCl_(2)decreased the hydration degree of DBFS-CC but enhanced that of WBFS-CC.Adding CuO promoted the hydration degree of both composites,while adding CuS exhibited inhibitory effects.DBFS-CC immobilized CuCl_(2)better due to a higher hydration degree,while WBFS-CC immobilized CuO and CuS better due to having finer unhydrated BFS particles and a denser matrix.This study not only focuses on the Cu(II)immobilization effect but also reveals the differ-ential effects of Cu(II)species on the hydration process,providing novel insights into heavy metal interactions in BFS-CC systems and their safe disposal.展开更多
Today,a well-devised charging operation scheme is urgently needed by on-site workmen and is critical for building an intelligent blast furnace(BF).Previous research on charging operations always focused on the two-dim...Today,a well-devised charging operation scheme is urgently needed by on-site workmen and is critical for building an intelligent blast furnace(BF).Previous research on charging operations always focused on the two-dimensional shape of the burden surface(i.e.,a single radial profile)while neglecting the unique feature of global dissymmetry,severely restricting the development of precise charging.For this reason,this study proposes an innovative optimization strategy for the charging operation under the three-dimensional burden surface,which is the first attempt in this field.First,a practicable region partitioning scheme is introduced,and the partitioning results are then integrated with the charging mechanism to construct a three-dimensional burden surface prediction model.Next,the intrinsic relationship between the operational parameters and charging volume is revealed based on the law of mass conservation,which forms the basis for defining a novel operational parameter with variable-speed utility,referred to as the neotype charging matrix(NCM).To find the best NCM,a customized NCM optimization strategy,involving a dual constraint handling technique in conjunction with a two-stage hybrid variable differential evolution algorithm,is further developed.The industrial experiment results manifest that the partitioning scheme significantly enhances the accuracy of burden surface description.Moreover,the NCM optimization strategy offers greater flexibility and higher accuracy than current mainstream optimization strategies for the charging matrix(CM).展开更多
In this study,innovative ellipsoid pellet with craters on its surface was designed,and the direct reduction process was compared with ellipsoid(without craters)and sphere pellets.In addition,furnace temperature and un...In this study,innovative ellipsoid pellet with craters on its surface was designed,and the direct reduction process was compared with ellipsoid(without craters)and sphere pellets.In addition,furnace temperature and uneven heat flux density effects on the pellet direct reduction process were also studied.The results show that ellipsoid pellet is better than that of spherical pellet on metallization ratio.However,under the condition of non-uniform heat flow,the ellipsoid pellet final metallization rate and zinc removal rate were lower.Although the heat transfer effect of ellipsoid pellet with craters was not improved significantly,the metallization rate and zinc removal rate were found improved,which will have a cumulative effect on the pellets direct reduction process in rotary hearth furnace.Under varying furnace temperature conditions,the pellet temperature was higher than that of the constant furnace temperature.After 1200 s,pellet Fe concentration increased to 123.6%,metallization rate and zinc removal rate increased to 113.7%and 102.2%,respectively.These results can provide references for the carbon-containing pellet design used in rotary hearth furnace.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
Mathematical model for mass transfer of chemical reactions on the surface of the smelting bath pit in oxygen top blown smelting furnace was put forward. Additionally, one of two mathematical models for mass transfer o...Mathematical model for mass transfer of chemical reactions on the surface of the smelting bath pit in oxygen top blown smelting furnace was put forward. Additionally, one of two mathematical models for mass transfer of chemical reactions forming copper matte in smelting bath and the other for parameters of smelting process were developed. The verification tests were simultaneously carried out in a pilot scale furnace and the experimental results show that these mathematical models are convincing. Thus, these numerical models are reliable to simulate pyritic smelting process for copper nickel mineral in oxygen top blown furnace.展开更多
