Numerical Simulation of Heat Transfer Process and Heat Loss Analysis in Siemens CVD Reduction Furnaces

The modified Siemens method is the dominant process for the production of polysilicon,yet it is characterised by high energy consumption.Two models of laboratory-grade Siemens reduction furnace and 12 pairs of rods industrial-grade Siemens chemical vapor deposition(CVD)reduction furnace were established,and the effects of factors such as the diameter of silicon rods,the surface temperature of silicon rods,the air inlet velocity and temperature on the heat transfer process inside the reduction furnace were investigated by numerical simulation.The results show that the convective and radiant heat losses in the furnace increased with the diameter of the silicon rods.Furthermore,the radiant heat loss of the inner and outer rings of silicon rods was inconsistent for the industrial-grade reduction furnace.As the surface temperature of the silicon rods increases,the convective heat loss in the furnace increases,while the radiative heat loss remains relatively constant.When the inlet temperature and inlet velocity increase,the convective heat loss decreases,while the radiant heat loss remains relatively constant.Furthermore,the furnace wall surface emissivity increases,resulting in a significant increase in the amount of radiant heat loss in the furnace.In practice,this can be mitigated by polishing or adding coatings to reduce the furnace wall surface emissivity.

Digital Kilns and Furnaces——the Development Direction of Industrial Kilns and Furnaces in the 21st Century

The digital manufacturing theory is applied to the special manufacturing equipments——industrial kilns and furnaces; the concept of digital kilns & furnaces is put forward. The present status of research and application for digital technologies in fuel industrial kilns & furnaces is also introduced. Then,take the case of gas fuel kilns & furnaces,their main key technical issues are discussed. Digital kilns & furnaces as an important constituent of the digital equipments are the crucial base of the digital manufacturing. The value of research on digital kilns & furnaces and the application prospect are undoubted. It will improve product quality,reduce the manpower cost,enhance product market competitive ability,promote comprehensively tradition industries such as ceramics,metallurgy industry,and so on.

Status and Progress of Refraetories for Aluminum Smelting Furnaces

Status and state-of-the-art progress on research,development and application of refractories for aluminum smelting furnaces and holding furnaces were reviewed and discussed in the present paper.The main types of aluminum smelting furnaces and smelting processes,and the service conditions of refractories and the requirements for refractory lining were also described and discussed.

The 4th International Exhibition on Refractories, Industrial Ceramics and Furnaces(RCF Expo'2003)Beijing, China, April 15-17, 2003In conjunction with China Refractories Seminar' 2003-Technology and Markets

Organizers and Sponsors: China Association of Refractories Industry The Chinese Society for Metals The Chinese Ceramic Society

Development and Application of Multi-phase Nitrides Bonded Silicon Carbide Lintel Blocks for Dry Quenching Furnaces

Multi-phase nitrides bonded silicon carbide lintel blocks were prepared using industrial SiC(SiC≥98 mass%,3-0.5,≤0.5 and≤0.044 mm),Si powder(Si≥98 mass%,≤0.044 mm),and SiO2 micropowder(SiO2≥96 mass%,d50=0.15 pm)as raw materials,and calcium lignosulfonate as the additive,batching,mixing,and molding on a vibration pressure molding machine,drying and then firing at 1420℃for 10 h in high-purity N2.The apparent porosity,the bulk density,the cold modulus of rupture,the hot modulus of rupture,and the linear expansion coefficient of the samples were tested.The phase composition and the microstructure of the samples at different nitriding depths(50,100,and 150 mm)were analyzed by XRD and SEM.The field application effects of the blocks were studied.The results show that:(1)the multi-phase nitrides bonded silicon carbide refractories can dynamically adjust their own phase composition and minimize structural and thermal stresses,improving the service life of key parts of dry quenching furnaces;(2)calcium lignosulfonate can improve the nitriding micro-environment of multi-phase nitrides bonded silicon carbide lintel blocks,successfully increasing the effective nitriding thickness of the blocks to 300 mm;(3)Sinosteel LI RR provides a unique concept in the design of materials and block types as well as the stable and scientific overall structure,promoting the industrialization process of dry quenching furnaces with long service life in China.

Cooling Water Flow Rate Calculation for Hearth of Large Blast Furnaces

The cooling water flow rate for hearth of large blast furnaces was calculated by simulation. The results show that the cooling water flow rate shall be above 4 200m3/ h for hearth of large blast furnaces; to meet requirements of the increasing smelting intensity and to ensure the safety at the end of the first campaign,the designed maximum cooling water flow rate should be 5 900m3/ h; according to the flow distribution stability and the calculated resistance loss,hearth cooling stave pipes with the specification of 76 mm × 6 mm shall be adopted to assure the flow velocity in pipes of hearth cooling stave in the range of 1. 9- 2. 3 m / s.

