To reduce the fuel consumption and emissions and also enhance the molten aluminum quality,a mathematical model with user-developed melting model and burning capacity model,were established according to the features of...To reduce the fuel consumption and emissions and also enhance the molten aluminum quality,a mathematical model with user-developed melting model and burning capacity model,were established according to the features of melting process of regenerative aluminum melting furnaces.Based on validating results by heat balance test for an aluminum melting furnace,CFD(computational fluid dynamics) technique,in association with statistical experimental design were used to optimize the melting process of the aluminum melting furnace.Four important factors influencing the melting time,such as horizontal angle between burners,height-to-radius ratio,natural gas mass flow and air preheated temperature,were identified by PLACKETT-BURMAN design.A steepest descent method was undertaken to determine the optimal regions of these factors.Response surface methodology with BOX-BEHNKEN design was adopted to further investigate the mutual interactions between these variables on RSD(relative standard deviation) of aluminum temperature,RSD of furnace temperature and melting time.Multiple-response optimization by desirability function approach was used to determine the optimum melting process parameters.The results indicate that the interaction between the height-to-radius ratio and horizontal angle between burners affects the response variables significantly.The predicted results show that the minimum RSD of aluminum temperature(12.13%),RSD of furnace temperature(18.50%) and melting time(3.9 h) could be obtained under the optimum conditions of horizontal angle between burners as 64°,height-to-radius ratio as 0.3,natural gas mass flow as 599 m3/h,and air preheated temperature as 639 °C.These predicted values were further verified by validation experiments.The excellent correlation between the predicted and experimental values confirms the validity and practicability of this statistical optimum strategy.展开更多
According to the characteristics of the ther-motechnical parameters such as temperature pressure and glass level for glass melting furnace, the design method for monitoring and controlling these parameters is introduc...According to the characteristics of the ther-motechnical parameters such as temperature pressure and glass level for glass melting furnace, the design method for monitoring and controlling these parameters is introduced in this paper based on MACROMAX-2 concentrated and dis-tributedcontrol system. The configuration of management information and control loop is described, and research tests were performed to check the functions of system.展开更多
Under some assumptions and dividing the combustion space into several isothermal zones and isothermal surface elements, a two-dimensional mathematical model for combustion space in cross-fired glass melting furnaces w...Under some assumptions and dividing the combustion space into several isothermal zones and isothermal surface elements, a two-dimensional mathematical model for combustion space in cross-fired glass melting furnaces was constructed. The finite element method and the Gauss integration were used to calculate direct ex-change areas, and a inverse matrix was used to obtained the total ex-change areas. The temperature distributions were obtained by itera-tions. Some results were presented to show the effects of the fire tem-perature distribution, the convective -heat transfer coefficients and the heat losses through crown surfaces on the temperature distributions.展开更多
Regenerator checkerwork for glass melting furnaces should have high resistance against thermal stress and chemical attack,high mechanical stability,high efficiency to recover the heat from waste gas and low tendency f...Regenerator checkerwork for glass melting furnaces should have high resistance against thermal stress and chemical attack,high mechanical stability,high efficiency to recover the heat from waste gas and low tendency for clogging.This article reviews the innovation of the regenerator checkerwork from the past decades.The state of the art for optimised material choice and optimised checker shapes will be reported.展开更多