A mathematical model was established to describe the direct reduction of pellets in a rotary hearth furnace （RHF）. In the model, heat transfer, mass transfer, and gas-solid chemical reactions were taken into account...A mathematical model was established to describe the direct reduction of pellets in a rotary hearth furnace （RHF）. In the model, heat transfer, mass transfer, and gas-solid chemical reactions were taken into account. The behaviors of iron metallization and dezincification were analyzed by the numerical method, which was validated by experimental data of the direct reduction of pellets in a Si-Mo furnace. The simulation results show that if the production targets of iron metallization and dezincification are up to 80% and 90%, respectively, the furnace temperature for high-temperature sections must be set higher than 1300~ C. Moreover, an undersupply of secondary air by 20% will lead to a decline in iron metallization rate of discharged pellets by 10% and a decrease in dezincing rate by 13%. In addition, if the residence time of pellets in the furnace is over 20 min, its further extension will hardly lead to an obvious increase in production indexes under the same furnace temperature curve.展开更多
Blast furnace data processing is prone to problems such as outliers.To overcome these problems and identify an improved method for processing blast furnace data,we conducted an in-depth study of blast furnace data.Bas...Blast furnace data processing is prone to problems such as outliers.To overcome these problems and identify an improved method for processing blast furnace data,we conducted an in-depth study of blast furnace data.Based on data samples from selected iron and steel companies,data types were classified according to different characteristics;then,appropriate methods were selected to process them in order to solve the deficiencies and outliers of the original blast furnace data.Linear interpolation was used to fill in the divided continuation data,the Knearest neighbor(KNN)algorithm was used to fill in correlation data with the internal law,and periodic statistical data were filled by the average.The error rate in the filling was low,and the fitting degree was over 85%.For the screening of outliers,corresponding indicator parameters were added according to the continuity,relevance,and periodicity of different data.Also,a variety of algorithms were used for processing.Through the analysis of screening results,a large amount of efficient information in the data was retained,and ineffective outliers were eliminated.Standardized processing of blast furnace big data as the basis of applied research on blast furnace big data can serve as an important means to improve data quality and retain data value.展开更多
Titanium-bearing blast furnace slag(BFS)has valuable compositions and potential environmental hazardousness.Thus,developing efficient and green approaches to utilize BFS is highly desired for resource economization an...Titanium-bearing blast furnace slag(BFS)has valuable compositions and potential environmental hazardousness.Thus,developing efficient and green approaches to utilize BFS is highly desired for resource economization and environmental protection.In the past decades,many attempts have been adopted to reuse BFS efficiently,and significant advances in understanding the fundamental features and the development of efficient approaches have been achieved.This review provides a comprehensive overview of the latest progress on the efficient utilization of BFS and discusses the mechanism and characteristics of various approaches,along with their application prospects.In particular,the extraction and enrichment of titanium-bearing phases from BFS are highlighted because of the high availability of titanium resources.This systemic and comprehensive review may benefit the design of new and green utilization routes with high efficiency and low cost.展开更多
It has long been thought that a reheating furnace, with its inherent measurement difficulties and complex dynamics, posed almost insurmountable problems to engineers in steel plants. A novel software sensor is propos...It has long been thought that a reheating furnace, with its inherent measurement difficulties and complex dynamics, posed almost insurmountable problems to engineers in steel plants. A novel software sensor is proposed to make more effective use of those measurements that are already available, which has great importance both to slab quality and energy saving. The proposed method is based on the mixtures of Gaussian processes (GP) with the expectation maximization (EM) algorithm employed for parameter esti- mation of the mixture of models. The mixture model can alleviate the computational complexity of GP and also accords with the changes of operating condition in practical processes. It is demonstrated by on-line estimation of the furnace gas temperature in 1580 reheating furnace in Baosteel Corporation (Group).展开更多
A novel hydrothermal process was developed to extract zinc from pure zinc ferrite（ZnFe2O4） nanopowder and zinc-containing electric arc furnace（EAF） dust using hexahydrated ferric chloride（FeCl3-6H2O） as a decomp...A novel hydrothermal process was developed to extract zinc from pure zinc ferrite（ZnFe2O4） nanopowder and zinc-containing electric arc furnace（EAF） dust using hexahydrated ferric chloride（FeCl3-6H2O） as a decomposing agent.The effects of solid FeCl3-6H2O to ZnFe2O4 ratio by mass（RF/Z）,hydrothermal reaction temperature,and time on zinc extraction were systematically investigated.In the results,when the hydrothermal reaction is conducted at 150℃ for 2 h with RF/Z of 15：20,the efficiency of zinc extraction from ZnFe2O4 reaches97.2%,and the concentration of ferric ions（Fe^3＋） in the leaching solution is nearly zero,indicating a high selectivity for zinc.In addition,the zinc extraction efficiency from the EAF dust reaches 94.5%in the case of the hydrothermal reaction performed at 200℃ for 10 h with the solid FeCl3-6H2O to EAF dust ratio by mass（RF/EAF dust） of 15：10.Zinc and iron separation is achieved by adjusting the pH value of the leaching solution according to the different precipitation pH values of metal hydroxides.展开更多