Kaolinite Refractory Bricks for Blast Furnaces

This standard is suitable to the fireclay bricks for blast furnace.

Theory and Practice of Heat Transfer in Electric Arc and Flare Furnaces and Power Plants

The author describes the fundamental laws of physics, the laws of thermal radiation of ionized and non-ionized gas volumes. Based on open laws, a modern theory of heat transfer and methods for calculating heat transfer in electric arc and flare metallurgical furnaces, furnaces of steam boilers, and combustion chambers of gas turbine plants of power plants have been developed. The use of scientific discovery makes it possible to create innovative electric arc steel-smelting furnaces, flare heating furnaces, and combustion chambers in which the consumption of electricity and fuel is reduced, productivity and service life are increased, and the amount of harmful emissions into the environment is reduced.

A History of Industrial Kilns and Furnaces——Lessons for Future Energy Conservation and Environmental Protection

This is a historical compilation and analysis of the world-wide development of kilns and furnaces, covering those ones ranging from ancient earthenware kilns to modern high-tech furnaces、 including nuclear reactors and fuel cells. Special emphasis is on energy conservation and environmental protection. the historical lessons from which can be applied to future activities.

Bauxite Based Refractory Bricks for Blast Furnaces

This standard is applicable to the bauxite based refractory bricks under the bosh for blast furnaces.

Direct-bonded Magnesite-Chrome Bricks for Kilns and Furnaces of Building Materials Industry

JC 497-92 (96)1 Contents and Applied ScopeThis standard specifies the classification, shapes and dimensions, technical requirements, test methods, inspection rules, marking, packing, transportation, storage and quality certificate of direct-bonded magnesite-chrome bricks for building materials industry. This standard is applicable to the direct-bonded magnesite-chrome bricks for cement kiln, glass melting tank and other industrial furnaces.2 Normative ReferencesGB 2997: Test method for the apparent porosity, water absorption, bulk density and true porosity of dense shaped refractory productsGB 5070: Chemical analysis method for magnesite-Chrome refractoriesGB 5072: Test method for cold crushing strength of dense shaped refractory productsGB 5989: Test method for refractoriness under load of dense shaped refractory products (Differential, with rising temperature)GB 7320: Test method for thermal expansion of refractory productsGB 7321: Sample preparation for testing of dense shaped refractory productsGB 10324: Type definition of refractory productsGB 10325: Piling, sampling, acceptance, storage and transportation of refractory products

Direct reduction swelling behavior of pellets in hydrogen-based shaft furnaces under typical atmospheres

Hydrogen-based shaft furnace process is gaining more and more attention due to its low carbon emission, and the reduction behavior of iron bearing burdens significantly affects its operation. In this work, the effects of reduction degree, temperature, and atmosphere on the swelling behavior of pellet has been studied thoroughly under typical hydrogen metallurgy conditions. The results show that the pellets swelled rapidly in the early reduction stage, then reached a maximum reduction swelling index (RSI) at approximately 40%reduction degree. The crystalline transformation of the iron oxides during the reduction process was the main reason of pellets swelling. The RSI increased significantly with increasing temperature in the range of 850-1050℃, the maximum RSI increased from 6.66%to 25.0%in the gas composition of 100%H_(2). With the temperature increased, the pellets suffered more thermal stress resulting in an increase of the volume. The maximum RSI decreased from 19.78%to 17.35%with the volume proportion of H_(2) in the atmosphere increased from 55%to 100%at the temperature of 950℃.The metallic iron tended to precipitate in a lamellar structure rather than whiskers. Consequently, the inside of the pellets became regular, so the RSI decreased. Overall, controlling a reasonable temperature and increasing the H_(2) proportion is an effective way to decrease the RSI of pellets.

Outlier screening for ironmaking data on blast furnaces

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.

Quantificational indexes for design and evaluation of copper staves for blast furnaces

The quantificational and normative design is the precondition of improving the design of copper staves for blast furnaces. Based on a 3-dimensional temperature field calculation model, from the view point of heat transfer and long campaigns note with the core of forming accretion, the forming-accretion-ability （FAA） and the rib hot surface maximum temperature difference （ATmax） as quantificational indexes to direct and evaluate the design of copper staves for blast furnaces were presented. The application of the two indexes in design essentially embodies the new long campaigns in the stage of design. With the application of the two indexes, good results can be obtained. Firstly, it was suggested that the rib height of a copper stave can be reduced to 15 mm, which is a new method and theory for the reduction of copper staves. Secondly, the influence of insert on FAA and ATmax, is decided by the volume of insert. According to this, the principle of design for the hot surface geometry of copper staves was put forward that the ratio of the rib hot surface to the copper stave hot surface （abbreviated as the ratio of rib to stave） must be maintained in the range of 45% to 55%; for the present copper stave with a 35-40 mm thick rib, the ratio of rib to stave in the range of 50% to 55% can optimize the design of copper staves; for the copper stave with a smaller rib thickness, for example 15 ram, the ratio of rib to stave in the range of 45% to 50% can optimize the design of copper staves. It can be summarized that the thicker the rib thickness, the larger is the ratio of rib to stave. 2008 University of Science and Technology Beijing. All rights reserved.