A system-level evaluation was used to analyze the induction furnace operation and process system in this study. This paper presents an investigation into the relationship between the instantaneous chemical composition...A system-level evaluation was used to analyze the induction furnace operation and process system in this study. This paper presents an investigation into the relationship between the instantaneous chemical composition of a molten bath and its energy consumption in steelmaking. This was evaluated using numerical modelling to solve for the estimated melting time prediction for the induction furnace operation. This work provides an insight into the lowering of energy consumption and estimated production time in steelmaking using material charge balancing approach. Enthalpy computation was implemented to develop an energy consumption model for the molten metal using a specific charge composition approach. Computational simulation program engine (CastMELT) was also developed in Java programming language with a MySQL database server for seamless specific charge composition analysis and testing. The model performance was established using real-time production data from a cast iron-based foundry with a 1 and 2-ton induction furnace capacity and a medium carbon-based foundry with a 10- and 15-ton induction furnace capacity. Using parameter fitting techniques on the measured operational data of the induction furnaces at different periods of melting, the results from the model predictions and real-time melting showed good correlation between 81% - 95%. A further analysis that compared the relationship between the mass composition of a current molten bath and melting, time showed that energy consumption can be reduced with effective material balancing and controlled charge. Melting time was obtained as a function of the elemental charge composition of the molten bath in relation to the overall scrap material charge. This validates the approach taken by this research using material charge and thermodynamic of melting to optimize and better control melting operation in foundry and reduce traditional waste during iron and steel making.展开更多
1 Scope This standard specifies the brand, technical requirements, test methods, inspection rules, marking, packing, transportation, storage, and quality certificate of sintered AZS bricks for glass melting furnace. ...1 Scope This standard specifies the brand, technical requirements, test methods, inspection rules, marking, packing, transportation, storage, and quality certificate of sintered AZS bricks for glass melting furnace. This standard is applicable to sintered AZS bricks for glass melting furnace.展开更多
JC/T 494-92(96) 1 ScopeThis standard specifies the technical requirements, test methods, inspection rules, marking, packing, transportation, and storage of fused cast alumina refractory products for glass melting furn...JC/T 494-92(96) 1 ScopeThis standard specifies the technical requirements, test methods, inspection rules, marking, packing, transportation, and storage of fused cast alumina refractory products for glass melting furnace. This standard is applicable to the fused cast alumina refractory products for glass melting furnace (called products for short).2 Normative ReferencesGB 2997 Test method for apparent porosity, water absorption, bulk density and true porosity of dense shaped refractory productsGB 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 10204 Test method for corrosion resistance of refractories for glass melting furnace to molten glassGB 10325 Stacking, sampling, acceptance, storage and transportation of shaped refractory productsGB 10326 Inspections of dimension, appearance and section of refractory productsGB/T 14351 Chemical analysis method of fused cast alumina refractoriesYB 4015 Sample preparation for testing of refractory products for glass melting furnaceYB 4016 Sampling and inspection of refractory products for glass melting furnaceJC 493 Fused cast zirconia corundum refractory products for glass melting furnace展开更多
1 Scope This standard specifies the classification, technical requirements, test method, inspection rules, marking, packing, transportation, storage and quality certification of silica refractory bricks for glass mel...1 Scope This standard specifies the classification, technical requirements, test method, inspection rules, marking, packing, transportation, storage and quality certification of silica refractory bricks for glass melting furRaces.展开更多
This standard specifies the classification, technical requirements, test methods, inspection rules, marking, packing, transportation, storage and quality certificate of low porosity fireclay bricks for glass melting f...This standard specifies the classification, technical requirements, test methods, inspection rules, marking, packing, transportation, storage and quality certificate of low porosity fireclay bricks for glass melting furnace.展开更多
This standard specifies the classification, technical requirements, test method, inspection rules, marking, packing, transportation, storage and quality certification of high quality silica bricks for glass melting fu...This standard specifies the classification, technical requirements, test method, inspection rules, marking, packing, transportation, storage and quality certification of high quality silica bricks for glass melting furnace.展开更多
The conditions and points for attentions of molybdenum electrode, which used in glass melting furnace, are introduced. Problems in corrosion of molybdenum electrodes are analyzed through the glass components, temperat...The conditions and points for attentions of molybdenum electrode, which used in glass melting furnace, are introduced. Problems in corrosion of molybdenum electrodes are analyzed through the glass components, temperature and current density, and how to eliminate bubble formation on the process. At last, the specific requests of the applications of molybdenum electrode in glass industry are presented.展开更多
