A Novel Sensing Imaging Equipment Under Extremely Dim Light for Blast Furnace Burden Surface:Starlight High-Temperature Industrial Endoscope

Blast furnace(BF)burden surface contains the most abundant,intuitive and credible smelting information and acquiring high-definition and high-brightness optical images of which is essential to realize precise material charging control,optimize gas flow distribution and improve ironmaking efficiency.It has been challengeable to obtain high-quality optical burden surface images under high-temperature,high-dust,and extremelydim(less than 0.001 Lux)environment.Based on a novel endoscopic sensing detection idea,a reverse telephoto structure starlight imaging system with large field of view and large aperture is designed.Combined with a water-air dual cooling intelligent self-maintenance protection device and the imaging system,a starlight high-temperature industrial endoscope is developed to obtain clear optical burden surface images stably under the harsh environment.Based on an endoscope imaging area model,a material flow trajectory model and a gas-dust coupling distribution model,an optimal installation position and posture configuration method for the endoscope is proposed,which maximizes the effective imaging area and ensures large-area,safe and stable imaging of the device in a confined space.Industrial experiments and applications indicate that the proposed method obtains clear and reliable large-area optical burden surface images and reveals new BF conditions,providing key data support for green iron smelting.

Process metallurgy and data-driven prediction and feedback of blast furnace heat indicators

The prediction and control of furnace heat indicators are of great importance for improving the heat levels and conditions of the complex and difficult-to-operate hour-class delay blast furnace(BF)system.In this work,a prediction and feedback model of furnace heat indicators based on the fusion of data-driven and BF ironmaking processes was proposed.The data on raw and fuel materials,process op-eration,smelting state,and slag and iron discharge during the whole BF process comprised 171 variables with 9223 groups of data and were comprehensively analyzed.A novel method for the delay analysis of furnace heat indicators was established.The extracted delay variables were found to play an important role in modeling.The method that combined the genetic algorithm and stacking efficiently im-proved performance compared with the traditional machine learning algorithm in improving the hit ratio of the furnace heat prediction model.The hit ratio for predicting the temperature of hot metal in the error range of±10℃ was 92.4%,and that for the chemical heat of hot metal in the error range of±0.1wt%was 93.3%.On the basis of the furnace heat prediction model and expert experience,a feedback model of furnace heat operation was established to obtain quantitative operation suggestions for stabilizing BF heat levels.These sugges-tions were highly accepted by BF operators.Finally,the comprehensive and dynamic model proposed in this work was successfully ap-plied in a practical BF system.It improved the BF temperature level remarkably,increasing the furnace temperature stability rate from 54.9%to 84.9%.This improvement achieved considerable economic benefits.

Coke behavior with H_(2)O in a hydrogen-enriched blast furnace:A review

Hydrogen-enriched blast furnace ironmaking has become an essential route to reduce CO_(2)emissions in the ironmaking process.However,hydrogen-enriched reduction produces large amounts of H_(2)O,which places new demands on coke quality in a blast furnace.In a hydrogen-rich blast furnace,the presence of H_(2)O promotes the solution loss reaction.This result improves the reactivity of coke,which is 20%-30%higher in a pure H_(2)O atmosphere than in a pure CO_(2)atmosphere.The activation energy range is 110-300 kJ/mol between coke and CO_(2)and 80-170 kJ/mol between coke and H_(2)O.CO_(2)and H_(2)O are shown to have different effects on coke degradation mechanisms.This review provides a comprehensive overview of the effect of H_(2)O on the structure and properties of coke.By exploring the interactions between H_(2)O and coke,several unresolved issues in the field requiring further research were identified.This review aims to provide valuable insights into coke behavior in hydrogen-rich environments and promote the further development of hydrogen-rich blast furnace ironmaking processes.

Cross-upgrading of biomass hydrothermal carbonization and pyrolysis for high quality blast furnace injection fuel production:Physicochemical characteristics and gasification kinetics analysis

The paper proposes a biomass cross-upgrading process that combines hydrothermal carbonization and pyrolysis to produce high-quality blast furnace injection fuel.The results showed that after upgrading,the volatile content of biochar ranged from 16.19%to 45.35%,and the alkali metal content,ash content,and specific surface area were significantly reduced.The optimal route for biochar pro-duction is hydrothermal carbonization-pyrolysis(P-HC),resulting in biochar with a higher calorific value,C=C structure,and increased graphitization degree.The apparent activation energy(E)of the sample ranges from 199.1 to 324.8 kJ/mol,with P-HC having an E of 277.8 kJ/mol,lower than that of raw biomass,primary biochar,and anthracite.This makes P-HC more suitable for blast furnace injection fuel.Additionally,the paper proposes a path for P-HC injection in blast furnaces and calculates potential environmental benefits.P-HC of-fers the highest potential for carbon emission reduction,capable of reducing emissions by 96.04 kg/t when replacing 40wt%coal injec-tion.

