Diagnostics, Optimization and Mathematical Models of Coke-Sinter-Hot Metal Production Process

2019 ◽  
Author(s):  
O. Lebid ◽  
Y. Vyshinskya ◽  
N. Gordon ◽  
V. Chaika ◽  
G. Izumskiy ◽  
...  
Keyword(s):  
Mathematical Models ◽  
Production Process ◽  
Hot Metal ◽  
Metal Production

scholarly journals Utilization of Organic Mixed Biosludge from Pulp and Paper Industries and Green Waste as Carbon Sources in Blast Furnace Hot Metal Production

2021 ◽  
Vol 13 (14) ◽  
pp. 7706
Author(s):  
Tova Jarnerud ◽  
Andrey V. Karasev ◽  
Chuan Wang ◽  
Frida Bäck ◽  
Pär G. Jönsson
Keyword(s):  
Blast Furnace ◽  
Carbon Sources ◽  
Hydrothermal Carbonization ◽  
Pulp And Paper ◽  
Hot Metal ◽  
Technological Parameters ◽  
Metal Production ◽  
Green Waste ◽  
Fuel Rate ◽  
Pulp And Paper Industries

A six day industrial trial using hydrochar as part of the carbon source for hot metal production was performed in a production blast furnace (BF). The hydrochar came from two types of feedstocks, namely an organic mixed biosludge generated from pulp and paper production and an organic green waste residue. These sludges and residues were upgraded to hydrochar in the form of pellets by using a hydrothermal carbonization (HTC) technology. Then, the hydrochar pellets were pressed into briquettes together with commonly used briquetting material (in-plant fines such as fines from pellets and scraps, dust, etc. generated from the steel plant) and the briquettes were top charged into the blast furnace. In total, 418 tons of hydrochar briquettes were produced. The aim of the trials was to investigate the stability and productivity of the blast furnace during charging of these experimental briquettes. The results show that briquettes containing hydrochar from pulp and paper industries waste and green waste can partially be used for charging in blast furnaces together with conventional briquettes. Most of the technological parameters of the BF process, such as the production rate of hot metal (<1.5% difference between reference days and trial days), amount of dust, fuel rate and amount of injected coal, amount of slag, as well as contents of FeO in slag and %C, %S and %P in the hot metal in the experimental trials were very similar compared to those in the reference periods (two days before and two days after the trials) without using these experimental charge materials. Thus, it was proven that hydrochar derived from various types of organic residues could be used for metallurgical applications. While in this trial campaign only small amounts of hydrochar were used, nevertheless, these positive results support our efforts to perform more in-depth investigations in this direction in the future.

Possibilities Reducing of Energy Consumption by Cast Iron Production in Foundry

2020 ◽  
Vol 998 ◽  
pp. 36-41
Author(s):  
Peter Futaš ◽  
Alena Pribulová ◽  
Marcela Pokusova
Keyword(s):  
Cast Iron ◽  
Energy Consumption ◽  
Iron Production ◽  
Hot Metal ◽  
Metal Production ◽  
Material Efficiency ◽  
Electric Induction ◽  
Wide Range ◽  
The Cost ◽  
Metal Melting

Modern metal melting includes of cast iron production in different types furnaces with specific characteristics. Furnaces usually adopted are cupola and induction furnaces. Casting cast iron is a manufacturing process characterized by its energy-intensive nature (ie, the use of large amounts of energy per unit of product for main activities) and a long tradition. An example of the energy balance in a foundry is the design of procedures to reduce energy consumption. The most important is the consumption of energy in the production of hot metals (52%), therefore reducing the cost of preparing hot metal is especially important by reducing the energy consumption of metal melting. The most important energy cost practices are the consumption of hot metal to produce 1mt of high quality castings (often 1700 kg) and reduce the energy consumption of hot metal production that varies over a wide range (from 500 to 1300 kWh/mt). Although scientific and technological aspects are now well established, new studies seem to be needed to describe "foundry of the future", where energy and material efficiency is of great importance to ensure competitiveness alongside environmental protection. The paper presents specific procedures for reducing both economically important indicators in cupola and electric induction furnaces.

Utilization of Coke-Breeze Briquets in Hot-Metal Production at PAO Koks

2019 ◽  
Vol 62 (10) ◽  
pp. 447-449
Author(s):  
V. S. Solodov ◽  
T. G. Cherkasova ◽  
S. P. Subbotin ◽  
E. V. Vasileva ◽  
S. E. Wagner ◽  
...  
Keyword(s):  
Coke Breeze ◽  
Hot Metal ◽  
Metal Production

Optimization Simulation of Hybrid Assembly Production Sequencing Management

2013 ◽  
Vol 850-851 ◽  
pp. 1008-1011
Author(s):  
Jian Feng Liu
Keyword(s):  
Mathematical Models ◽  
Production Process ◽  
Production Line ◽  
Production Capacity ◽  
Simulation Models ◽  
Manufacturing Plant ◽  
Hybrid Assembly ◽  
Automobile Engine ◽  
Optimization Simulation ◽  
Assembly Production

Sequencing of hybrid assembly production directly affects the balancecontinuity and punctuality of production process. First, the mathematical models with MILP of hybrid assembly production are established, and then the sets of sequencing scheme of minimum makespan which meet customers demands are obtained. Furthermore workshop simulation models with Flexsim software are established. In this paper, the painting hybrid assembly production line of some automobile engine manufacturing plant was employed to analyze the sequencing as an example, and the obtained painting production line sequencing scheme is consistent with the actual production of enterprises and it improves production capacity.

