Calculating Method for Influence of Material Flow on Energy Consumption in Steel Manufacturing Process

From the viewpoint of systems energy conservation, the influences of material flow on its energy consumption in a steel manufacturing process is an important subject. The quantitative analysis of the relationship between material flow and the energy intensity is useful to save energy in steel industry. Based on the concept of standard material flow diagram, all possible situations of ferric material flow in steel manufacturing process are analyzed. The expressions of the influence of material flow deviated from standard material flow diagram on energy consumption are put forward.

A process-level hierarchical structural decomposition analysis (SDA) of energy consumption in an integrated steel plant

A hierarchical structural decomposition analysis(SDA) model has been developed based on process-level input-output(I-O) tables to analyze the drivers of energy consumption changes in an integrated steel plant during 2011-2013. By combining the principle of hierarchical decomposition into D&L method, a hierarchical decomposition model for multilevel SDA is obtained. The developed hierarchical IO-SDA model would provide consistent results and need less computation effort compared with the traditional SDA model. The decomposition results of the steel plant suggest that the technology improvement and reduced steel final demand are two major reasons for declined total energy consumption. The technical improvements of blast furnaces, basic oxygen furnaces, the power plant and the by-products utilization level have contributed mostly in reducing energy consumption. A major retrofit of ancillary process units and solving fuel substitution problem in the sinter plant and blast furnace are important for further energy saving. Besides the empirical results, this work also discussed that why and how hierarchical SDA can be applied in a process-level decomposition analysis of aggregated indicators.

Investigation of the environmental impacts of steel deck pavement based on life cycle assessment

To investigate the environmental impacts of steel deck pavement through the whole life cycle,the steel deck pavement was divided into five stages:raw materials production,asphalt mixture mixing,pavement construction,operation management,and pavement removing stage.Based on the process-based life cycle assessment(PLCA)method,the calculation methods of energy consumption and gas emissions of two typical steel deck pavement systems(EA+EA pavement and GA+SMA pavement)were determined.The data lists of two pavements were analyzed,and the calculation model was built.Four characteristic indices including primary energy demand(PED),global warming potential(GWP),acidification potential(AP)and respiratory inorganics(RI)were used to quantify the environmental impacts of two pavements.The results show that the environmental impact of the GA+SMA pavement is more than 1.3 times that of the EA+EA pavement.Moreover,the critical stage of energy-saving and emission-reduction of EA+EA pavement and GA+SMA pavement are the raw material production stage and asphalt mixture mixing stage,respectively.

Machinability Investigation and Optimization of Process Parameters in Cryogenic Assisted Sustainable Turning of AISI‑L6 Tool Steel

The application of cutting fluid is significantly increased in the machining sector to improve productivity.However,the inherent characteristics of cutting fluids on ecology,environment,and society shift the interest of researchers to work on environmentally friendly cooling conditions such as cryogenic cooling.Here,the effect of cutting speed and feed rate on the machining performance of the AISI‑L6 tool steel is investigated under cryogenic cooling conditions.Then,the L9 Taguchi based grey relational analysis(GRA)is conducted to investigate the essential machining indices such as cutting energy,surface roughness,tool wear,and material removal rate(MRR).The results indicate that the cutting speed of 160 m/min and feed rate of 0.16 mm/r are the optimum parameters that significantly improves the machining performance of AISI‑L6 tool steel.

Reducing energy demand and environmental emissions in secondary steel processing by using modular dry mechanical vacuum pumping systems

Steel production remains an energy-intensive industry in a world where there is an ever-increasing emphasis on lowering energy costs,reducing greenhouse gas emissions,ensuring environmental compliance,and improving production rates.As the growth in demand for speciality steels continues its steady increase,and new market opportunities for ever higher steel performance appear,significant global attention is focused on secondary steel processing,and on the VD,VOD and RH processes.One new technology is able to address all of these issues and concerns together-the integrated ladle tank vacuum degassing station equipped with the new modular mechanical vacuum pumping systems.This paper will examine the economic and environmental benefits, operational characteristics,and recent results provided by such steel degassing installations.

