Mathematical Model of Hearth and Bottom Erosion in Blast Furnace

Furnace lining erosion is closely related to the operation stability and safety. The detection technology for hearth lining thickness of blast furnace was introduced.By using the data of thermocouples installed in the bottom of furnace hearth,a mathematical model of erosion was established; the real state of the hearth and bottom erosion was studied; the erosion condition was followed,serving for the furnace longevity.

Numerical simulation for the lower shaft and the hearth bottom of blast furnace

One of the methods forming the shell is to appropriately design the coolingstaves and hearth without overheating during the campaign life of the furnace. The three-dimensionalsteady mathematical models for calculating the temperature distribution in the coolers andtwo-dimensional unsteady mathematical models with phase-change latent heat for calculating thetemperature distribution of the hearth bottom were established. The calculation results show thatthe formation of the slag-metal protection shell can be achieved by optimizing the design parametersof the coolers. Increasing the heat conductivity of the carbon brick can move the isothermal lineof 1150 deg C upward outside the hearth bottom.

Numerical modeling of multiphase flow,heat transfer and titanium flow behavior in blast furnace hearth

Understanding the complex phenomena in BF hearth is essential to increase furnace productivity and to extend furnace campaign.We have developed several continuum-based mathematical/numerical models to simulate the multi-phase flow,heat transfer and chemical reactions in the BF hearth.These models have generated an improved insight on the mechanisms for liquid drainage efficiency,lining erosion and wall protection in BF hearth under operational conditions.The current paper gives an overview of these studies in three aspects:Gas flow and pressure on the liquid surface,and their effect on the drainage characteristics;The flow and temperature distributions of liquid iron in BF hearth,and the temperature distribution in the refractories;Finally,titanium behaviors due to titania injection to form Ti(C,N) -rich scaffold on the hearth surface,to protect the hearth from erosion.

Mathematical model of burden distribution for the bell-less top of a blast furnace

Due to the difficulty in measuring the burden trajectory directly in an actual blast furnace （BF）, a mathematical model with Coriolis force and gas drag force considered was developed to predict it. The falling point and width of the burden flow were obtained and analyzed by the model, the velocities of particles at the chute end were compared with and without the existence of Coriolis force, and the effects of chute length and chute torque on the falling point were also discussed. The simulation results are in good agreement with practical measurements with laser beams in a 2500 m3 BF.

Designing for Long Campaign Life Blast Furnace (1)──The Mathematical Model of Temperature Field for Blast Furnace Lining and Cooling Apparatus and New Concept of Long Campaignship Blast Furnace Cooler Design

The physical and mathematical model of temperature field for blast furnace stave coolers was established. The computation results show that the heat resistance of 2-6 mm water scale within the cooling pipe is about 7%-20% of the total heat resistance of cooling stave body, as for drilling duct type, the heat resistance of 2-6 mm water scale is about 88%-98% of the total heat resistance. Using drilling duct or full cast pipe can eliminate gas clearance and coating layer between pipes and cast iron body and reduce the heat resistance of the cooler sharply and improve the coefficient of heat transfer to a great extent. The water velocity within coolers can be kept at the 1evel of 0.5- 1 .5 m/s, the higher water velocity can not decrease the hot surface temperature, but can increase energy consumption for cooling water.

A mathematical model capable of describing the liquid flow mainly in a blast furnace

The molten liquid flow inside a packed bed is a familiar momentum transportation phenomenon in a blast furnace. With regard to the reported mathematical models describing the liquid flow within a packed bed, there are some obstacles for their application in engineering design, or some limitations in the model itself. To overcome these problems, the forces from the packed bed to the liquid flow were divided into appropriate body and surface forces on the basis of three assumptions. Consequently, a new mathematical model was built to present the liquid flow inside the coke bed in a blast furnace. The mathematical model can predict the distribution of liquid flowrate and the liquid flowing range inside the packed bed at any time. The predicted results of this model accord well with the experimental data. The model will be applied considerably better in the simulation on the ironmaking process compared with the existent models.

