Determination of optimal oil pumping plans

This paper presents the results of determining the optimal plans for pumping oil through the main oil pipelines of Kazakhstan. The calculation methodology is based on determining the minimum unit cost of pumping depending on oil flow rate. Oil pumping energy-saving modes are determined under optimal operating conditions of pumping units and heating furnaces at stations. Determination of the optimal pumping plan is implemented as a separate module of the SmartTranPro software. Pumped oil volumes on the oil pipeline sections were determined on the basis of the automated system of control and metering of electrical energy data of KazTransOil JSC. Optimal pumping plans for monthly oil volumes in the Kalamkas – Karazhanbas and Dzhumagaliev – Atasu pipeline sections for cold and warm periods were calculated on the basis of the found dependence of the pumping unit cost. For each range of oil mass flow rate, specific costs for oil pumping and a list of operating pumps at oil pumping stations located along the pipeline section are indicated.

Statistical modeling of temperature operating modes of heating furnaces for hot strip mills

The article provides a method of mathematical modeling to improve temperature operating modes of heating furnaces for hot strip mills. The object of the research is the thermal operation of a continuous walking beam furnace for heating slabs before rolling. The subject of the research is statistical modeling of metal heating in furnaces of this type. The creation of a statistical model consists of factors selection, construction of regression model, correlation analysis and assessment of the variables significance, adjustment of factors and obtaining regression equations. The main part of the research refers to a statistical model based on a comprehensive analysis. This model is based on the results of 15 automated industrial experiments on Russian heating furnaces of hot strip mills and describes the heating process in walking-beam furnace with acceptable accuracy. The adaptation of the statistical model and error calculation has been carried out. The article contains graphs comparing real temperatures and temperatures calculated on the basis of mathematical and statistical models for one of the experiments. The main conclusions are formulated based on the results of the research done. For the first time in metallurgical practice, a statistical model has been developed that describes the process of metal heating in a five-zone continuous furnace with eight heating subzones. Since the regression function is defined, interpreted and justified, and the assessment of the accuracy of the regression analysis meets the requirements, it can be assumed that the model and predicted values have sufficient reliability.

Simulation of oil pipeline shutdown and restart modes

The paper is devoted to the simulating of non-stationary processes of shutdown and restart on the example of a section of the Zhetybai-Uzen “hot” oil pipeline. A mathematical model of thermal-hydraulic calculation is given taking into account the rheological properties of the pumping oil. The special module of the SmartTran software developed by the work’s authors carried out the calculations. In the calculations, the decrease in time of oil temperature in the pipeline during cooling and the increase in oil pressure, temperature, velocity after the restart are determined. In addition, the calculations determine the power of pumping units, heating furnaces and the power consumption, which are necessary for restart of the pipeline after the shutdown. Simulation the processes of the pipeline cooling and restart after a shutdown makes it possible choosing the optimum parameters of pumping units at pumping stations and the time of safe shutdown of the oil pipeline.

Key technologies for energy saving and emission reduction of heating furnaces in petrochemical plants

The safety instrumented system is a system that is independent of the petrochemical production process control system and can independently complete the safety interlock protection function. It can avoid significant hazards to production equipment caused by process production failures, field instrument failures, system power supply failures, etc., and ensure safe operation of production equipment. In petrochemical plants, it is imperative to configure a safe, reliable, and timely safety instrumented system. Combined with applying the burner management system of the heating furnace in a refinery, the paper focuses on the technical realization of the hardware structure, system configuration, logic programming, man-machine interface configuration system debugging of the TRICON system. Practical application shows that TRICON?s safety instrumented system is a set of safety instrumented systems with comprehensive functions, safety and reliability, and easy to learn.

MATHEMATICAL MODELING AND OPTIMIZATION OF HEAT PROCESSING OF SQUARE CROSS SECTION STEEL BAR ON THE TECHNOLOGICAL LINE “CONTINUOUS CASTING MACHINE - TUNNEL THERMOS - HEATING FURNACE”

The PAO Severstal continuous casting machine (CCM) casts square section 100´100 and 150´150 mm billets that after the gas cutting have average temperature 1000-1100 °С. Then billets CCM, transported to the section mill shop, should be placed into a tunnel thermos for preserving their sensible heat and temperature leveling along their section. In this case hot billets are loadedin the heating furnaces, and heating of the billets to required temperature before rolling can be accelerated several times, increasing capacity of the heating furnace and diminishing the specific fuel consumption. The authors present the mathematical model that allows evaluating the heat state of a square section billet on the technological line “CCM - thermos - heating furnace”. The results of numerical simulation of the billet heat state at optimal modes of heat treatment in the thermos and the heating furnace are given.