Basic oxygen furnace slag（BOFS） has the potential to remove hexavalent chromium（Cr（VI））from wastewater by a redox process due to the presence of minerals containing Fe2＋. The effects of the solution p H, initia...Basic oxygen furnace slag（BOFS） has the potential to remove hexavalent chromium（Cr（VI））from wastewater by a redox process due to the presence of minerals containing Fe2＋. The effects of the solution p H, initial Cr（VI） concentration, BOFS dosage, BOFS particle size, and temperature on the removal of Cr（VI） was investigated in detail through batch tests. The chemical and mineral compositions of fresh and reacted BOFS were characterized using scanning electron microscope（SEM） equipped with an energy dispersive spectrometer（EDS）system and X-ray diffractometer（XRD）. The results show that Cr（VI） in wastewater can be efficiently removed by Fe2＋released from BOFS under appropriate acidic conditions. The removal of Cr（VI） by BOFS significantly depended on the parameters mentioned above. The reaction of Cr（VI） with BOFS followed the pseudo-second-order kinetic model. Fe2＋responsible for Cr（VI） removal was primarily derived from the dissolution of Fe O and Fe3O4 in BOFS. When H2SO4 was used to adjust the solution acidity, gypsum（Ca SO4·2H2O）could be formed and become an armoring precipitate layer on the BOFS surface, hindering the release of Fe2＋and the removal of Cr（VI）. Finally, the main mechanism of Cr（VI） removal by BOFS was described using several consecutive reaction steps.展开更多
The molten liquid flow inside a packed bed is a familiar momentum transportation phenomenon in a blast furnace. With regard to the reported mathematical models describing the liquid flow within a packed bed, there are...The molten liquid flow inside a packed bed is a familiar momentum transportation phenomenon in a blast furnace. With regard to the reported mathematical models describing the liquid flow within a packed bed, there are some obstacles for their application in engineering design, or some limitations in the model itself. To overcome these problems, the forces from the packed bed to the liquid flow were divided into appropriate body and surface forces on the basis of three assumptions. Consequently, a new mathematical model was built to present the liquid flow inside the coke bed in a blast furnace. The mathematical model can predict the distribution of liquid flowrate and the liquid flowing range inside the packed bed at any time. The predicted results of this model accord well with the experimental data. The model will be applied considerably better in the simulation on the ironmaking process compared with the existent models.展开更多
This paper provides a mathematical model for the billet reheating process in furnace.A new optimum method is brought up that the objective function is the integral value of enthalpy increasing process of a billet.Diff...This paper provides a mathematical model for the billet reheating process in furnace.A new optimum method is brought up that the objective function is the integral value of enthalpy increasing process of a billet.Different delays are simulated and calculated,some proper delay strategies are ob- tained.The on-line computer control model is de- veloped.The real production conditions simulated, the temperature deviation of drop out billet from the target temperature is kept within±15℃.展开更多
The process characteristics of heat treatment of aluminum alloy auto body sheet and the working principle of air cushion furnace were introduced.The process position and irreplaceable role of air cushion furnace in th...The process characteristics of heat treatment of aluminum alloy auto body sheet and the working principle of air cushion furnace were introduced.The process position and irreplaceable role of air cushion furnace in the aluminum alloy auto body sheet production was pointed out after the difficulty and key points in the whole production process of auto body sheet were studied.Then the development process of air cushion furnace line of aluminum alloy sheet was reviewed,summarized and divided to two stages.Based on the research of air cushion furnace,the key technology of it was analyzed,then the key points on process,equipment and control models of air cushion furnace for aluminum alloy auto body sheet in future were put forward.With the rapid development of automotive industry,there will be certainly a new upsurge of research and application of air cushion furnace for heat treatment of aluminum alloy auto body sheet.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
基金the Tangshan University Doctor Innovation Fund(Project Number:1402306).