Extraction of Valuable Metals from Titanium-bearing Blast Furnace Slag by Acid Leaching

To realize the resource utilization of the valuable metals in the titanium-containing blast furnace slag,the process route of “hydrochloric acid leaching-electrolysis-carbonization and carbon dioxide capture-preparation of calcium carbonate” was proposed.In this study,the influences of process conditions on the leaching rates of calcium,magnesium,aluminum,and iron and the phases of the leaching residue were investigated for the leaching process.The experimental results show that the HCl solution could selectively leach the elements from the titanium-containing blast furnace slag.The better leaching conditions are the HCl solution concentration of 4 mol/L,the leaching time of 30 min,the ratio of liquid volume to solid gas of 10 mL/g,and the stirring paddle speed of 300 r/min.Under the conditions,the leaching rates of calcium,magnesium,aluminum,and iron can reach 85.87%,73.41%,81.35%,and 59.08%,and the leaching rate of titanium is 10.71%.The iron and the aluminum are removed from the leachate to obtain iron-aluminum water purification agents,and the magnesium is removed from the leachate to obtain magnesium hydroxide.The leaching residue phase is dominated by perovskite,followed by magnesium silicate and tricalcium aluminate,and the titaniumrich material could be obtained from the leaching residue by desiliconization.

Analysis and Prospect of Waste Heat Utilization from Blast Furnace Slag Flushing

Estimating the residual heat of blast furnace slag flushing in China,classifying and introducing the current proposed methods of slag flushing waste heat utilization,and listing existing cases.In order to better save energy and water in the slag flushing process of blast furnaces,an ideal comprehensive cascade utilization system scheme for annual recovery of waste heat is proposed.Based on the measured waste heat data of a steel plant,design calculations are carried out to further analyze the economic feasibility of the new scheme and provide reference for its promotion and application.

Synthesis,Characterization of NaA Zeolite from Blast Furnace Slag(BFS)via Alkaline Fusion and Hydrothermal Treatment

A blast furnace slag zeolite(BFSZ)material was successfully synthesized from BFS by alkaline fusion and hydrothermal treatment.Via the analyses of XRD,FT-IR,FE-SEM,XRF,CEC and BET surface area measurement,when zeolite was synthesized at a crystallization temperature of 100℃with initial Si/Al ratio of 1:1,the main composition in the product is Na-A zeolite.Under the above conditions,the BFSZ was synthesized with CEC of 3.06 meq/g and maximum BET surface area of 37.55 m^(2)·g^(-1).Moreover,the incorporating of BFS-derived minor metals(such as Mg,Fe,and Ca)are found to be of little importance for the synthesis of BFSZ.Thus the obtained BFSZ material has a great adsorption performance for removing Mn^(2+),Cu^(2+),and NH_(4)^(+)ions diluted in water,owing to the higher CEC.

Minimax entropy-based co-training for fault diagnosis of blast furnace

Due to the problems of few fault samples and large data fluctuations in the blast furnace(BF)ironmaking process,some transfer learning-based fault diagnosis methods are proposed.The vast majority of such methods perform distribution adaptation by reducing the distance between data distributions and applying a classifier to generate pseudo-labels for self-training.However,since the training data is dominated by labeled source domain data,such classifiers tend to be weak classifiers in the target domain.In addition,the features generated after domain adaptation are likely to be at the decision boundary,resulting in a loss of classification performance.Hence,we propose a novel method called minimax entropy-based co-training(MMEC)that adversarially optimizes a transferable fault diagnosis model for the BF.The structure of MMEC includes a dual-view feature extractor,followed by two classifiers that compute the feature's cosine similarity to representative vector of each class.Knowledge transfer is achieved by alternately increasing and decreasing the entropy of unlabeled target samples with the classifier and the feature extractor,respectively.Transfer BF fault diagnosis experiments show that our method improves accuracy by about 5%over state-of-the-art methods.

Efficient Use of Steel Slag in Alkali-Activated Blast Furnace Slag Based Geopolymer

Energy shortage and the emission of greenhouse gases have become a global problem of urgent concern.Therefore,there is an urgent need to develop a low carbon building material.Geopolymers have become a hot topic due to their environmental sustainability and the feasibility of immobilizing industrial waste.In this paper,steel slag(SS)fines were investigated as auxiliary materials of blast furnace slag(BFS)based geopolymer.The hydration heat properties,flowability,compressive strength,sorptivity coefficient,X-ray diffraction(XRD),and scanning electron microscopy(SEM)of the geopolymer pastes were determined.The results showed that the incorporation of SS weakened the reactivity of the BFS-based geopolymer paste and improved the flow values of the paste.The compressive strength of the geopolymer with 20%SS content reached 117 MPa at 28 d.The geopolymer specimens with high compressive strength showed a low sorptivity coefficient.The microscopic results showed that the addition of the appropriate amount of SS reduced the cracks,improved the density of the geopolymer,and produced a geopolymer composite with excellent mechanical properties.