The effect of sinter with different MgO contents on the softening-melting behavior of mixed burden made from chro- mium-bearing vanadium-titanium magnetite was investigated. The results show that with increasing MgO c...The effect of sinter with different MgO contents on the softening-melting behavior of mixed burden made from chro- mium-bearing vanadium-titanium magnetite was investigated. The results show that with increasing MgO content in the sinter, the softening interval and melting interval increased and the location of the cohesive zone shifted downward slightly and became moderately thicker. The softening-melting characteristic value was less pronounced when the MgO content in the sinter was 2.98wt%-3.40wt%. Increasing MgO content in the sinter reduced the content and recovery of V and Cr in the dripped iron. In addition, greater MgO contents in the sinter resulted in the generation of greater amounts of high-melting-point components, which adversely affected the permeability of the mixed burden. When the softening-melting behavior of the mixed burden and the recovery of valuable elements were taken into account, proper MgO con- tents in the sinter and slag ranged from 2.98wt% to 3.40wt% and from 11.46wt% to 12.72wt%, respectively, for the smelting of burden made from chromium-bearing vanadium-titanium magnetite in a blast furnace.展开更多
The effect of sinter basicity on softening-melting behaviors of mixed burden made from chromium-bearing vanadium-titanium magnetite(Cr-V-Ti magnetite) was investigated and the function mechanism was simultaneously ana...The effect of sinter basicity on softening-melting behaviors of mixed burden made from chromium-bearing vanadium-titanium magnetite(Cr-V-Ti magnetite) was investigated and the function mechanism was simultaneously analyzed.The results show that with increasing sinter basicity from 1.71 to 2.36,the softening interval tends to increase from 149.3 ℃ to 181.7 ℃while the melting interval tends to decrease from 178.0 ℃ to 136.7 ℃.The location of cohesive zone moves downwards firstly and then ascends slightly,but the cohesive zone becomes thinner.The softening-melting characteristic value becomes small,which indicates that the permeability of burden column is improved.The dripping ratio of mixed burden tends to increase firstly and then decrease,which comes to the highest value of 74.50%when the sinter basicity is 2.13.The content and the recovery of V and Cr in dripping iron are all increased.The generation amount of components with high melting point in slag becomes little with the increase of sinter basicity,which could improve the permeability of mixed burden.Taking softening-melting behaviors of mixed burden and recovery of valuable elements into account,the proper sinter basicity is no less than 2.13 for smelting mixed burden made from Cr-V-Ti magnetite in blast furnace.展开更多
Iron carbon agglomerates(ICA)are the composite burden for low-carbon blast furnace(BF)ironmaking.In order to optimize the reactivity of ICA according to the evolution characteristics of ICA in the BF smelting process,...Iron carbon agglomerates(ICA)are the composite burden for low-carbon blast furnace(BF)ironmaking.In order to optimize the reactivity of ICA according to the evolution characteristics of ICA in the BF smelting process,the evolution behavior and mechanism of different reactive ICA under simulated BF smelting conditions were studied.The results show that the existence of more sillimanite and aluminosilicate and less active sites of metallic iron will weaken gasification reaction and carburization ability of ICA-1(containing 10%iron ore).It weakens the promoting effect of ICA-1 on the reduction,softening,and melting of ferrous burdens and the dripping of slag-iron.The aluminosilicate with a high melting point decreases,the low melting point slag phase and Fe–Si alloy increase,and many active sites of metallic iron exist,which strengthen the gasification reaction and carburization ability of ICA-2(containing 30%iron ore).The promoting effect of ICA-2 on the reduction,softening,and melting of ferrous burdens and the dripping of slag-iron is significantly improved.The gasification reaction capacity of ICA-3(containing 35%iron ore)is reduced,and the improvement in ICA-3 on the softening–melting performance of mixed burdens is reduced.The appropriate proportion of iron ore in ICA is about 30%.展开更多
In the paper, the characters and fields were introduced for utilizing the Series/Parallel Switch (SPS). The circuit principle of the SPS technology was analyzed in detailed, explained and illuminated. We understood cl...In the paper, the characters and fields were introduced for utilizing the Series/Parallel Switch (SPS). The circuit principle of the SPS technology was analyzed in detailed, explained and illuminated. We understood clearly the difference between SPS and single-phase transformator by the figure and table. Finally, it summarized that the main characters of SPS.展开更多