文摘The so-called close-coupled gas atomization process involves melting a metal and using a high-pressure gas jet positioned close to the melt stream to rapidly break it into fine,spherical powder particles.This technique,adapted for blast furnace slag granulation using a circular seam nozzle,typically aims to produce solid slag particles sized 30–140μm,thereby allowing the utilization of slag as a resource.This study explores the atomization dynamics of liquid blast furnace slag,focusing on the effects of atomization pressure.Primary atomization is simulated using a combination of the Volume of Fluid(VOF)method and the Shear Stress Transport k-ωturbulence model,while secondary atomization is analyzed through the Discrete Phase Model(DPM).The results reveal that primary atomization progresses in three stages:the slag column transforms into an umbrella-shaped liquid film,whose leading edge fragments into particles while forming a cavity-like structure,which is eventually torn into ligaments.This primary deformation is driven by the interplay of airflow velocity in the recirculation zone and the guide tube outlet pressure(Fp).Increasing the atomization pressure amplifies airflow velocity,recirculation zone size,expansion and shock waves,though the guide tube outlet pressure variations remain irregular.Notably,at 4.5 MPa,the primary deformation is most pronounced.Secondary atomization yields finer slag particles as a result of more vigorous primary atomization.For this pressure,the smallest average particle size and the highest yield of particles within the target range(30–140μm)are achieved.
基金Supported by the National Key Projects for Fundamental Research and Development of China(2016YFB0600904)
文摘Large quantities of blast furnace(BF) slag and CO_2 are discharged annually from iron and steel industries, along with a large amount of waste heat.The mineral carbonation of BF slag can not only reduce emissions of solid waste but also realize the in-situ fixation of CO_2 with low energy consumption if integrated with the waste heat utilization.In this study, based on our previous works, Aspen Plus was employed to simulate and optimize the carbonation process and integrate the process energy.The effects of gehlenite extraction, MgSO_4 carbonation,and aluminum ammonium sulfate crystallization were studied systematically.The simulation results demonstrate that 2.57 kg of BF slag can sequester 1 kg of CO_2, requiring 5.34 MJ of energy(3.3 MJ heat and 2.04 MJ electricity), and this energy includes the capture of CO_2 from industrial flue gases.Approximately 60 kg net CO_2 emission reduction could be achieved for the disposal of one ton of BF slag.In addition, the by-product,aluminum ammonium sulfate, is a high value-added product.Preliminary economic analysis indicates that the profit for the whole process is 1127 CNY per ton of BF slag processed.
基金supported by the National Natural Science Foundation of China under Grant U1960114,51774337,and U1660206the Open Sharing Fund for the Large-scale Instruments and Equipments of Central South University under Grant CSUZC201905the Fundamental Research Funds for the Central Universities of Central South University under Grant 2018zzts220.
文摘Effect of distribution of iron concentrates between pelletized and matrix feed on the preparation of blast furnace burdens from two different kinds of fine iron concentrates (magnetite and hematite) by composite agglomeration process (CAP) was explored. It was found that when the mass ratio of iron concentrate A (magnetite) to iron concentrate B (hematite) in the mixed feed was constant, the proportion of iron concentrate A in the pelletized and matrix feed significantly affected the quality of CAP products. Particularly, as the proportion of iron concentrate A in the pelletized feed increased from 0 to 100%, the yield decreased from 82.11% to 79.19% and the tumbler index decreased from 71.33% to 68.27%. The mineralization characterization results indicated that when 100% iron concentrate A was used as the pelletized feed, the crystallization styles of the outer layer and the inner layer of the pellet were different, and a lot of pores exist around hematite and magnetite phases in the pelletized part, with the weak connection of pelletized and matrix part, resulting in poor strength of agglomeration product.