Prediction method for energy con sumption per ton of fused magnesium furnaces using data driven and mechanism model

The electric energy consumed in every ton of acceptable product, namely energy consumption per ton (ECT), is an important overall index for the production process of a fused magnesium furnace. The furnace is the equipment for producing the fused magnesia. The ECT value depends on the current in the smelting process. The optimal operation for a fused magnesium furnace is supposed to have the ECT as low as possible, where the key is to predict ECT accurately. By introducing an unknown high-order non linear term, this paper builds a dynamic ECT model for differe nt production batches based on the static ECT model for one batch. The average current is taken as the input of the dynamic ECT model, which is composed of the unknown high-order nonlinear term and a nonlinear model with unknown parameters. The order of the nonlinear term is determined by the distance correlatio n and the nonlinear term is estimated by the stochastic con figuration n etwork, while the parameters of the non linear model is ide ntified by the least square method. The estimation of the nonli near term alter nates with the parameter identification. This paper proposes a prediction method for ECT, which is composed of the order identification of the non linear term, the alternating identification of the model and the ECT prediction model. The simulation experiments are conducted by the on-site data, and the results verify the effectiveness of the proposed prediction method.

多级耗能后张预应力筋预制节段墩的抗震性能分析

为提升节段墩的抗震性能,采用多级耗能方法实现多节段共同参与耗能.将耗能钢筋从节段墩底部向上依次穿过多个接缝,从而实现多级耗能.通过数值模拟,研究多级耗能节段墩体系的耗能能力,并针对三级耗能节段墩体系的轴压比和耗能钢筋配筋率进行参数分析.结果表明,多级耗能节段墩体系可以提高节段墩的耗能能力,而每一级别耗能体系存在耗能上限,且随多级耗能体系级别的提升而增加.在不同级别耗能体系中,耗能钢筋配筋率存在不同的临界值,一级耗能体系的耗能钢筋配筋率临界值为0.23%,二级耗能体系为1.31%.为获得较强的耗能能力,建议将耗能钢筋配筋率取值为1.31%,轴压比取值为0.1.

装配式冷弯厚壁型钢半刚性梁-柱节点抗震性能试验研究

冷弯型钢在装配式结构中应用具有天然的优势,为了扩展冷弯厚壁型钢结构的使用范围,克服冷弯厚壁钢的缺点,设计6个新型分层装配式“十字型”梁-柱节点,进行循环加载试验,对梁-柱节点的破坏模式、初始刚度、骨架曲线、等效黏滞阻尼系数、能量耗散系数、割线刚度、滞回曲线和关键部位应变分布进行研究,主要得到以下结论:通过螺栓和节点板的滑移,半刚性节点具有一定的耗能能力。增设高强螺栓可以提高梁柱节点的承载力,初始刚度和耗能能力也得到提高,避免梁端与连接板孔壁承压。增加可更换节点翼缘板,对梁-柱节点的破坏模式没有明显影响,承载能力、耗能能力、初始刚度分别得到较大提高。

反复荷载下圆钢管型钢再生混凝土组合柱耗能能力及延性分析

对11个圆钢管型钢再生混凝土组合柱试件进行了低周反复荷载试验,观察了组合柱的破坏形态及特征,获取了组合柱的滞回曲线、等效粘滞阻尼系数、延性系数及侧向位移角等性能指标,分析了再生粗骨料取代率、型钢截面形式、轴压比、型钢配钢率和圆钢管径厚比等参数对组合柱耗能能力及延性的影响规律。结果表明:反复荷载作用下组合柱呈压弯塑性铰破坏模式;组合柱的荷载-位移滞回曲线饱满呈纺梭形,屈服位移后的等效粘滞阻尼系数在0.30~0.48之间,平均位移延性系数大于3.0,极限侧向位移角介于1/30~1/20之间且均大于规范限值1/50,组合柱表现出良好的耗能能力和延性。此外,组合柱的耗能能力和延性受再生粗骨料取代率的影响较大,全再生混凝土较普通混凝土耗能能力下降14.5%;增加钢管壁厚或型钢配钢率有利于提升组合柱的耗能能力和延性,而增大轴压比则对组合柱的延性和变形不利;内置型钢采用箱型截面时,组合柱耗能及延性最优,与工字型钢相比,采用箱型截面型钢的组合柱耗能能力和延性分别提升了23.5%和51.9%。

一种纯弯曲耗能阻尼器的力学性能分析及优化设计

提出了一种新型纯弯曲耗能阻尼器。通过理论计算给出了耗能钢板与限位移钢板的高度关系,对耗能钢板进行三角形开孔设计,通过理论计算给出单次加载下各尺寸耗能钢板不会产生剪切屈服的最大开孔率,通过数值模拟得到了耗能系数最大时的开孔高度与开孔底边长度。利用有限元软件对影响钢板耗能的几何参数进行力学分析。结果表明:耗能钢板的厚度与限位移钢板的高度对阻尼器的耗能系数影响较大,耗能钢板的宽度和数量对其影响较小。最后通过正交试验给出一个耗能性能强的阻尼器尺寸。