3D model study of coal/coke combustion in a blast furnace effects of coal properties

A three-dimensional mathematical model of the combustion of pulverized coal and coke has been developed.The model is applied to the blowpipe-tuyere-raceway-coke bed region in an ironmaking blast furnace in one computational domain,which includes two parts:pulverized coal combustion model in the blowpipe-tuyere-raceway cavity and the coal/coke combustion model in the surrounding coke bed.The effects of coal properties are examined comprehensively,in terms of coal burnout and gas species distributions.The results indicate that using a coal of fine particle size or high VM content could improve burnout and would affect the gas composition considerably.The burnout is examined in two ways:compared with burnout along tuyere axis,burnout over the raceway surface is a more sensitive and sensible parameter to describe the amount of unburnt char entering the coke bed.The model is useful for examining the flow-thermo-chemical characteristics of the pulverized coal injection (PCI) process under various conditions in a blast furnace.

Development and Introduction of Monitoring System of Refractory Lining Wear in Blast Furnace Hearth

To diagnose the lining condition of the blast furnace hearth during its campaign, are widely used methods based on the analysis of the temperature characteristics of the refractory lining. Measurement of the temperature characteristics is performed by means of a few hundred thermocouples placed inside the refractory lining. The peculiarity of proposed and used mathematical models is a fully three-dimensional assessment of the refractory lining, presence mechanisms of adaptation to the actual thermal conductivity of refractories and optimization calculations to the work in the on-line mode. The new monitoring systems of the lining wear of the blast furnace hearth are established on 5 blast furnaces of integrated iron-and-steel works of China： No.4 by volume 3,200 m3 of “Jinan Iron ＆ Steel Company” in Jinan （683 thermocouples）, No.2 by volume 1,080 m3 of “Henan Jiyuan Iron ＆ Steel （Group） Company” in Jiyuan （212 thermocouples）, No.4 by volume 2,500 m3 of “Guangxi Liuzhou Iron ＆ Steel （Group） Company” in Liuzhou （383 thermocouples）, No.3 by volume 1,750 m3 of “Jinan Iron ＆ Steel Company” in Jinan （524 thermocouples）; No.1 by volume 1,750 m3 of “Jinan Iron ＆ Steel Company” in Jinan （524 thermocouples）.

Zonal method solution of radiative heat transfer in a one-dimensional long roller-hearth furnace in CSP

A radiative heat transfer mathematical model for a one-dimensional long furnace was set up in a through-type roller-hearth furnace （TTRHF） in compact strip production （CSP）. To accurately predict the heat exchange in the furnace, modeling of the complex gas energy-balance equation in volume zones was considered, and the heat transfer model of heating slabs and wall lines was coupled with the radiative heat transfer model to identify the surface zonal temperature. With numerical simulation, the temperature fields of gas, slabs, and wall lines in the furnace under one typical working condition were carefully accounted and analyzed. The fundamental theory for analyzing the thermal process in TI＇RI-IF was provided.

Investigating effect of coke porosity on blast furnace performance based on multi-physical fields

Reducing coke use is an effective measure to reduce carbon emission and energy consumption in the blast furnace(BF)ironmaking.Essentially,BF is a high-temperature moving bed reactor,where complex physical transformations coupled with complicated reactions occur.This makes it challenging to investigate the factors determining BF performance with the conventional method.A multi-physical field coupling mathematical model of BF was thus developed to describe its mass and heat transfer as well as its intrinsic reactions.Then,the proposed model was validated with the production data.Under coupling conditions,influences of dominating reactions on BF performance(temperature distribution,gas distribution,iron formation reaction,and direct reduction degree)were revealed.The results indicated that coke combustion,indirect reduction,and direct reduction of iron ore mainly took place nearby the shaft tuyere,cohesive zone,and dripping zone,respectively.Besides,the rate of coke solution loss reaction was increased with the rising coke porosity in the cohesive zone.Considering the effect of coke porosity on the efficiency and stability of BF,the coke porosity of 0.42 was regarded as a reasonable value.

