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Burden matrix control based on gas flow characteristics of blast furnace 基于高炉煤气流动特性的炉料矩阵控制
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2210937
Donghui Gao, G. Luo, Yueming Wang, Guocheng Zhang, Yifan Chai
ABSTRACT Bernoulli′s principle was adopted to analyze gas flow characteristics in the cohesive zone, and the numerical condition for forming a gas flow whirlpool in the cohesive zone was calculated, a method of controlling the burden matrix was thus obtained and applied to industrial production. The results show that the numerical condition for forming a gas flow whirlpool field in the cohesive zone are obtained by the energy conservation law. Adopting this numerical condition, by ensuring a reasonable ore–coke ratio in the ore zone, moving the burden matrix angle outward to the wall of blast furnace, narrowing the burden matrix angle difference of the ore, and increasing the area of the ore-free zone, to form a funnel of certain depth in the ore-free zone, which is conducive to forming a gas flow whirlpool field that the indexes of blast furnace are obviously improved.
摘要采用伯努利原理分析了黏结区内气体流动特性,计算了黏结区内气体流动漩涡形成的数值条件,从而得到了一种控制炉料矩阵的方法,并应用于工业生产。结果表明,利用能量守恒定律得到了在黏合区内形成气流漩涡场的数值条件。采用该数值条件,通过保证矿区合理的矿焦比,将炉料基质角向高炉壁外移动,缩小矿石的炉料基质角差,增大无矿区面积,在无矿区形成一定深度的漏斗,有利于形成气流漩涡场,使高炉各项指标得到明显改善。
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引用次数: 0
Vacuum degassing impact on non-metallic inclusions during clean steelmaking 清洁炼钢过程中真空脱气对非金属夹杂物的影响
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2208987
Kamrooz Riyahi Malayeri
ABSTRACT The objective of this article was to study the impact of duration of vacuum degassing process on the type and morphology of non-metallic inclusions which are undesired & unavoidable by product of steelmaking process. During the vacuum degassing stage five top slag and steel samples were taken. All sample occasions measured chemical composition of the molten steel and top slag, and SEM analysis of the non-metallic inclusions. It was seen that during vacuum degassing process the chemistry, dispersions as well as the morphology of the non-metallic inclusions is constantly changing. The Alumina content of the top slag is increased while CaO content is reduced. The percentage share of calcium aluminate type of inclusions verses spinel is increased. In the beginning of the vacuum degassing wt-% of Al in non-metallic inclusions is the highest however as the time passes this wt-% is reduced at the same time inclusions with larger ECDs appear.
摘要本文的目的是研究真空脱气过程的持续时间对非金属夹杂物类型和形态的影响,这些非金属夹杂物是炼钢过程中不可避免的。在真空脱气阶段,采集了五个顶部炉渣和钢样品。所有取样场合均测量了钢水和顶渣的化学成分,并对非金属夹杂物进行了扫描电镜分析。可以看出,在真空脱气过程中,非金属夹杂物的化学成分、分散体以及形态都在不断变化。顶渣中氧化铝含量增加,而CaO含量降低。铝酸钙型夹杂物相对于尖晶石的百分比份额增加。在真空脱气开始时,非金属夹杂物中Al的wt%最高,但随着时间的推移,该wt%降低,同时出现具有较大ECD的夹杂物。
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引用次数: 0
Process parameter optimization for spring back in steel grade sheet materials under V-bending using FEM and ANN approach 基于有限元和人工神经网络的钢板V形弯曲回弹工艺参数优化
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2210465
Varsha M. Magar, N. Agrawal
ABSTRACT Spring back compensation is essential for accurate geometry of sheet metal components. In this paper the effect of process parameters namely sheet thickness, bend angle and tool travel rate on spring back in SS304 and C80 material sheets under V-bending is predicted by using finite element method and artificial neural network approaches. Total nine experiments were designed considering three process parameters, each with three levels, by using Taguchi`s L9 orthogonal array. The results obtained by ANN model are in good agreement with FEM model. This establish the robustness of ANN model for predicting spring back value and may be used an alternative to FEM model as the latter is more expensive and time consuming. The optimized value of sheet thickness, bend angle and tool travel rate are 2 mm, 80° and 6 mm ms–1 respectively for SS 304 material and 2 mm, 80° and 2 mm ms–1 for C80 material.