scholarly journals Technological modes of metals direct reduction in an aggregate of jet-emulsion type

2020 ◽  
Vol 63 (5) ◽  
pp. 364-372
Author(s):  
I. A. Rybenko ◽  
Hans­-Görg Roos
Keyword(s):  
Mathematical Models ◽  
Optimization Problems ◽  
Direct Reduction ◽  
Model Systems ◽  
Metal Reduction ◽  
Fourth Stage ◽  
Metal Production ◽  
Optimization Criteria ◽  
Reduction Processes ◽  
Instrumental System

The paper presents the method and instrumental system for modeling and optimizing technological modes of direct metal reduction processes in a jet-emulsion aggregate (JER). Stages of the method are considered. The first one is the problem statement: formation of target conditions, choice of the process type, the task and system of optimization criteria. The second stage includes selection of the object of study: setting parameters of input and output flows, process parameters, stages and subprocesses. The third one includes thermodynamic modeling to assess the final equilibrium state in which optimization problem is solved to determine the best conditions for implementation of the processes of metal reduction from oxides in model systems. The fourth stage is development of metallurgical technology (finding the optimum modes and ways for achieving these modes by specified output stream parameters). And the final one is process optimization in technical and economic indicators. As part of the fourth stage, the complex of mathematical models has been developed that reflects relationship of flows and processes in a metallurgical unit. The structure of instrumental system is presented, in which mathematical models and an algorithm for determining optimal technological modes are implemented. A set of optimization criteria has been developed and a scheme for solving two types of optimization problems are presented: finding optimal conditions for reduction processes in thermodynamic systems and determining optimal modes of direct metal reduction. Application of the method to develop optimal technological modes of direct metal production in a JER-type aggregate is shown: metal production from cast iron and mill scale; direct reduction of metal from dusty ores and iron-containing man-made materials; obtaining manganese alloys from carbonate and oxide ores; processing titanium-magnetite concentrates with an almost complete separation of iron-containing and titaniumcontaining component; and direct reduction of iron with associated production of high-calorie synthesis gas.

Technological advancements in evaluating the performance of the pulverized coal injection through tuyeres in blast furnace

2020 ◽  
Vol 117 (6) ◽  
pp. 611
Author(s):  
Ashish Agrawal ◽  
Rohit Kumar Tiwari ◽  
Sanjiv Kumar ◽  
Rajeswar Chatterjee ◽  
Basant Kumar Singh ◽  
...  
Keyword(s):  
Blast Furnace ◽  
Pulverized Coal ◽  
Injection System ◽  
Metallurgical Coke ◽  
Hot Metal ◽  
Metal Production ◽  
Replacement Ratio ◽  
Pulverized Coal Injection ◽  
Factors Influencing ◽  
Coal Injection

The pulverized coal injection (PCI) is pursued to reduce the hot metal production cost by replacing the expensive metallurgical coke with the non-coking coal. Increasing the PCI rate causes various difficulties in the blast furnace (BF) operation. In the present work, an attempt is made to review the various aspects of PC injection in BF such as the challenges with increasing the PCI rate and modifications in the injection system to circumvent the concerns related to higher PCI rate. Various methods for detecting the tuyere blockage and failure caused due to the high PCI rate are elaborated. The factors influencing the combustion of coal in front of tuyeres have been discussed and their impact in the replacement ratio has been discussed. Further, recommendations are made to improve the coal combustibility in front of tuyeres.

Ecological hot metal production using the coke plant and blast furnace route

2005 ◽  
Vol 102 (3) ◽  
pp. 171-182 ◽  
Author(s):  
P. Schmöle ◽  
H.-B. Lüngen
Keyword(s):  
Blast Furnace ◽  
Coke Plant ◽  
Hot Metal ◽  
Metal Production

Employing Industrial Waste in Sinter and Hot-Metal Production

2019 ◽  
Vol 49 (7) ◽  
pp. 472-477 ◽  
Author(s):  
L. D. Nikitin ◽  
N. G. Dyachok ◽  
A. V. Vashchenko ◽  
A. I. Shentsov ◽  
V. I. Kutran’
Keyword(s):  
Industrial Waste ◽  
Hot Metal ◽  
Metal Production

scholarly journals Dual fluidized bed based technologies for carbon dioxide reduction — example hot metal production

2020 ◽  
Author(s):  
Stefan Müller ◽  
Lara Theiss ◽  
Benjamin Fleiß ◽  
Martin Hammerschmid ◽  
Josef Fuchs ◽  
...  
Keyword(s):  
Natural Gas ◽  
Large Scale ◽  
Point Of View ◽  
Hot Metal ◽  
Metal Production ◽  
Technological Readiness ◽  
Novel Approach ◽  
Readiness Level ◽  
Dual Fluidized Bed ◽  
Natural Gas Demand

Abstract The present work describes the results achieved during a study aiming at the full replacement of the natural gas demand of an integrated hot metal production. This work implements a novel approach using a biomass gasification plant combined with an electrolysis unit to substitute the present natural gas demand of an integrated hot metal production. Therefore, a simulation platform, including mathematical models for all relevant process units, enabling the calculation of all relevant mass and energy balances was created. As a result, the calculations show that a natural gas demand of about 385 MW can be replaced and an additional 100 MW hydrogen-rich reducing gas can be produced by the use of 132 MW of biomass together with 571 MW electricity produced from renewable energy. The results achieved indicate that a full replacement of the natural gas demand would be possible from a technological point of view. At the same time, the technological readiness level of available electrolysis units shows that a production at such a large scale has not been demonstrated yet.

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