scholarly journals Thermostatic cover for improving energy and technological efficiency of steel mills

2019 ◽  
Vol 110 ◽  
pp. 01003
Author(s):  
Konstantin Strogonov ◽  
Sergey Tolkanov ◽  
Karina Korkots ◽  
Alexander Fedyukhin
Keyword(s):  
Steel Casting ◽  
Energy Savings ◽  
Casting Process ◽  
Technical Solution ◽  
Metal Release ◽  
Thermal Fields ◽  
Steel Mills ◽  
Stable Production ◽  
Technological Efficiency ◽  
The Stability

The article proposes a technical solution for reducing the energy costs of casting process and providing more stable production conditions, specifically, the use of a thermostatic cap. Two variants of steel casting are considered: with and without the application of a thermostatic cover using the example of a bucket with a capacity of six tons of steel. The technical challenge is to reduce heat losses through the bucket neck to ensure the stability of the melting temperature throughout the casting and to reduce the temperature of metal release from the steelmaking unit. The design of the thermostatic cover with specifications, as well as the duration of process steps in the steel casting with and without the use of a thermally insulated cap are described. The balance calculations were carried out using MathCAD environment, which confirmed significant energy savings with a slight increase in casting time associated with the appearance of an additional technological operation for installing the thermostatic cover after pouring. Using ANSYS Academic software, a study was carried out on the thermal fields of the ladle and steel at various stages of casting for two options, which confirmed the effectiveness of using a thermostatic cover.

scholarly journals Comparison of Optimization-Regulation Algorithms for Secondary Cooling in Continuous Steel Casting

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 237
Author(s):  
Michal Brezina ◽  
Tomas Mauder ◽  
Lubomir Klimes ◽  
Josef Stetina
Keyword(s):  
Convergence Rate ◽  
Water Flow ◽  
Steel Casting ◽  
Casting Process ◽  
Continuous Steel Casting ◽  
Continuous Steel ◽  
Cooling Zone ◽  
Secondary Cooling ◽  
Flow Rates ◽  
Secondary Cooling Zone

The paper presents the comparison of optimization-regulation algorithms applied to the secondary cooling zone in continuous steel casting where the semi-product withdraws most of its thermal energy. In steel production, requirements towards obtaining defect-free semi-products are increasing day-by-day and the products, which would satisfy requirements of the consumers a few decades ago, are now far below the minimum required quality. To fulfill the quality demands towards minimum occurrence of defects in secondary cooling as possible, some regulation in the casting process is needed. The main concept of this paper is to analyze and compare the most known metaheuristic optimization approaches applied to the continuous steel casting process. Heat transfer and solidification phenomena are solved by using a fast 2.5D slice numerical model. The objective function is set to minimize the surface temperature differences in secondary cooling zones between calculated and targeted surface temperatures by suitable water flow rates through cooling nozzles. Obtained optimization results are discussed and the most suitable algorithm for this type of optimization problem is identified. Temperature deviations and cooling water flow rates in the secondary cooling zone, together with convergence rate and operation times needed to reach the stop criterium for each optimization approach, are analyzed and compared to target casting conditions based on a required temperature distribution of the strand. The paper also contains a brief description of applied heuristic algorithms. Some of the algorithms exhibited faster convergence rate than others, but the optimal solution was reached in every optimization run by only one algorithm.

Thin-Wall Steel Casting Process for Exhaust Components

2002 ◽  
Author(s):  
Nobuyoshi Sasaki ◽  
William L. Tordoff ◽  
Kazuyuki Kurisu ◽  
Yuji Yoshida
Keyword(s):  
Steel Casting ◽  
Casting Process ◽  
Thin Wall

scholarly journals An Evaluation of the Stability of Mould Flux Properties in the Process of Continuous Steel Casting