焦化行业政策演变及山西焦化面临的机遇与挑战

梳理了近年来国务院、各部委、中国焦化行业协会和山西省政府及各部门多层面的与焦化发展相关的政策文件,归纳出焦化行业大气污染物排放标准与吨焦能耗指标随着国家清洁生产、绿色制造、“双碳”目标的变化历程。分析了山西焦化行业发展目前存在的问题,并给出了具有可操性的应对策略。

不同构造下的钢管混凝土柱-钢梁节点抗震性能研究

与普通节点不同,钢管混凝土柱-钢梁节点在地震作用下更容易发生破坏,为了提高钢管混凝土柱与钢梁连接节点的抗震性能,进行了不同构造下的钢管混凝土柱-钢梁节点抗震性能研究。以预埋锚杆构造的两种钢管混凝土柱-钢梁节点和钢梁穿透式构造的钢管混凝土柱-钢梁节点为研究对象,在梁体中部设置了横向支承,采用层间位移角控制周期性荷载,当地震荷载不同时,测试了3种构造钢管混凝土柱-钢梁连接节点的抗震性能。结果表明,钢梁穿透式构造的钢管混凝土柱-钢梁节点对地震具有较高的承载能力,弱化伸缩梁端节点的构造方法符合抗震设计要求,通过端板的屈曲可以消散大部分能量,具有强大的耗能能力。

降低太钢AOD炉和钢包用耐火材料单耗的控制措施

介绍了在耐火材料区域整体承包模式下,钢铁企业关注的指标不仅仅只是耐火材料吨钢成本,更要重点关注耐火材料吨钢消耗指标,降低耐火材料吨钢消耗,既能提高炉包寿命,降低耐火材料吨钢成本,又能保证耐火材料产品不污染钢水,提高钢水纯净度,实现耐火材料企业和钢铁企业双赢。以太钢不锈钢冶炼耐火材料消耗占比较大工序AOD炉和钢包为例,对不锈钢冶炼用AOD炉和钢包冶炼环境进行了分析,对降低耐火材料单耗的方法进行了介绍。通过采用优质耐火材料原料改进材质、加强砌筑管理、优化生产节奏、采用在线热态喷补技术、提高透气砖寿命等,使不锈钢冶炼用耐火材料单耗和成本最低。

纳米复合瓷球作磁铁矿细磨介质磨矿特征研究

三段磨矿工艺通常采用钢锻或钢球作为细磨介质,存在高能耗、高球耗和粒度分布特性差等问题。以尖山铁矿三段球磨机给矿作为研究对象,进行了批次磨矿试验,研究了钢锻和瓷球作为细磨介质下的磨矿动力学特征以及瓷球磨矿工艺参数对产品粒度特性的影响。结果表明:超细粒级磁铁矿磨矿动力学线性特征不明显,更倾向于一阶磨矿动力学特征,且瓷球的细磨能力优于钢锻。瓷球磨矿工业应用后,在相同溢流细度和铁精矿品位下,球耗降幅达17.52%,节电幅度达42.37%,综合磨矿成本下降32.11%。瓷球可作为新型介质完全替代钢锻磨矿。

可控转角摩擦型铰节点滞回耗能研究

提出一种可控转角摩擦型铰节点,介绍了该节点的构造。利用既有试验对有限元软件ABAQUS模型材料参数进行验证,结果表明,试验结果与数值模拟结果吻合较好。建立25个不同参数的节点模型,探究螺栓预紧力、拼板间摩擦系数、梁固定端距销轴轴心距离、梁连接端肋板厚度、梁连接端肋板外伸长度、节点处肋板厚度、节点处肋板外伸长度共7个变化参数对节点滞回耗能的影响。通过拟合获得的数据,建立了节点摩擦反力提高系数与摩擦系数、节点安全储备系数与摩擦系数的关系曲线。结果表明:当节点转角大于设定转角后,节点产生的限位接触使节点反力大幅增加,实现限制节点转角的目的;摩擦系数在0.35左右耗能最大;在节点转角小于设定转角时,滑动摩擦反力与螺栓预紧力的比值约等于摩擦系数;节点最终破坏的总耗能随螺栓预紧力的增加而增大;螺栓预紧力超过规范规定的设计值时,对节点的累积耗能提高程度不明显;梁固定端距销轴轴心距离在梁高的0.95至2倍时耗能最佳;梁固定端距销轴轴心距离过大时,将降低节点的极限反力;梁连接端肋板厚度、梁连接端肋板外伸长度、节点处肋板厚度和节点处肋板外伸长度对节点滞回性能影响不显著。