基金Project(2009BSXT022) supported by the Dissertation Innovation Foundation of Central South University, ChinaProject(07JJ4016) supported by Natural Science Foundation of Hunan Province, ChinaProject(U0937604) supported by National Natural Science Foundation of China
文摘To reduce the fuel consumption and emissions and also enhance the molten aluminum quality, a mathematical model with user-developed melting model and burning capacity model, were established according to the features of melting process of regenerative aluminum melting furnaces. Based on validating results by heat balance test for an aluminum melting furnace, CFD （computational fluid dynamics） technique, in association with statistical experimental design were used to optimize the melting process of the aluminum melting furnace. Four important factors influencing the melting time, such as horizontal angle between burners, height-to-radius ratio, natural gas mass flow and air preheated temperature, were identified by PLACKETT-BURMAN design. A steepest descent method was undertaken to determine the optimal regions of these factors. Response surface methodology with BOX-BEHNKEN design was adopted to further investigate the mutual interactions between these variables on RSD （relative standard deviation） of aluminum temperature, RSD of furnace temperature and melting time. Multiple-response optimization by desirability function approach was used to determine the optimum melting process parameters. The results indicate that the interaction between the height-to-radius ratio and horizontal angle between burners affects the response variables significantly. The predicted results show that the minimum RSD of aluminum temperature （12.13%）, RSD of furnace temperature （18.50%） and melting time （3.9 h） could be obtained under the optimum conditions of horizontal angle between burners as 64°, height-to-radius ratio as 0.3, natural gas mass flow as 599 m3/h, and air preheated temperature as 639 ℃. These predicted values were further verified by validation experiments. The excellent correlation between the predicted and experimental values confirms the validity and practicability of this statistical optimum strategy.
基金Project(2019JJ51007)supported by the Natural Science Foundation of Hunan Province,China。
文摘In order to reduce the materials cost of COREX ironmaking process,sinter has been introduced into the composite burden in China.This work explored the reducing process of sinter in COREX shaft furnace to clarify its reduction properties change and then the effect of sinter proportion on metallurgical performance of composite burden was investigated.The results show that the reducing process of sinter in COREX shaft furnace was basically same with that in blast furnace but sinter seems like breaking faster.Under reducing condition simulated COREX shaft furnace,sinter possessed the worst reduction degradation index(RDI)and undifferentiated reduction index(RI)compared with pellet and iron ore lumps.Macroscopic and microscopic mineralogy changes indicated that sinter presents integral cracking while pellet and lump ore present surface cracking,and no simple congruent relationship exists between cracks of the burden and its ultimate reduction degradation performance.The existence of partial metallurgical performance superposition between composite and single ferrous burden was confirmed.RDI_(+6.3)≥70%and RDI_(+3.15)≥80%were speculated as essential requirements for the composite burden containing sinter in COREX shaft furnace.
基金financially sponsored by the Key R&D Program of Xinjiang Uygur Autonomous Region,China(No.2023B03007-2)the Tianshan Innovation Team,China(No.2023D14013)+9 种基金the Tianchi Hundred-Talent Program,China(No.RSSQ00066865)the Fundamental Research Funds for the Central Universities,China(No.FRF-BD-25-037)the Ganpo Talent Plan,the Taishan Industrial Experts Program,the National Natural Science Foundation of China(Nos.52204414,52204413,and 52204412)the Beijing Natural Science Foundation,China(No.2242046)the National Key R&D Program of China(No.2024YFC3907701)the Postdoctoral Fellowship Program of China Postdoctoral Science Foundation(No.GZC20230243)the China Postdoctoral Science Foundation(No.2024M750178)the Guangdong Basic and Applied Basic Research Foundation,China(No.2023A1515011609 and 2023A1515110094)the Key Technology Innovation and Advanced Development Program of Chongqing,China(No.CSTB2022TIADKPX0112)the Open Project of State Key Laboratory of Green Building Materials.