Numerical Investigation of Fuel Dilution Effects on the Performance of the Conventional and the Highly Preheated and Diluted Air Combustion Furnaces

This numerical study investigates the effects of using a diluted fuel （50% natural gas and 50% N2） in an industrial furnace under several cases of conventional combustion （air with 21% O2 at 300 and 1273 K） and the highly preheated and diluted air （1273 K with 10% O2 and 90% N2） combustion （HPDAC） conditions using an in-house computer program. It was found that by applying a combined diluted fuel and oxidant instead of their uncombined and/or undiluted states, the best condition is obtained for the establishment of HPDAC＇s main unique features. These features are low mean and maximum gas temperature and high radiation/total heat transfer to gas and tubes; as well as more uniformity of theirs distributions which results in decrease in NOx pollutant formation and increase in furnace efficiency or energy saving. Moreover, a variety of chemical flame shape, the process fluid and tubes walls temperatures profiles, the required regenerator efficiency and finally the concentration and velocity patterns have been also qualitatively/quantitatively studied.

Numerical analysis on Joule heating of double-loop channel induction furnaces

In order to investigate Joule heating power,a three-dimensional finite element model(FEM) was developed to predict Joule heating power in the channels of double-loop inductor. The simulated results were compared with experimental data from low load trials for a 400 kW inductor. The results,such as power factor and Joule heating power,show reasonable correlation with experimental data,and Joule heating rate reaches the maximum at the corners and the minimum at the centre of the cross-section area. With increasing relative permeability of iron core,length of coils,current frequency and resistivity of metal melt,the power factor and Joule heating power change. It is concluded that current frequency,the resistivity and length of the coil play a critical role in determining the power factor and Joule heating power,whereas relative permeability of the magnetic core shows no significant influence on them.

Improvement of fuel consumption and maintenance of heating furnaces using a modified heating pattern

This article studies the transient heat conduction in a slab when passing through various sections of the furnace, and focuses on the thickness of the scale layer formed on the slab. The transient heat conduction behavior of a slab in various sections of the heating furnace is analyzed using the Laplace transformation method, including the pre-heating zone, the first heating zone, the second heating zone, and the soaking zone. The heating pattern of the furnace is then modified to reduce fuel consumption. The simulation results show that the scale layer formed on the slab significantly influences the quality of the hot rolled coil formed, and how the furnace parameters affect the efficiency of the furnace and the quality of the coil.

Investigation on the relationship between hearth wall erosion and deadman permeability for large blast furnaces

In this study, the relationship between hearth wall erosion and deadman permeability was investigated based on the change in the hearth bottom and hearth sidewall temperatures. Additionally, the operation practice for controlling hearth wall erosion in the large No. 1 blast furnace at Baosteel was also investigated. The reasons for the decrease in the permeability of deadman coke were analyzed, and measures for improving the permeability of deadman coke and controlling hearth wall temperature rising were described. The results show that a decrease in deadman coke permeability is the main reason for refractory temperature increase and hearth wall erosion. This indicates the importance of monitoring changes in hearth working conditions and taking appropriate measures to maintain sufficient permeability of the deadman and balance the hot metal flow and drainage of slag. At this rate, the decline in the hearth bottom temperature and fast rising of the hearth wall temperature can be restrained.

Corrosion Mechanism of Alumina-magnesia Dry Materials for Smelting Manganese/chromium Steel in Coreless Medium Frequency Induction Furnaces

Alumina-magnesia dry materials are widely used in induction furnace linings, but they show different kinds of damage when melting different kinds of alloy steel. In this paper, the chemical composition, phase composition, and microstructure of the post-use dry materials for the working liners melting different kinds of steel were evaluated. Furthermore, the corrosion mechanism of the steel on the furnace lining materials was comprehensively analyzed. The findings reveal a significant ability of the Mn element in the molten steel to diffuse and penetrate into the refractories. Mn oxidizes to form MnO at the steel-refractory interface, and then forms a liquid phase with Al_(2)O_(3). The Cr element is dissolved into corundum and spinel of the refractories, resulting in lattice defects and structural damage of the materials. TiO2reacts with Al_(2)O_(3) to form Al_(2)TiO_(5), which plays a crucial role in preventing crack formation and propagation. Part of Ti4+dissolves into magnesia-alumina(MA), densifying the materials. TiO2also slows down the reaction between the Cr element and refractory components, further improving the corrosion resistance of the materials.