摘要回弹补偿对于精确的钣金零件几何结构至关重要。本文采用有限元方法和人工神经网络方法,预测了SS304和C80材料板材V形弯曲时,板材厚度、弯曲角度和刀具行程速率等工艺参数对回弹的影响。利用田口L9正交阵列设计了总共九个实验,考虑了三个工艺参数,每个参数有三个水平。人工神经网络模型的计算结果与有限元模型吻合较好。这建立了用于预测回弹值的ANN模型的鲁棒性,并且可以用作FEM模型的替代方案,因为后者更昂贵且更耗时。对于SS 304材料,板材厚度、弯曲角度和刀具移动速率的优化值分别为2 mm、80°和6 mm ms–1,对于C80材料,则分别为2 mm。
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引用次数: 0
Influence of mould level instability on the unevenness of solidified shell deformations during continuous casting 结晶器水平不稳定性对连铸凝固壳变形不均匀性的影响
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2201751
K. Furumai, H. Zurob, A. Phillion, K. Oikawa
ABSTRACT The influence of mould level instability during continuous casting on the unevenness of the initial solidified shell in hypo-peritectic steels has been investigated. Water model experiments and in-plant casting experiments revealed that mould level instability, which increases with increasing casting speed, is related to longitudinal cracking resulting from the unevenness of the solidification shell. A numerical model which considers the effect of mould level instability was developed and used to simulate the formation of the unevenness of the solidification shell and solidified shell deflections. The calculation results show that an increase in the non-uniform infiltration of mould flux increases the unevenness of the solidified shell. On the other hand, the unevenness of the solidified shell decreases due to mild cooling. Overall, the results of the plant tests and calculations show that non-uniform infiltration of mould flux dramatically affects air gap formation and the unevenness of the solidified shell.
研究了连铸过程中结晶器水平不稳定性对亚包晶钢初凝固壳不均匀度的影响。水模型试验和厂内铸造试验表明,结晶器水平失稳与凝固壳不均匀引起的纵向开裂有关,随浇注速度的增加而增加。建立了考虑结晶器水平失稳影响的凝固壳不均匀和凝固壳挠曲的数值模拟模型。计算结果表明,铸型助焊剂不均匀渗透的增加增加了凝固壳的不均匀性。另一方面,由于温和的冷却,凝固壳的不均匀性降低。总体而言,工厂试验和计算结果表明,结晶剂的不均匀渗透显著影响气隙的形成和凝固壳的不均匀性。
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引用次数: 0
Strip tracking control using novel insights into the differential rolling process 带钢跟踪控制采用新的见解到差动轧制过程
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2185737
P. Schaak
ABSTRACT Steel strips suffer from lateral shift when being rolled in a rolling mill, especially at the head and tail ends. That results in strip pinches with costly downtime and damage to the work rolls and the strip itself. The lateral shift can be reduced by levelling the gauge control cylinders in response to shift measurements and differential roll force measurements. Designing such controllers gave rise to the desire for analytical relations that describe the shifting process. Novel insights have been revealed, which include the differential material modulus, the differential mill modulus and the ratio to apportion the effect of levelling to entry and exit strip speed changes. The insights have resulted in compact analytical process models that have been used to implement strip tracking controllers safely and sensibly, and to schedule control gains based on actual process parameters. Focus has been on hot strip mills.
钢带在轧机中轧制时受到横向位移的影响,尤其是在头端和尾端。这导致带钢夹紧,停机时间昂贵,并损坏工作辊和带钢本身。横向位移可以通过调平厚度控制缸来减少,以响应位移测量和差动轧辊力测量。设计这样的控制器引起了对描述位移过程的分析关系的渴望。新的见解已经被揭示,其中包括差异材料模量,差异轧机模量和比例,以分摊调平对入口和出口带钢速度变化的影响。这些见解导致了紧凑的分析过程模型,该模型已用于安全合理地实现条带跟踪控制器,并根据实际过程参数调度控制增益。焦点一直放在热轧带钢上。
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引用次数: 0
Continuous measurement of ferrous sinter size distributions using an optical sensor system 用光学传感器系统连续测量铁烧结矿粒度分布
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2208979
Mike Holliday, Yufeng Lai, M. Hobbs, Nick Boone, Tariq Al-Haji, Iain Scott, Jon Willmott
ABSTRACT The size distribution of iron ore sinter is critical to efficient blast furnace operation and is an optimised variable in sinter plants globally. Prompt process control response to discrepancies in sinter size is essential, and the standard sieve measurement test introduces significant delay in data acquisition. We introduce a networked optical sensor system that is shown to accurately measure size distribution within 5 s, collect data continuously at 0.5 Hz, and is well correlated to sieving measurements. This system is deployed at the end of a sinter plant, providing real-time process control data with digital image analysis performed on an integrated microprocessor. The systems performance was assessed with a 12-week validation period, showing excellent correlation with sieve data. Systems such as ours can be widely implemented in sinter plants, and in similar steelmaking applications, due to its cost-effective implementation of continuous data acquisition and the systems versatility to be adapted.