Influence of furnace temperature and non-uniform heat flux density on direct reduction process of newly designed carbon containing pellet

In this study,innovative ellipsoid pellet with craters on its surface was designed,and the direct reduction process was compared with ellipsoid(without craters)and sphere pellets.In addition,furnace temperature and uneven heat flux density effects on the pellet direct reduction process were also studied.The results show that ellipsoid pellet is better than that of spherical pellet on metallization ratio.However,under the condition of non-uniform heat flow,the ellipsoid pellet final metallization rate and zinc removal rate were lower.Although the heat transfer effect of ellipsoid pellet with craters was not improved significantly,the metallization rate and zinc removal rate were found improved,which will have a cumulative effect on the pellets direct reduction process in rotary hearth furnace.Under varying furnace temperature conditions,the pellet temperature was higher than that of the constant furnace temperature.After 1200 s,pellet Fe concentration increased to 123.6%,metallization rate and zinc removal rate increased to 113.7%and 102.2%,respectively.These results can provide references for the carbon-containing pellet design used in rotary hearth furnace.

Mathematical model of burden distribution in bell-less top blast furnace

The burden distribution in the shaft of blast furnace is known to affect the gas distribution,heat transfer,and chemical reactions inside the furnace.However,the internal layer structure of burden in the shaft cannot be directly measured.Hence,a mathematical model for evaluating burden profile and layer structure was established.A sensitivity analysis based on the model was implemented to elucidate the effect of some factors on the burden distribution,including the stockline height and the mass of central coke.The results show that the width of funnel zone widens with the increase in stockline height,and the mass percentage of ore to coke in this zone slightly increases.Besides,the mass of central coke shows a significant influence on the width of coke channel,and 2%of batch mass of coke is recommended to implement central coke charging operation.The model has been indirectly verified by the gas temperature in operating blast furnace and successfully applied to online evaluate burden distribution.

含钛高炉渣制备复合吸附剂及其铬吸附性能

Cr(Ⅵ)是一种有害污染物,既污染水环境,也会对人体造成伤害。本文以工业固废含钛高炉渣为原料,通过酸浸得到浸出渣基体,经壳聚糖改性,制备一种新型GLZ-jcz/CS复合吸附剂,用来去除废水中的Cr(Ⅵ)。研究了吸附温度、废水pH、吸附剂量、Cr(Ⅵ)初始浓度、吸附时间对Cr(Ⅵ)吸附性能的影响。以Cr(Ⅵ)吸附率为评价指标,确定最优实验条件,并研究了GLZ-jcz/CS复合吸附剂的再生性能。采用扫描电子显微镜、傅里叶红外变换光谱仪、X射线光电子能谱仪、BET比表面积测试仪对GLZ-jcz/CS复合吸附剂进行表征,结合吸附动力学模型和吸附等温线模型分析,确定吸附机理。实验结果表明:当吸附温度为70℃、废水pH=4、吸附剂用量为0.13g、Cr(Ⅵ)初始浓度为50mg/L、吸附时间为2h时,吸附率达到99.8%,吸附容量可以达到67mg/g,GLZ-jcz/CS复合吸附剂经过6次洗脱,吸附率仍可达到96%以上,吸附模型符合拟二级动力学模型和Langmuir吸附等温模型。

Mathematical Model and Its Hybrid Dynamic Mechanism in Intelligent Control of Ironmaking

A hybrid dynamic model was proposed, which considered both the hydrokinetic and the chaotic properties of the blast furnace ironmaking process; and great emphasis was put on its mechanism. The new model took the high complexity of the blast furnace as well as the effects of main parameters of the model into account, and the predicted results were in very good agreement with actual data.

Mathematical model of the direct reduction of dust composite pellets containing zinc and iron

Direct reduction of dust composite pellets containing zinc and iron was examined by simulating the conditions of actual production process of a rotary hearth furnace （RHF） in laboratory. A mathematical model was constructed to study the reduction kinetics of iron oxides and ZnO in the dust composite pellets. It was validated by comparing the calculated values with experimental results. The effects of furnace temperature, pellet radius, and pellet porosity on the reduction were investigated by the model. It is shown that furnace temperature has obvious influence on both of the reduction of iron oxides and ZnO, but the influence of pellet radius and porosity is much smaller. Model calculations suggest that both of the reduction of iron oxides and ZnO are under mixed control with interface reactions and Boudouard reaction in the early stage, but only with interface reactions in the later stage.