The energy required for continuous glass melting usually accounts for about 30~75% of the total energy consumptions supplied to the glass industry, and the energy cost contributes to about 10~25% of total glass manufa...The energy required for continuous glass melting usually accounts for about 30~75% of the total energy consumptions supplied to the glass industry, and the energy cost contributes to about 10~25% of total glass manufacturing cost depending upon the type of glass and manufacturing efficiency. Typically, energy efficiency of glass furnaces offers major opportunities for manufacturing cost reduction.Significant rising of energy cost, environmental requirements for clean air and pressure for reducing global warming and carbon dioxide emissions, as well as the cost of capitals are main drivers for the technology developments. In this paper, energy efficiency of glass furnaces is discussed. Technology developments in selective batching, oxy-fuel firing with preheating batch and cullet, non-conventional advanced melting systems, such as segmented glass melting and submerged combustion melting, as well as using math modeling to optimize fuel distribution for energy savings are presented.展开更多
基金Project(2009BSXT022) supported by the Dissertation Innovation Foundation of Central South University, ChinaProject(07JJ4016) supported by Natural Science Foundation of Hunan Province, ChinaProject(U0937604) supported by National Natural Science Foundation of China
文摘To reduce the fuel consumption and emissions and also enhance the molten aluminum quality,a mathematical model with user-developed melting model and burning capacity model,were established according to the features of melting process of regenerative aluminum melting furnaces.Based on validating results by heat balance test for an aluminum melting furnace,CFD(computational fluid dynamics) technique,in association with statistical experimental design were used to optimize the melting process of the aluminum melting furnace.Four important factors influencing the melting time,such as horizontal angle between burners,height-to-radius ratio,natural gas mass flow and air preheated temperature,were identified by PLACKETT-BURMAN design.A steepest descent method was undertaken to determine the optimal regions of these factors.Response surface methodology with BOX-BEHNKEN design was adopted to further investigate the mutual interactions between these variables on RSD(relative standard deviation) of aluminum temperature,RSD of furnace temperature and melting time.Multiple-response optimization by desirability function approach was used to determine the optimum melting process parameters.The results indicate that the interaction between the height-to-radius ratio and horizontal angle between burners affects the response variables significantly.The predicted results show that the minimum RSD of aluminum temperature(12.13%),RSD of furnace temperature(18.50%) and melting time(3.9 h) could be obtained under the optimum conditions of horizontal angle between burners as 64°,height-to-radius ratio as 0.3,natural gas mass flow as 599 m3/h,and air preheated temperature as 639 °C.These predicted values were further verified by validation experiments.The excellent correlation between the predicted and experimental values confirms the validity and practicability of this statistical optimum strategy.
文摘According to the characteristics of the ther-motechnical parameters such as temperature pressure and glass level for glass melting furnace, the design method for monitoring and controlling these parameters is introduced in this paper based on MACROMAX-2 concentrated and dis-tributedcontrol system. The configuration of management information and control loop is described, and research tests were performed to check the functions of system.
文摘Under some assumptions and dividing the combustion space into several isothermal zones and isothermal surface elements, a two-dimensional mathematical model for combustion space in cross-fired glass melting furnaces was constructed. The finite element method and the Gauss integration were used to calculate direct ex-change areas, and a inverse matrix was used to obtained the total ex-change areas. The temperature distributions were obtained by itera-tions. Some results were presented to show the effects of the fire tem-perature distribution, the convective -heat transfer coefficients and the heat losses through crown surfaces on the temperature distributions.
文摘Regenerator checkerwork for glass melting furnaces should have high resistance against thermal stress and chemical attack,high mechanical stability,high efficiency to recover the heat from waste gas and low tendency for clogging.This article reviews the innovation of the regenerator checkerwork from the past decades.The state of the art for optimised material choice and optimised checker shapes will be reported.