文摘The effect of heavy metals on the properties and hydration of blast furnace slag-cement composites(BFS-CC)remain unclear.In this study,two BFS-CC(denoted as DBFS-CC and WBFS-CC)were prepared by dry and wet grinding of BFS,respectively.The effect of Cu(II)on BFS-CC’s properties and hydration was investigated by adding representative copper contaminants(CuO,CuCl_(2),and CuS)to the composites.Adding 1.0wt%CuO and 0.5wt%CuS increased the 3-d compressive strength of DBFS-CC by 14.9%and 5.7%,respectively,but suppressed the 3-d strength of WBFS-CC.This trend reversed at 28-d curing,where adding 1.5wt%CuO,2.0wt%CuCl_(2),and 1.5wt%CuS enhanced the compressive strength of WBFS-CC by 23.4%,6.2%,and 13.6%,respectively,but adversely affected the strength of DBFS-CC.For 28-d hydration,adding CuCl_(2)decreased the hydration degree of DBFS-CC but enhanced that of WBFS-CC.Adding CuO promoted the hydration degree of both composites,while adding CuS exhibited inhibitory effects.DBFS-CC immobilized CuCl_(2)better due to a higher hydration degree,while WBFS-CC immobilized CuO and CuS better due to having finer unhydrated BFS particles and a denser matrix.This study not only focuses on the Cu(II)immobilization effect but also reveals the differ-ential effects of Cu(II)species on the hydration process,providing novel insights into heavy metal interactions in BFS-CC systems and their safe disposal.
基金supported in part by the Science and Technology Innovation Program of Hunan Province(2024RC1007)the Young Scientists Fund of the National Natural Science Foundation of China(62303491)+2 种基金the Major Program of Xiangjiang Laboratory(22XJ01005)the Young Scientists Fund of the National Natural Science Foundation of China(62203473)Central South University Post-Graduate Independent Exploration and Innovation Project(2024ZZTS0451).
文摘Today,a well-devised charging operation scheme is urgently needed by on-site workmen and is critical for building an intelligent blast furnace(BF).Previous research on charging operations always focused on the two-dimensional shape of the burden surface(i.e.,a single radial profile)while neglecting the unique feature of global dissymmetry,severely restricting the development of precise charging.For this reason,this study proposes an innovative optimization strategy for the charging operation under the three-dimensional burden surface,which is the first attempt in this field.First,a practicable region partitioning scheme is introduced,and the partitioning results are then integrated with the charging mechanism to construct a three-dimensional burden surface prediction model.Next,the intrinsic relationship between the operational parameters and charging volume is revealed based on the law of mass conservation,which forms the basis for defining a novel operational parameter with variable-speed utility,referred to as the neotype charging matrix(NCM).To find the best NCM,a customized NCM optimization strategy,involving a dual constraint handling technique in conjunction with a two-stage hybrid variable differential evolution algorithm,is further developed.The industrial experiment results manifest that the partitioning scheme significantly enhances the accuracy of burden surface description.Moreover,the NCM optimization strategy offers greater flexibility and higher accuracy than current mainstream optimization strategies for the charging matrix(CM).
基金Project(cstc 2018 jszx-cyzdx 0100)supported by the Chongqing Technology Innovation and Application Demonstration Project,China。
文摘In this study,innovative ellipsoid pellet with craters on its surface was designed,and the direct reduction process was compared with ellipsoid(without craters)and sphere pellets.In addition,furnace temperature and uneven heat flux density effects on the pellet direct reduction process were also studied.The results show that ellipsoid pellet is better than that of spherical pellet on metallization ratio.However,under the condition of non-uniform heat flow,the ellipsoid pellet final metallization rate and zinc removal rate were lower.Although the heat transfer effect of ellipsoid pellet with craters was not improved significantly,the metallization rate and zinc removal rate were found improved,which will have a cumulative effect on the pellets direct reduction process in rotary hearth furnace.Under varying furnace temperature conditions,the pellet temperature was higher than that of the constant furnace temperature.After 1200 s,pellet Fe concentration increased to 123.6%,metallization rate and zinc removal rate increased to 113.7%and 102.2%,respectively.These results can provide references for the carbon-containing pellet design used in rotary hearth furnace.
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.
文摘Mathematical model for mass transfer of chemical reactions on the surface of the smelting bath pit in oxygen top blown smelting furnace was put forward. Additionally, one of two mathematical models for mass transfer of chemical reactions forming copper matte in smelting bath and the other for parameters of smelting process were developed. The verification tests were simultaneously carried out in a pilot scale furnace and the experimental results show that these mathematical models are convincing. Thus, these numerical models are reliable to simulate pyritic smelting process for copper nickel mineral in oxygen top blown furnace.