2017 ◽  
Vol 62 (2) ◽  
pp. 885-889 ◽  
Author(s):  
J. Falkus
Keyword(s):  
Process Parameters ◽  
Liquidus Temperature ◽  
Casting Process ◽  
Continuous Steel Casting ◽  
Time Intervals ◽  
Equal Time ◽  
Industrial Experiments ◽  
Mould Flux ◽  
Steel Cast ◽  
The Stability

AbstractThis paper presents research on the mould slag formed on the basis of two mould fluxes. In the conducted industrial experiments, slag was sampled in equal time intervals between adding subsequent portions of mould flux. The research focused on the an evaluation of the stability of slag parameters by assessing the change in its liquidus temperature. It was shown that a mould flux needs to be assessed individually taking into account the casting process parameters and the steel cast grade.

Minimization of Negative Impact of Well Cementing on Productive Horizons by Utilization of Swellable Packers

2021 ◽  
Author(s):  
Mykhaylo Paduchak ◽  
Viktor Dudzych ◽  
Anatolii Boiko
Keyword(s):  
Negative Impact ◽  
Differential Pressure ◽  
High Rate ◽  
Donets Basin ◽  
Technical Solution ◽  
Negative Consequences ◽  
Well Completion ◽  
Stable Production ◽  
Geological Conditions ◽  
Gas Tight

Abstract Avoiding of negative impact of slurry contact with productive sections by utilization of swellable pakers well completion systems as a key solution for depleted reservoirs. Results are compared to previously used classic well completion method with production casing cementing The new method of the well completion is based on a long period and many wells operations within Svyrydivske field in Dnipro-Donets Basin (here and after DDB). Precise selection of hybrid, oil and water based elastomers and correct placement in the appropriate hole zones for water and sectional isolation together with oil based mud utilization during drilling have provided stable production in depleted reservoirs and have minimized negative consequences from water filtration. The results achieved and the well completion method are described in detail to allow readers to replicate all results in a comparable geological conditions in DDB. Current well completion method has a couple of outstanding results achieved: –well integrity barrier is based on sufficient differential pressure provided by swellable packers;–reliable long term water isolation of all detected water contained intervals;–the production sections are not polluted by slurry filtrated water;–increased production rate comparing to cemented wells;–no risks of slurry loss during well cementing. This technology has been successfully implemented in both vertical and deviated wells on 4.5″ (114.3 mm) casing OD, in the interval 5100-5450 meters, bottom hole temperature 120-135°C. The differential pressure provided by swellable packer is up to 10,000 PSI (68.9 MPa). Fluid reactive packers are ready to expand and isolate highly cavernous hole sections and keep differential pressure sustainably. To achieve the best results with this well completion method, it is also important to use reliable gas tight casing connections and know precise reservoir characteristics. That is why the technology is recommended to be customized for well known brownfield reservoirs with high rate of depletion. The main benefit of the well completion method is a proved and safe technical solution for mainly depleted deep gas and condensate deposits in DDB (Ukraine) with sensitive economics

scholarly journals Improvement of operation of steam cushion system for sensible thermal energy storage

2019 ◽  
Vol 116 ◽  
pp. 00107
Author(s):  
Ryszard Zwierzchowski
Keyword(s):  
Heat Flux ◽  
Energy Storage ◽  
Thermal Energy ◽  
Thermal Energy Storage ◽  
Energy Savings ◽  
Operating Conditions ◽  
Production Costs ◽  
Technical Solution ◽  
Atmospheric Air ◽  
Suction Pipe

The paper contains a method for improvement of operation of steam cushion system including its energy savings analyses, for a Thermal Energy Storage (TES) tank. Energy savings analyses were performed using operational data from selected Combined Heat and Power plants, which supply heat to large cities in Poland and are furnished with the TES. The role of the steam cushion system in the TES tank is to prevent the stored water against absorbing oxygen from atmospheric air. In the TES tank, which is a non-pressure tank, oxygen from atmospheric air could penetrate to the network water through the surge chamber and safety valves. The steam pressure under the roof is generated from technological steam injected under the roof. Energy savings in the steam cushion system are generated by using an appropriate technical solution for the upper orifice and suction pipe for circulation water, i.e., to make it movable through the use of pontoons. An isolating buffer layer is created at the top of the tank with very small convective and turbulent heat transport, which causes limited heat transfer from steam bed to the stored water in the tank. This results in heat flux of approximately 10% of the heat flux that occurs in the typical technical solution of the upper orifice and suction pipe for circulation water in the TES tank. This technology offers great opportunities to improve the operating conditions of District Heating System, cutting energy production costs and emissions of pollutants to the atmosphere.