文摘A system-level evaluation was used to analyze the induction furnace operation and process system in this study. This paper presents an investigation into the relationship between the instantaneous chemical composition of a molten bath and its energy consumption in steelmaking. This was evaluated using numerical modelling to solve for the estimated melting time prediction for the induction furnace operation. This work provides an insight into the lowering of energy consumption and estimated production time in steelmaking using material charge balancing approach. Enthalpy computation was implemented to develop an energy consumption model for the molten metal using a specific charge composition approach. Computational simulation program engine (CastMELT) was also developed in Java programming language with a MySQL database server for seamless specific charge composition analysis and testing. The model performance was established using real-time production data from a cast iron-based foundry with a 1 and 2-ton induction furnace capacity and a medium carbon-based foundry with a 10- and 15-ton induction furnace capacity. Using parameter fitting techniques on the measured operational data of the induction furnaces at different periods of melting, the results from the model predictions and real-time melting showed good correlation between 81% - 95%. A further analysis that compared the relationship between the mass composition of a current molten bath and melting, time showed that energy consumption can be reduced with effective material balancing and controlled charge. Melting time was obtained as a function of the elemental charge composition of the molten bath in relation to the overall scrap material charge. This validates the approach taken by this research using material charge and thermodynamic of melting to optimize and better control melting operation in foundry and reduce traditional waste during iron and steel making.
文摘1 Scope This standard specifies the brand, technical requirements, test methods, inspection rules, marking, packing, transportation, storage, and quality certificate of sintered AZS bricks for glass melting furnace. This standard is applicable to sintered AZS bricks for glass melting furnace.
文摘JC/T 494-92(96) 1 ScopeThis standard specifies the technical requirements, test methods, inspection rules, marking, packing, transportation, and storage of fused cast alumina refractory products for glass melting furnace. This standard is applicable to the fused cast alumina refractory products for glass melting furnace (called products for short).2 Normative ReferencesGB 2997 Test method for apparent porosity, water absorption, bulk density and true porosity of dense shaped refractory productsGB 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 10204 Test method for corrosion resistance of refractories for glass melting furnace to molten glassGB 10325 Stacking, sampling, acceptance, storage and transportation of shaped refractory productsGB 10326 Inspections of dimension, appearance and section of refractory productsGB/T 14351 Chemical analysis method of fused cast alumina refractoriesYB 4015 Sample preparation for testing of refractory products for glass melting furnaceYB 4016 Sampling and inspection of refractory products for glass melting furnaceJC 493 Fused cast zirconia corundum refractory products for glass melting furnace
文摘1 Scope This standard specifies the classification, technical requirements, test method, inspection rules, marking, packing, transportation, storage and quality certification of silica refractory bricks for glass melting furRaces.
文摘This standard specifies the classification, technical requirements, test methods, inspection rules, marking, packing, transportation, storage and quality certificate of low porosity fireclay bricks for glass melting furnace.
文摘This standard specifies the classification, technical requirements, test method, inspection rules, marking, packing, transportation, storage and quality certification of high quality silica bricks for glass melting furnace.
文摘The conditions and points for attentions of molybdenum electrode, which used in glass melting furnace, are introduced. Problems in corrosion of molybdenum electrodes are analyzed through the glass components, temperature and current density, and how to eliminate bubble formation on the process. At last, the specific requests of the applications of molybdenum electrode in glass industry are presented.
基金the National Natural Science Foundation of China (51574067)the National High Technology Research and Development Program of China (2012AA062302 and 2012AA062304)the Fundamental Research Funds for the Central Universities of China (N110202001)
文摘The effect of sinter with different MgO contents on the softening-melting behavior of mixed burden made from chro- mium-bearing vanadium-titanium magnetite was investigated. The results show that with increasing MgO content in the sinter, the softening interval and melting interval increased and the location of the cohesive zone shifted downward slightly and became moderately thicker. The softening-melting characteristic value was less pronounced when the MgO content in the sinter was 2.98wt%-3.40wt%. Increasing MgO content in the sinter reduced the content and recovery of V and Cr in the dripped iron. In addition, greater MgO contents in the sinter resulted in the generation of greater amounts of high-melting-point components, which adversely affected the permeability of the mixed burden. When the softening-melting behavior of the mixed burden and the recovery of valuable elements were taken into account, proper MgO con- tents in the sinter and slag ranged from 2.98wt% to 3.40wt% and from 11.46wt% to 12.72wt%, respectively, for the smelting of burden made from chromium-bearing vanadium-titanium magnetite in a blast furnace.