基金financially supported by the National Key Basic Research and Development Program of China(No. 2012CB720405)
文摘A mathematical model was established to describe the direct reduction of pellets in a rotary hearth furnace （RHF）. In the model, heat transfer, mass transfer, and gas-solid chemical reactions were taken into account. The behaviors of iron metallization and dezincification were analyzed by the numerical method, which was validated by experimental data of the direct reduction of pellets in a Si-Mo furnace. The simulation results show that if the production targets of iron metallization and dezincification are up to 80% and 90%, respectively, the furnace temperature for high-temperature sections must be set higher than 1300~ C. Moreover, an undersupply of secondary air by 20% will lead to a decline in iron metallization rate of discharged pellets by 10% and a decrease in dezincing rate by 13%. In addition, if the residence time of pellets in the furnace is over 20 min, its further extension will hardly lead to an obvious increase in production indexes under the same furnace temperature curve.
基金This work is financially supported by the National Nature Science Foundation of China(No.52004096)the Hebei Province High-End Iron and Steel Metallurgical Joint Research Fund Project,China(No.E2019209314)+1 种基金the Scientific Research Program Project of Hebei Education Department,China(No.QN2019200)the Tangshan Science and Technology Planning Project,China(No.19150241E).
文摘Blast furnace data processing is prone to problems such as outliers.To overcome these problems and identify an improved method for processing blast furnace data,we conducted an in-depth study of blast furnace data.Based on data samples from selected iron and steel companies,data types were classified according to different characteristics;then,appropriate methods were selected to process them in order to solve the deficiencies and outliers of the original blast furnace data.Linear interpolation was used to fill in the divided continuation data,the Knearest neighbor(KNN)algorithm was used to fill in correlation data with the internal law,and periodic statistical data were filled by the average.The error rate in the filling was low,and the fitting degree was over 85%.For the screening of outliers,corresponding indicator parameters were added according to the continuity,relevance,and periodicity of different data.Also,a variety of algorithms were used for processing.Through the analysis of screening results,a large amount of efficient information in the data was retained,and ineffective outliers were eliminated.Standardized processing of blast furnace big data as the basis of applied research on blast furnace big data can serve as an important means to improve data quality and retain data value.
基金This work was financially supported by the National Nat-ural Science Foundation of China(No.51974011)the Key R&D Program of Ningxia Hui Autonomous Region,China(No.2019BFG02032).
文摘Titanium-bearing blast furnace slag(BFS)has valuable compositions and potential environmental hazardousness.Thus,developing efficient and green approaches to utilize BFS is highly desired for resource economization and environmental protection.In the past decades,many attempts have been adopted to reuse BFS efficiently,and significant advances in understanding the fundamental features and the development of efficient approaches have been achieved.This review provides a comprehensive overview of the latest progress on the efficient utilization of BFS and discusses the mechanism and characteristics of various approaches,along with their application prospects.In particular,the extraction and enrichment of titanium-bearing phases from BFS are highlighted because of the high availability of titanium resources.This systemic and comprehensive review may benefit the design of new and green utilization routes with high efficiency and low cost.
基金This work was financially supported by the National High-Tech Research and Development Program of China(No.2002AA4120I0).
文摘It has long been thought that a reheating furnace, with its inherent measurement difficulties and complex dynamics, posed almost insurmountable problems to engineers in steel plants. A novel software sensor is proposed to make more effective use of those measurements that are already available, which has great importance both to slab quality and energy saving. The proposed method is based on the mixtures of Gaussian processes (GP) with the expectation maximization (EM) algorithm employed for parameter esti- mation of the mixture of models. The mixture model can alleviate the computational complexity of GP and also accords with the changes of operating condition in practical processes. It is demonstrated by on-line estimation of the furnace gas temperature in 1580 reheating furnace in Baosteel Corporation (Group).