基于运动轨迹和径向距离的高炉料面堆积形状建模方法

高炉料面形貌是反映煤气流分布和煤气利用率的关键指标,研究高炉料面炉料堆积形状数学建模方法对实现高炉精准布料控制和“双碳”战略在钢铁行业落地具有重要意义.针对高炉多环布料情况下料面堆积形状预测难的问题,本文提出了一种基于炉料运动轨迹和径向移动距离的高炉料面炉料堆积形状建模方法.首先,提出了一种与炉料初始状态和溜槽状态相关的炉料运动轨迹建模方法,获取炉料从节流阀至料面的炉料运动轨迹,并确定炉料在炉喉空区的内轨迹曲线和外轨迹曲线.然后,基于炉料运动轨迹和初始料面形状,以体积守恒原则为约束,提出了一种基于炉料径向移动距离的高炉料面炉料堆积形状数学建模方法,获取炉料在料面的堆积形状.最后,基于某钢铁厂2#高炉的尺寸建立离散单元法(Discrete element method,DEM)仿真模型,模型仿真结果验证了所提方法的准确性和有效性.

高炉内料层结构动态追踪的技术开发

炉料径向分布影响着高炉下部所形成软熔带的形状和位置,进而间接决定和控制了高炉燃料比的高低.建立了预测高炉内部料层结构的数学模型,并将其转化为可视化界面的软件,供现场人员在线使用,用于计算不同布料参数下料层结构的详细信息,布料参数包括布料矩阵、料线高度、布料方向、径向下降速度分布,预测结果包括径向矿焦比分布、追踪料层位置、料层厚度变化.计算结果均可为现场布料制度优化提供参考依据.

高炉炼铁大数据技术的发展现状与思考

因缺少废钢资源,我国钢铁生产将长期采用高炉-转炉长流程工艺,高炉操作至今仍主要依赖于人类专家的经验。从高炉数学模型、炼铁知识获取与应用、过程数据的获取等方面阐述了高炉炼铁大数据技术的发展现状,并提出了推进高炉炼铁大数据技术的思考。认为各种类型的数学模型是工业软件,在炼铁大数据技术中处于核心地位,但需要针对不同高炉的具体条件研究开发;对高炉内衬工作状态、炉缸内渣铁蓄积量、风口回旋区煤气焦炭,以及滴落带渣铁行为等的在线监测需要先进的检测技术;加强高炉下部焦炭降级行为的研究是高炉炼铁大数据技术发展的迫切需要。

包钢7号高炉炉缸活跃性量化模型的开发及应用

针对包钢7号高炉的生产操作特点,开发了涵盖高炉炉缸透液水平、高炉透气水平、渣铁热水平、人炉焦炭质量等,以“天”为计量单位和以“铁次”为计量单位的高炉炉缸活跃性量化模型。7号高炉炉缸活跃性量化模型的应用结果表明:炉缸活跃性评价分值>80,炉缸活跃性良好;炉缸活跃性评价分值73~80,炉缸活跃性一般;炉缸活跃性评价分值60~73,炉缸活跃性较差,需及时调整以保证炉况顺行;炉缸活跃性评价分值<60,炉缸活跃性极差,需加大调整力度,及时恢复到正常水平,避免高炉出现失常现象。

高炉渣基沸石分子筛材料的制备及其响应面优化

以高炉渣(BFS)为原料制备高炉渣基沸石分子筛(BFSZ),为实现对BFSZ制备工艺条件的优化,基于单因素试验结果,采用Box-Behnken Design(BBD)响应面法考察晶化时间(A)、晶化温度(B)、初始硅铝物质的量比(C)等因素对BFSZ阳离子交换量(CEC)的影响。结果表明:响应面法建立的回归模型方程具有高度的显著性,可信度和精确度较高,得到制备BFSZ的优化工艺条件:碱熔温度为600℃、液固比为5∶1 mL/g、晶化时间为8.74 h、晶化温度为98.41℃、初始硅铝物质的量比1.18,此时BFSZ的CEC为3.21 meq/g。经验证,BFSZ的CEC实际值与预测值的相对误差约为1.9%,表明该模型能够很好地反映各因素对BFSZ的CEC影响。