Specific Energy Consumption Analysis Model and Its Application in Typical Steel Manufacturing Process

Theoretical minimum and actual specific energy consumptions （SEC） of typical manufacturing process （SMP） were studied. Firstly, a process division of a typical SMP in question was conducted with the theory of SEC analysis. Secondly, an exergy analysis model of a subsystem consisting of several parallel processes and a SEC analysis model of SMP were developed. And finally, based on the analysis models, the SEC of SMP was analyzed by means of the statistical significance. The results show that the SEC of typical SMP comprises the theoretical minimum SEC and the additional SEC derived from the irreversibility~ and the SMP has a theoretical minimum SEC of 6.74 GJ/t and an additional SEC of 19.32 GJ/t, which account for 25.88% and 74.12% of the actual SEC, respectively.

爆炸荷载作用下曲面钢-混凝土钢组合板的动态响应研究

为探究钢-混凝土-钢组合板(组合板)的抗爆性能,设计四种不同曲率的组合板;利用有限元软件ABAQUS对比研究这四种组合板在爆炸荷载作用下的损伤、位移和能量耗散情况。同时,以曲率为0.75的组合板为例,参数化分析了炸高、炸药量、钢板厚度、混凝土厚度、栓钉间距和直径对其动态响应的影响。研究表明:在相同爆炸作用下,组合板的最大动能和最大跨中位移均随着曲率增大而减小。当内外层钢板总厚度不变时,适度增大内层钢板厚度更有利于降低组合板的最大跨中位移。适度增加组合板的曲率,适度减小栓钉间距或增大栓钉直径均有利于提高组合板的抗爆性。根据非线性回归拟合得到了组合板的最大跨中位移与钢板厚度(或混凝土厚度)和炸药量的两种经验公式。

寒冷地区模块化钢框架结构多目标优化设计方法

针对寒冷地区模块化钢框架结构节能性与经济性之间的矛盾问题,对模块化钢框架结构能耗和成本两个设计目标进行同步优化研究。根据模块化钢框架结构的特点进行参数化设计研究,提出在不同建筑尺寸下模块化钢框架结构的BIM模型自动建模方法;在Energyplus建筑能耗分析软件计算数据的基础上,采用多种机器学习算法进行建筑能耗预测,建立一种高效精确的建筑能耗预测模型;联立建筑能耗预测模型和建筑成本计算公式,在满足结构承载力的约束条件下,基于NSGA-Ⅱ算法进行模块化钢框架结构能耗和成本的多目标优化设计,生成帕累托最优解集。多目标优化设计方法解决了模块化钢框架结构“能耗+成本”的多目标一体化设计难题,推动了模块化钢框架结构的智能化升级,实现了模块化钢框架结构设计的快速高效化。

不锈钢连铸坯热送热装生产实践

介绍了宝钢德盛不锈钢有限公司热轧厂1150 mm生产线热送热装技术应用于200系不锈钢(铬锰系奥氏体不锈钢)的生产实践。通过提升连铸板坯质量、投用炼轧计划管理系统、连铸坯热塑性研究与热轧加热工艺优化及现场生产计划编排、组织协调等措施,宝钢德盛在改善200系不锈钢产品质量、缩短产品生产工艺流程、节能降耗等方面取得显著效果,为将来在宝钢德盛热轧厂1780 mm生产线进一步扩大热送热装工艺应用奠定了基础。

电渗析浓缩钢铁工业浓盐水试验研究

以泰山钢铁反渗透浓水为对象进行电渗析(ED)浓缩中试研究。结果表明:ED对钢铁工业浓盐水具有较为理想的浓缩效果,能够实现浓盐水电导率的高倍浓缩,浓缩倍数为5~10倍。ED淡水电导率均<3000μs/cm;ED对浓盐水的浓缩效果受水中不同离子种类的影响;ED对COD的浓缩效果不明显,具有一定的抗有机物污染能力;试验期间ED能耗为2.3~2.4 kWh/t,浓水系统回收率≥85%,能够低能耗、高效率地实现浓盐水浓缩减量,为进一步实施废水零排放提供了可行性方向。