The Research and Application of Nuclear Power Valve Steel Casting by CAD / CAE Simulation Design and Refining Technology

2011 ◽  
Vol 480-481 ◽  
pp. 1293-1297
Author(s):  
Hai Feng Chen ◽  
Feng Cao
Keyword(s):  
Steel Casting ◽  
Nuclear Power ◽  
Aluminum Content ◽  
Solidification Process ◽  
Casting Process ◽  
Hot Cracking ◽  
Simulation Design ◽  
Flow And Heat Transfer ◽  
Valve Steel ◽  
Cae Simulation

With China cast CAE / InteCAST, we analyzed the ordinary valve casting parameters of solidification process, flow and heat transfer, and frequency smelting refining furnace used in the process of feeding wire, argon technology in the intermediate. Comparison-ray testing and physical anatomy of the results, we developed nuclear power valve steel casting process parameters. The results showed that the software forecast casting the shrinkage tendency of value; frequency smelting refining controlled sulfur, phosphorus and aluminum content; products fully comply with the ASTM A216/A216M overcome hot cracking defects, improving the casting ability of anti-fatigue.

scholarly journals Numerical Modelling of Metal/Flux Interface in a Continuous Casting Mould / Modelowanie Numeryczne Powierzchni Międzyfazowej Metal/Ciekły Żużel W Krystalizatorze Do Ciągłego Odlewania Stali

2015 ◽  
Vol 60 (4) ◽  
pp. 2905-2912 ◽  
Author(s):  
J. Jowsa ◽  
M. Bielnicki ◽  
A. Cwudziński
Keyword(s):  
Liquid Steel ◽  
Steel Casting ◽  
Liquid Slag ◽  
Submerged Entry Nozzle ◽  
Casting Process ◽  
Continuous Steel Casting ◽  
Research Areas ◽  
Slab Casting ◽  
Metal Flux ◽  
Continuous Casting Mould

The behaviour of liquid slag in the mould is one of the key research areas of the continuous steel casting process. Numerical simulations of steel casting in the mould equipped with submerged entry nozzle, intended for slab casting, have been carried out within the study. For modelling the behaviour of the interfaces of the liquid steel - liquid slag - air system, the VOF method was employed. In the conducted simulations, seven different procedures for the discretization of the interface of individual phases were tested. The computation results have revealed that the “entrapment” of fine slag portions into liquid steel occurs in the system under investigation; the cause of this phenomenon is explicated by the Kelvin-Helmholtz theory.

Research on Key Technologies of 38CrMoAl Steel Produced by BOF-LF-RH-CC Process

2011 ◽  
Vol 284-286 ◽  
pp. 1031-1038 ◽  
Author(s):  
Yong Chen ◽  
Jian Hua Zeng ◽  
Min Zhang ◽  
Hong Pan
Keyword(s):  
Continuous Casting ◽  
Molten Steel ◽  
Casting Process ◽  
Al Content ◽  
Good Surface ◽  
High Aluminum Steel ◽  
Continuously Cast ◽  
And Performance ◽  
Si Content ◽  
The Stability

