Machine learning mathematical model for the automatic setup of the cal and hrd flow during the process of primary aceration in electric ovens

In this work, a mathematical model is developed for the automatic predisposition of the flow of lime and HRD during the primary steeling process in HEA of the steel mill of Sidor, C.A. Model that was possible through an intelligent dynamic process control system, under a descriptive field research profile; considering a sample of 46 commercial grade steel castings (ASTM A 1018). The system consists of two simulation modules that ensure the ideal thermodynamic condition (steel temperature between 1535 to 1575 ° C, ITHD indicator less than 1,5% and a binary base index of the slag between 2 to 2,6 ) for the protection of refractory material and dephosphorization of steel. Having as a result, a reduction of the Tap To Tap of 7,08%; reduction of lime consumption by 5,28% and an increase in productivity of 7,51%. Keywords: Primary Metallurgy; Electric Arc Furnace (HEA); Mathematical Model; Machine Learning. References [1]Asociación Latinoamericana del Acero, "Alacero", [Online]. Available: https://www.alacero.org/sites/default/files/publicacion/proceso_siderurgico.pdf. [Last access: July 04, 2020]. [2]F. Morral, E. Jimeno y P. Molera, Metalúrgia general, Barcelona: Reverté, 1985. [3]B. Bucciarelli, G. Torga, F. Sabugal, F. Díaz y M. Lardizabal, "Evolución en el control del fósforo en la acería de Ternaris SIDERCA", de 18a Conferencia de acería del IAS, Rosario, Santa Fe, 2011. [4]S. Kalpakjian y S. Schmid, Manufactura, ingenieria y tecnología, 4ta ed., México: Pearson educación, 2002. [5]M. Oropeza, J. López, A. Pérez y J. Ucar, "Contribuciones para el control del fósforo cuando se utiliza mineral reducido de hierro", Revista metalurgia, vol. 35, nº 2, pp. 479-490, 2008. [6]J. Castro y F. Echeverría, Introducción a las técnicas de computación inteligente, 1era ed., Venezuela: Universidadde los andes, 2001. [7]A. Sadeghian y J. Lavers, "Application of radial basis function networks to model electric arc furnaces", IJCNN,vol. 6, pp. 3996-4001, 1999. [8]J. Brito, "Diseño de un control automatizado para la alimentación de cal mezcla en función del HRD para ajustar la basicidad binaria de la escoria del horno eléctrico #1 de la acería de planchones de Ternium SIDOR", trabajo de grado inédito, 2008. [9]A. Zambrano, V. Collazo, N. Troncone y J. Rodríguez, "A computer tool for closed-loop dynamical system identificaction through artificial neural networks", Universidad, Ciencia y Tecnología (UCT), vol. 16, nº 64, pp. 190-202, 2012. [10]E. Moreno, Tecnología de producción del ferrosilicio, 3era ed., Venezuela: Ferroatlántica de Venezuela, 2005. [11]C. García, "Optimización del proceso de formación de escoria espumosa en los hornos eléctricos de acerías de planchones de Sidor", trabajo de grado inédito, UNEFM, Punto Fijo, 2011. [12]M. Rojas, "Estudio del consumo de cal, coque, oxígeno y HRD en el proceso de formación de esocria epsumosa en el HE-5 de la acería de planchones de Sidor, C.A.", trabajo de grado inédito, UNEXPO, Puerto Ordaz, 2012. [13]R. Morales, R. Lule, F. López, J. Camacho y J. Romaero, "The slag foaming practice in EAF and its influence on the stelmaking shop productivity", ISIJ International, vol. 35, nº 9, pp. 1054-1062, 1995. [14]W. García, "Implementación de prácticas de escorias espumosa en los EAF de la acería eléctrica de planchones de Sidor, C.A.", trabajo de grado inédito, USB, Caracas, 2002. [15]S. Alameddine, B. Bowman, S. Paege y P. Stafford, "Innovation in EAF and in steelmaking processes", de AIM, Milano-Italia, 2009. [16]J. Mateos, "Análisis y optimización de costes en una planta de procesado y producción de acero", trabajo de grado inédito, UC3M, Madrid, 2010. [17]A. Conejo y J. Cárdenas , "Energy consumption in the EAF with 100% DRI", AISTECH Proceddings, vol. 1, pp. 529-535, 2006. [18]M. Rojas, O. Prado, O. Carvajal y R. Higuerey, "Impacto del consumo de cal, coque, oxígeno y HRD en la formación de escoria espumosa durante el proceso de aceración primaria en hornos de arco eléctrico", Universidad, Ciencia y Tecnología (UCT), vol. 17, nº 67, pp. 134-140, 2013.

Modern concepts of refractory materials application in production of steel and cast iron

Refractory lining is an integral part of metallurgical facilities and requires constant perfection. Examples of successful interaction of specialists-steelmakers, companies-manufacturers of refractories and engineering companies on increasing efficiency of refractories application in steel industry presented. The wide application of drying and heating stations of steel ladles, EAFs, BOFs was noted because of using refractory gunned castable at their current repairs. The growth of unmolded refractory share in the BF production was shown. At the stoves repair technology of guniting and shotcreting is widely used. Transfer to application of modern concrete at lining of shoots, ramming mixtures and repairs with application of liquid concrete addition resulted in a decrease of labor­ intensiveness of repair work, accelerated the process of repair and considerably decreased specific consumption of refractory materi­als. Nevertheless, within a predictable period, despite of increase of unmolded refractories application, it is expected that the molded refractories would take the main share of the refractory market in the steelmaking. Creation of partial load conditions in a metallurgical facility is an important factor for increasing lining resistivity. Slag foaming in EAF screens radiation from electrodes in the process of the furnace running. Blowing of the final slag (preliminary enriched by magnesium oxide in case of necessity) forms a scull on the working surface of the BOF lining, thus preventing intensive contact of the refractory lining with steel melt and slag. Modem technologies of instrumental control the lining state of metallurgical facility within the period of its running considered, which allowto accomplish operation of hot repair at particular arears of the lining, avoiding overconsumption of the repair material. It was noted that apart from the task of decreasing specific expenses for refractory materials, the customers most often estimate the indirect costs, cover of loss and obtaining additional profit due to increase of metal production because of increase of overhaul period and decrease of time of lining repair. This is the purpose of cooperation of specialists of refractories manufacturers and metallurgical plants.