摘要铁矿石烧结矿的粒度分布对高炉的高效运行至关重要,也是全球烧结厂的优化变量。对烧结矿尺寸差异做出及时的过程控制响应是至关重要的,而标准筛测量测试在数据采集方面引入了显著的延迟。我们介绍了一种联网的光学传感器系统,该系统可在5秒内准确测量尺寸分布,在0.5 Hz下连续收集数据,并与筛分测量结果良好相关。该系统部署在烧结厂的末端,提供实时过程控制数据,并在集成微处理器上进行数字图像分析。系统性能在12周的验证期内进行了评估,显示出与筛网数据的良好相关性。像我们这样的系统可以在烧结厂和类似的炼钢应用中广泛实施,因为它具有成本效益高的连续数据采集实施方式和可调整的系统多功能性。
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引用次数: 0
Effect of Zr addition on toughness in the simulated heat-affected zone of high-titanium low-alloy steels Zr对高钛低合金钢模拟热影响区韧性的影响
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2210910
Hao Yao, Chengjun Liu, Lifeng Zhang
ABSTRACT The effect of Zr addition on the impact energy at −20°C, the microstructure, and inclusions of high-titanium low-alloy steels in the simulated heat-affected zone was investigated. The impact energy of the steel without Zr addition was 25.7 J and increased to 242.9 J for the steel with the addition of 80 ppm Zr. When the heat input was 300 kJ cm−1, the impact energy of the steel without Zr addition was 17.5 J and increased to 140.9 J for the steel with 80 ppm Zr, the nucleation potential of AFs increased from 24.4 /mm2 to 76.7  /mm−2, and the average nucleation potential of inclusions decreased from 2.02 to 1.67. The grain refinement by the formation of acicular ferrites stemmed from the increase of 1–3 μm Al-Ti-Zr-O inclusions was responsible for the toughness improvement in CGHAZ of the Zr-bearing steel.
摘要研究了Zr对模拟热影响区内高钛低合金钢−20°C冲击能量、组织和夹杂物的影响。未添加Zr的钢的冲击能为25.7J,而添加80ppm Zr的钢材的冲击能增加到242.9J。当热输入为300kJ时 cm−1时,未添加Zr的钢的冲击能为17.5 J,添加80 ppm Zr的钢材的冲击能增加到140.9 J,AF的成核潜力从24.4/mm2增加到76.7 /mm−2,夹杂物的平均成核势从2.02下降到1.67。针状铁氧体形成的晶粒细化源于1-3的增加 μm的Al-Ti-Zr-O夹杂物是提高含锆钢CGHAZ韧性的主要原因。
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引用次数: 1
Interface reaction between carbon composite brick and blast furnace slag 碳复合砖与高炉矿渣的界面反应
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2199609
Cui Wang, Jian-liang Zhang, K. Gao, K. Jiao, Zheng-jian Liu, Xue-wei Zhang
ABSTRACT The interface reaction between carbon composite brick and blast furnace slag was investigated to clarify the formation and evolution mechanism of slag-rich protective layer on the brick’s surface in blast furnace. The wettability, microscopic morphology, phase components and thickness of the reaction layer between the original/modified brick and slag with different basicities, MnO, CaF2 and FeO additions were analyzed respectively. The results revealed that the mechanism of the deposition process of the slag-rich protective layer was relevant to the ash in the brick and coke, and the slag entrained by coke, the wettability between the brick and slag and the oxides such as MnO and FeO in the slag, the precipitated Ti(C,N) from the molten iron, etc.