Nozzle blockage is easy to take place in continuous casting process when producing 38CrMoAl steel due to high content of aluminum ([Al]=0.7%~1.1%). Slag-steel reaction will lead to large transformation for composition of molten steel and performance of slag on the condition of traditional high content of SiO2 in slag. And it will reduce the cleanliness of steel as well. The control target of refining slag and tundish powder has been gotten through the analysis of refining & continuous casting characteristics of high aluminum steel. Based on this, the content of Si and Al in molten steel can be controlled accurately, and the cleanliness of steel has gone to a higher level. Moreover, mold powder with high basicity and vitrification ensures the stability of slag after sorbing Al2O3 inclusions in theory. Continuous casting can be carried out successfully with the control of inclusion morphology through slag washing during tapping. Industrial practice shows that Si content is 0.25%~0.40%, Al content is 0.80%~1.00%, S content is below 0.004% and T[O] is below 0.0015% in steel products. Moreover, casting bloom with good surface quality is achieved, and the rate of bloom without cleaning is as high as 100%. With all these countermeasures, 38CrMoAl steel can be continuously cast for more than 6 heats.

scholarly journals ASSESSMENT OF TECHNICAL POSSIBILITIES FOR PRODUCTION OF PK- TYPE TERMINALS FOR SEPARATE RAIL FASTENING OF THE RAILWAY TRACK

2021 ◽  
pp. 74-82
Author(s):  
Mykolai Bahrov ◽  
Keyword(s):  
Life Experience ◽  
Real Life ◽  
National Standards ◽  
Railway Track ◽  
Product Certification ◽  
Stable Production ◽  
Certification Procedure ◽  
Certification Body ◽  
The Stability

The availability of the production certificate gives an advantage to any company that cares about improving the efficiency of processes and quality of work. The production certificate is first of all necessary for the enterprises which plan to take partin tenders for supply of products for railway transport and its infrastructure. The production certification procedure involves checking the compliance of regulatory, technological, metrological support, personnel qualification level, organizational arrangements aimed at ensuring the stability of quality indicators of products or services provided, assessment of technical capabilities of the applicant company to ensure stable production/services that meet the requirements of current regulations in Ukraine (national standards, enterprise standards, etc.). Therefore, the assessment of the technical capabilities of the manufacturer, including PC-type terminals of separate rail fastening of the railway track, is the main and integral part of the production certification process. The information and data provided in this paper are based on the real-life experience of the certification body and relate to the quantitative assessment of the technical capabilities of the enterprise that manufactures PK-type terminals. Key words: product certification, assessment of technical capabilities, production certificate, certification body, technological accuracy reserve.

scholarly journals Geometrical Parametric Optimisation of A356 Alloy Composite in a Two-Stage Casting Process for Automobile Wheel Covers using Response Surface Methodology

2020 ◽  
Vol 7 (1) ◽  
pp. 457-478 ◽  
Author(s):  
Sunday Oke ◽  
Stephen Chidera Nwafor ◽  
Chris Abiodun Ayanladun
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Regression Models ◽  
Predictive Accuracy ◽  
A356 Alloy ◽  
Casting Process ◽  
Sand Casting ◽  
Phase Method ◽  
Technical Solution ◽  
Two Phase

In recent years, novel products from out–of–use A356 alloy engine components are increasingly produced for the automobile industries. Despite being a promising method the sand casting of these products reveals an inadequately understood cast geometry phenomenon for the process. At present, there is no technical solution to the optimisation of cast geometries for A356 alloy reconfigured into composites through organic matter reinforcements. This paper models and analyse sand casting process product geometries in a two–phase method. It utilises the response surface methodology with data on inputs and outputs to create the regression. Volume and density of the first casting process and the weight loss were evaluated for the various groupings of casting process variables, including length, weight, height, width of product for the first casting, weight, length, breadth of the product for the second casting, and the total weight of organic materials. The input and output associations were established in two models of regression analysis representing the central composite design, CCD. The influences of the cast geometrical variables on the evaluated responses were analysed. Furthermore, the predictive accuracy of the two regression models was evaluated. Results revealed that the applied CCD and the regression models reveals statistical adequacy and are competent to predict accurately.

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