基金Project(51574067)supported by the National Natural Science Fundation of ChinaProjects(2012AA062302,2012AA062304)supported by the National High Technology Research and Development Program of ChinaProject(N110202001)supported by the Fundamental Research Funds for the Central Universities of China
文摘The effect of sinter basicity on softening-melting behaviors of mixed burden made from chromium-bearing vanadium-titanium magnetite(Cr-V-Ti magnetite) was investigated and the function mechanism was simultaneously analyzed.The results show that with increasing sinter basicity from 1.71 to 2.36,the softening interval tends to increase from 149.3 ℃ to 181.7 ℃while the melting interval tends to decrease from 178.0 ℃ to 136.7 ℃.The location of cohesive zone moves downwards firstly and then ascends slightly,but the cohesive zone becomes thinner.The softening-melting characteristic value becomes small,which indicates that the permeability of burden column is improved.The dripping ratio of mixed burden tends to increase firstly and then decrease,which comes to the highest value of 74.50%when the sinter basicity is 2.13.The content and the recovery of V and Cr in dripping iron are all increased.The generation amount of components with high melting point in slag becomes little with the increase of sinter basicity,which could improve the permeability of mixed burden.Taking softening-melting behaviors of mixed burden and recovery of valuable elements into account,the proper sinter basicity is no less than 2.13 for smelting mixed burden made from Cr-V-Ti magnetite in blast furnace.
基金This work was financially supported by the National Natural Science Foundation of China-Liaoning Joint Funds(U1808212)National Natural Science Foundation of China(52074080)Xingliao Talent Plan(XLYC1902118).
文摘Iron carbon agglomerates(ICA)are the composite burden for low-carbon blast furnace(BF)ironmaking.In order to optimize the reactivity of ICA according to the evolution characteristics of ICA in the BF smelting process,the evolution behavior and mechanism of different reactive ICA under simulated BF smelting conditions were studied.The results show that the existence of more sillimanite and aluminosilicate and less active sites of metallic iron will weaken gasification reaction and carburization ability of ICA-1(containing 10%iron ore).It weakens the promoting effect of ICA-1 on the reduction,softening,and melting of ferrous burdens and the dripping of slag-iron.The aluminosilicate with a high melting point decreases,the low melting point slag phase and Fe–Si alloy increase,and many active sites of metallic iron exist,which strengthen the gasification reaction and carburization ability of ICA-2(containing 30%iron ore).The promoting effect of ICA-2 on the reduction,softening,and melting of ferrous burdens and the dripping of slag-iron is significantly improved.The gasification reaction capacity of ICA-3(containing 35%iron ore)is reduced,and the improvement in ICA-3 on the softening–melting performance of mixed burdens is reduced.The appropriate proportion of iron ore in ICA is about 30%.
文摘In the paper, the characters and fields were introduced for utilizing the Series/Parallel Switch (SPS). The circuit principle of the SPS technology was analyzed in detailed, explained and illuminated. We understood clearly the difference between SPS and single-phase transformator by the figure and table. Finally, it summarized that the main characters of SPS.
文摘The energy required for continuous glass melting usually accounts for about 30~75% of the total energy consumptions supplied to the glass industry, and the energy cost contributes to about 10~25% of total glass manufacturing cost depending upon the type of glass and manufacturing efficiency. Typically, energy efficiency of glass furnaces offers major opportunities for manufacturing cost reduction.Significant rising of energy cost, environmental requirements for clean air and pressure for reducing global warming and carbon dioxide emissions, as well as the cost of capitals are main drivers for the technology developments. In this paper, energy efficiency of glass furnaces is discussed. Technology developments in selective batching, oxy-fuel firing with preheating batch and cullet, non-conventional advanced melting systems, such as segmented glass melting and submerged combustion melting, as well as using math modeling to optimize fuel distribution for energy savings are presented.
基金supported by the National Key R&D Program of China (No. 2019YFC1905703)Provincial Science and Technology Plan Projects in Guangdong Province, China (No. GDKJ2020002)。