基金supported by the National Basic Research Priorities Program of China (Nos. 2014CB643401 and 2013AA032003)the National Natural Science Foundation of China (No.51372019)
文摘A novel hydrothermal process was developed to extract zinc from pure zinc ferrite（ZnFe2O4） nanopowder and zinc-containing electric arc furnace（EAF） dust using hexahydrated ferric chloride（FeCl3-6H2O） as a decomposing agent.The effects of solid FeCl3-6H2O to ZnFe2O4 ratio by mass（RF/Z）,hydrothermal reaction temperature,and time on zinc extraction were systematically investigated.In the results,when the hydrothermal reaction is conducted at 150℃ for 2 h with RF/Z of 15：20,the efficiency of zinc extraction from ZnFe2O4 reaches97.2%,and the concentration of ferric ions（Fe^3＋） in the leaching solution is nearly zero,indicating a high selectivity for zinc.In addition,the zinc extraction efficiency from the EAF dust reaches 94.5%in the case of the hydrothermal reaction performed at 200℃ for 10 h with the solid FeCl3-6H2O to EAF dust ratio by mass（RF/EAF dust） of 15：10.Zinc and iron separation is achieved by adjusting the pH value of the leaching solution according to the different precipitation pH values of metal hydroxides.
基金financially supported by the Fundamental Research Fund for the Central Universities(No.N130302004)the National Natural Science Foundation of China(No.21407020)
文摘Basic oxygen furnace slag（BOFS） has the potential to remove hexavalent chromium（Cr（VI））from wastewater by a redox process due to the presence of minerals containing Fe2＋. The effects of the solution p H, initial Cr（VI） concentration, BOFS dosage, BOFS particle size, and temperature on the removal of Cr（VI） was investigated in detail through batch tests. The chemical and mineral compositions of fresh and reacted BOFS were characterized using scanning electron microscope（SEM） equipped with an energy dispersive spectrometer（EDS）system and X-ray diffractometer（XRD）. The results show that Cr（VI） in wastewater can be efficiently removed by Fe2＋released from BOFS under appropriate acidic conditions. The removal of Cr（VI） by BOFS significantly depended on the parameters mentioned above. The reaction of Cr（VI） with BOFS followed the pseudo-second-order kinetic model. Fe2＋responsible for Cr（VI） removal was primarily derived from the dissolution of Fe O and Fe3O4 in BOFS. When H2SO4 was used to adjust the solution acidity, gypsum（Ca SO4·2H2O）could be formed and become an armoring precipitate layer on the BOFS surface, hindering the release of Fe2＋and the removal of Cr（VI）. Finally, the main mechanism of Cr（VI） removal by BOFS was described using several consecutive reaction steps.
基金supported by the National Natural Science Foundation of China (No.50704040, 20805060)the Natural Science Foundation Project of Chongqing Science & Technology Commission, China (No.CSTC,2009BB4197)
文摘The molten liquid flow inside a packed bed is a familiar momentum transportation phenomenon in a blast furnace. With regard to the reported mathematical models describing the liquid flow within a packed bed, there are some obstacles for their application in engineering design, or some limitations in the model itself. To overcome these problems, the forces from the packed bed to the liquid flow were divided into appropriate body and surface forces on the basis of three assumptions. Consequently, a new mathematical model was built to present the liquid flow inside the coke bed in a blast furnace. The mathematical model can predict the distribution of liquid flowrate and the liquid flowing range inside the packed bed at any time. The predicted results of this model accord well with the experimental data. The model will be applied considerably better in the simulation on the ironmaking process compared with the existent models.
文摘This paper provides a mathematical model for the billet reheating process in furnace.A new optimum method is brought up that the objective function is the integral value of enthalpy increasing process of a billet.Different delays are simulated and calculated,some proper delay strategies are ob- tained.The on-line computer control model is de- veloped.The real production conditions simulated, the temperature deviation of drop out billet from the target temperature is kept within±15℃.
文摘The process characteristics of heat treatment of aluminum alloy auto body sheet and the working principle of air cushion furnace were introduced.The process position and irreplaceable role of air cushion furnace in the aluminum alloy auto body sheet production was pointed out after the difficulty and key points in the whole production process of auto body sheet were studied.Then the development process of air cushion furnace line of aluminum alloy sheet was reviewed,summarized and divided to two stages.Based on the research of air cushion furnace,the key technology of it was analyzed,then the key points on process,equipment and control models of air cushion furnace for aluminum alloy auto body sheet in future were put forward.With the rapid development of automotive industry,there will be certainly a new upsurge of research and application of air cushion furnace for heat treatment of aluminum alloy auto body sheet.
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.