Post-mortem Microstructural Study of Aluminous Refractory Brick Used in Channels of Blast Furnaces

Aluminous refractory materials with high alumina contents are widely used in the steel industry,and the higher the alumina content,the higher the working temperature.Properties such as high refractoriness and thermal shock resistance lead these refractory materials to be used as channel linings of blast furnaces,where they are exposed to the attack by slag,molten steel,working cycles and sudden temperature changes between 25℃(room temperature)and 1520℃(the temperature of molten pig iron).In this work,microstructural changes in post-mortem aluminous refractory bricks were investigated by apparent porosity,X-ray diffraction analysis(XRD),Fourier transform infrared spectroscopy(FTIR),scanning electron microscopy,and X-ray dispersion energy spectrometry(SEM/EDS).The results showed an increase in the apparent porosity and the bulk density and the presence of the phases mullite,sillimanite,alumina,and quartz in the post-mortem brick.Calcium and magnesium were not detected in the microstructure of the post-mortem brick,indicating that slags did not corrode these refractory materials.Therefore,the microstructural changes that occurred in the post-mortem bricks must be due to thermal cycling.In the X-ray diffraction(XRD)test,mullite,sillimanite,quartz,andα-alumina phases were identified.These results indicate that the aluminous refractory was obtained from sillimanite.In infrared spectroscopy(FTIR)it was possible to identify the vibration bands referring to the Si-O and Al-O bonds.The increase in the porosity is a result of cracks caused by work cycles at high temperatures and the temperature gradient to which the refractory was subjected during use.Through the micrograph it was possible to identify the presence of acicular mullite.The absence of magnesium and calcium in the microanalysis results by energy dispersed X-ray spectrometry(EDS)indicates that there was no infiltration by slag or liquid iron.These results indicate that the microstructural changes that occurred in the post-mortem aluminous refractory were of a thermal nature.

Preparation and Properties of SiC Assembled Large Block for Blast Furnace Tuyeres

A SiC assembled large block for blast furnace tuyeres was prepared using silicon carbide particles(3-1 and 1-0.088 mm)and fine powder(<0.088 mm),silicon powder(<0.088 mm),industrial carbon black(N990),microsilica,ρ-Al_(2)O_(3) powder,etc.as raw materials.The developed block was compared with a silicon nitride bonded silicon carbide brick,a self-bonded silicon carbide brick and an imported self-bonded silicon carbide block to analyze and evaluate their service performance.The results show that:(1)in the 0-100 mm zone,the SiC large block mainly consists ofβ-SiC and nitrides such as O'-SiAlON,β-SiAlON,α-Si_(3)N_(4),and Si_(2)N_(2)O,the bulk density is 2.68-2.70 g·cm^(-3),the apparent porosity is 14%-15%,and the material structure is uniform;(2)in the 0-100 mm zone,β-SiC nano-whiskers intercalate with nitrides;with the depth increasing,the number of flocculentβ-SiC nano-whiskers increases,while the number of nitrides decreases;when the depth reaches 150 mm or more,the main bonding phases areβ-SiC and mullite;(3)compared with the reference products,the developed SiC large block has a good basic performance,and after alkali corrosion,the mass change rate is-0.1%,which is obviously superior to the imported self-bonded silicon carbide and the homemade silicon nitride bonded silicon carbide materials.

Research on Weighing System and Debugging Technology for Batching Under Blast Furnace Ore Tank

The article introduces the composition and working principle of the batching and weighing system underneath the blast furnace hearth.Besides,the shortcomings of the batching and weighing system during installation,debugging,and calibration,as well as the dynamic errors in the batching process are also analyzed.Corresponding solutions are then provided.

Effect of Blast Furnace Sludge (BFS) Characteristics on Suitable Recycling Process Determining

The present study aims to give a detailed characterization of blast furnace sludge (BFS) by using different techniques, in order to determine the most effective recycling method to recover valuable metals from this waste. BFS is composed mainly of hematite, as its iron-bearing phase, and carbon, in addition to fractions of silicate and carbonate materials. The studied BFS shows relatively high contents of iron (Fe) (390 g.kg-1), and carbon (C) (290 g.kg-1), due to abundance of hematite and coke, while the concentration of zinc (Zn) (2.5 g.kg-1) is low. The XRD analyses indicated that, hematite is more concentrated in the fine fraction (<20 μm), while the coarser fraction (90 - 250 μm) is dominated by calcite, quartz and X-ray amorphous coke. SEM-EDX analyses confirmed that particles rich in iron and zinc were detected in the fine fraction (<20 μm) of the sludge. Due to high Fe and C content in BFS, it can be utilized as self-reducing material and briquetting represent a potential method for recycling of blast furnace sludge.