摘要研究了碳复合砖与高炉矿渣的界面反应,阐明了高炉碳复合砖表面富渣保护层的形成和演化机理。分析了不同碱度、添加MnO、CaF2和FeO的原/改性砖与矿渣之间的润湿性、微观形态、相组成和反应层厚度。结果表明,富渣保护层沉积过程的机理与砖和焦炭中的灰分、焦炭夹带的炉渣、砖和炉渣与炉渣中MnO、FeO等氧化物的润湿性、铁液中析出的Ti(C,N)等有关。
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引用次数: 1
A theoretical approach to evaluate the effect of hydrocarbon and CO2 injection on blast furnace raceway: step towards reduction of CO2 emission 一种评价烃类和CO2喷注对高炉滚道影响的理论方法:迈向减少CO2排放的一步
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-18 DOI: 10.1080/03019233.2023.2210898
Sujan Hazra, S. Nag, Padmapal, S. Kundu
ABSTRACT A novel raceway heat and material balance model is developed considering all physico-chemical phenomena surrounding the raceway of the blast furnace (BF). This model is unique, as it considers reactions based on thermodynamics and determines important parameters such as raceway adiabatic flame temperature (RAFT), bosh gas properties, raceway coke rate etc. Importantly, the model also predicts blowing parameters in case of known RAFT and permeability of the furnace. This paper focuses on the raceway regime only considering the effect of different injectants, H2, CO, CH4, CO2 and coke oven gas (COG). Firstly, the paper describes the modelling approach, based on thermodynamic, heat and material balances. The first part of the paper quantifies the effect of injectants on the raceway keeping the blowing parameters constant, whereas second part presents the changes of raceway properties as well as blowing parameters keeping RAFT and permeability of the furnace constant.
摘要考虑了高炉滚道周围的各种物理化学现象,建立了一个新的滚道热物质平衡模型。该模型是独特的,因为它考虑了基于热力学的反应,并确定了重要参数,如滚道绝热火焰温度(RAFT)、波什气体特性、滚道焦炭率等。重要的是,该模型还预测了已知RAFT和熔炉渗透性情况下的吹制参数。本文只考虑了不同注入剂H2、CO、CH4、CO2和焦炉气(COG)的影响,重点研究了滚道状态。首先,本文描述了基于热力学、热平衡和材料平衡的建模方法。本文的第一部分量化了在保持吹制参数不变的情况下,注射剂对滚道的影响,而第二部分则介绍了在保持RAFT和炉内渗透性不变的条件下,滚道性能以及吹制参数的变化。
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引用次数: 0
A mathematical model for the thermal state of a steel ladle 钢包热状态的数学模型
IF 2.1 3区 材料科学 Q2 Materials Science Pub Date : 2023-05-14 DOI: 10.1080/03019233.2023.2201544
Ilpo Mäkelä, Ville-Valtteri Visuri, T. Fabritius
ABSTRACT A dynamic one-dimensional mathematical model was developed for predicting the thermal state of a steelmaking ladle. The model is intended to be used in process control applications, in which fast computational times are desirable alongside model accuracy. The calculation domain was discretized using the finite difference method, and time integration was performed using both the implicit Euler and Crank–Nicolson methods, the performances of which were compared. The model was implemented in Python programming language and validated using data from our own measurements and other studies available in the literature. The results indicate that the model can reproduce the measured temperature evolution of the ladles within 5°C at best. The worst performance was observed during cooling, where the model underestimates the temperature at the innermost measurement point by up to 200°C. With computation times of around 16–23 s for one hour of simulation, the model is computationally sufficiently fast for online applications.
摘要建立了一个动态的一维数学模型来预测钢包的热状态。该模型旨在用于过程控制应用,在过程控制应用中,除了模型精度外,还需要快速的计算时间。使用有限差分法对计算域进行离散化,并使用隐式Euler和Crank–Nicolson方法进行时间积分,比较了两者的性能。该模型是用Python编程语言实现的,并使用我们自己的测量数据和文献中的其他研究进行了验证。结果表明,该模型最多能再现5°C内钢包的实测温度演变。在冷却过程中观察到最差的性能,其中模型低估了最内部测量点的温度高达200°C。计算时间约为16-23 对于一个小时的模拟,该模型在计算上足够快,可以用于在线应用。
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引用次数: 0
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Ironmaking & Steelmaking
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