Status and development of mineral wool made from molten blast furnace slag

This study describes the characteristics of mineral wool and its applications,and also introduces the traditional process of mineral wool made from molten blast furnace （BF） slag. Compared with high energy consumption of the traditional process,the production of mineral wool by using molten BF slag will be able to take full advantage of the sensible heat of molten slag, and also reduce production costs. However, there are also further issues to resolve such as how to obtain the required amount of molten BF slag and how to make it homogeneous. Based on the physical and chemical properties of the molten BF slag,the investigation into the relationship between temperature and viscosity under different acidity coefficients of the slag and silicon mixture was conducted. Combined with the crystallization and phase diagram of slag wool, its heat resistance, water resistance, durability and corrosion resistance were analyzed. Finally, trends of the technology development are proposed.

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.

Study on the stability control technology of large-scaled blast furnaces

Nowadays,there are two major trends,which are the increasing blast furnace （BF） working volume and the decreasing fuel resource as well as the decline in its quality,in the ironmaking filed. The two trends lead to the difficulty in the BF operation. The decline of the BF stability requires higher and more elaborate operational techniques. A reasonable and compatible BF comprehensive operating system,as the base of the BF stabilization,is desired to satisfy the demand of large-scaled BF developments. Based on the practical operation of Baosteel No. 3 BF in 2010, the present work analyzes and discusses the basic rules of large-scaled BF stable control techniques,and further optimizes and improves its gas flow control techniques, develops strategies against the decline in fuel quality, which will contribute to the promotion of largescaled BF operational techniques progress.

Mechanism of zinc damaging to blast furnace tuyere refractory

The phenomena of tuyere upward-warp have been found at No.6 blast furnace in Kunming Steel Company China after its blow-in, which has made a great impact on the practical production of the furnace. Thus, a number of efforts have been made to elucidate the mechanism of this phenomenon. The results of investigation and tests revealed that the enrichment and expansion of zinc in the tuyere bricks is the main factor leading to the tuyere upward-warp. The eroding behavior of zinc is that the inner structure of the tuyere bricks turns from dense to loose with entering, enriching and expanding of zinc, which forms spot-like→stripe-like→ditch-like→vein-like→tumorlike eroding passage. Additionally, it is found that the sequence of deleterious ele- ments entering the tuyere refractory is K, Na, Zn and Pb, respectively. Finally, the phenomena and process of zinc crystallization and growth in the refractory have been clearly observed and recorded during this investigation.

Gasification kinetics of bulk coke in the CO2/CO/H2/H2O/N2 system simulating the atmosphere in the industrial blast furnace

The gasification characteristics and gasification kinetics of coke in complex CO2/CO/H2/H2O/N2 systems similar to the gas system of industrial blast furnace (BF) were studied by the method of isothermal thermogravimetric analysis. The experimental gas compositions and the corresponding temperature were chosen according to data reported for industrial BFs. The gasification behavior of coke was described by the Random Pore Model (RPM), Volumetric Model (VM), and Grain Model (GM). Results showed that the gas composition of the coke gasification zone in BF changes slightly and that the temperature is the most important factor affecting coke gasification. The lower activation energy of coke samples (Coke Reaction Index (CRI)>50) is due to the high Fe2O3 in the ash, lower degree of graphitization, and larger pore structure. In addition, the choice of kinetic model does not differ substantially in describing the gasification mechanism of coke in a BF.

Numerical Simulation of Innovative Operation of Blast Furnace Based on Multi-Fluid Model

A multi-fluid blast furnace model was simply introduced and was used to simulate several innovative ironmaking operations. The simulation results show that injecting hydrogen bearing materials, especially injecting natural gas and plastics, the hydrogen reduction is enhanced, and the furnace performance is improved simultaneously. Total heat input shows obvious decrease due to the decrease of heat consumption in direct reduction, solution loss and silicon transfer reactions. If carbon composite agglomerates are charged into the furnace, the temperature of thermal reserve zone will obviously decrease, and the reduction of iron-bearing burden materials will be retarded. However, the efficiency of blast furnace is improved just due to the decrease in heat requirements for solution loss, sinter reduction, and silicon transfer reactions, and less heat loss through top gas and furnace wall. Finally, the model is used to investigate the performance of blast furnace under the condition of top gas recycling together with plastics injection, cold oxygen blasting and carbon composite agglomerate charging. The lower furnace temperature, extremely accelerated reduction rate, drastically decreased CO2 emission and remarkably enhanced heat efficiency were obtained by using the innovative operations, and the blast furnace operation with superhigh efficiency can be realized.