Material Balance Calculations Research Articles

Numerical Simulation of Vanadium–Titanium Blast Furnace under Different Smelting Intensities

The blast furnace smelting of vanadium–titanium ore plays a crucial role in the efficient utilization of vanadium-titanium resources. In this research, a detailed numerical simulation study of the temperature, velocity, and concentration fields during the smelting process in a vanadium–titanium blast furnace was conducted. The actual production data from a 1750 m3 vanadium–titanium blast furnace was utilized, combined with softening and dripping parameters and material balance calculations, to develop a two-dimensional blast furnace model. This model was employed to analyze the effects of varying smelting intensities on the internal operating conditions of the furnace. The study found that as smelting intensity increased, significant changes occurred in the temperature fields and CO concentration fields within the furnace, thereby affecting the reduction efficiency of the burdens. Additionally, this research also shows that increasing the proportion of Baima pellets in the furnace will lead to the expansion of the soft melting zone and the upward movement of the soft melting zone. This investigation not only revealed the variations in the internal physical fields of the blast furnace under different operating conditions but also provided theoretical foundations and references for optimizing the design and operation of vanadium–titanium blast furnaces. By comparing the velocity field under different smelting intensities, it was found that the difference was small, which was mainly related to the expansion behavior of the pellets. These findings provide an important scientific basis for further improving the efficiency of blast furnace smelting and reducing costs.

Impact of Material Balance Calculation on Trapped Gas in Water-drive Gas Reservoir

Abstract The development of water-drive gas reservoir takes a very important position in China. Not only its recovery is markedly lower than that of dry gas reservoir, but also its residual gas saturation is higher. The main reason has been proven in the lab is water invasion which can generate trapped gas by sealing gas in porous media. However, it is still difficult to calculate the volume of trapped gas theoretically and practically. In order to quantify trapped gas, we designed experiments to simulate the development of water-drive gas reservoir. The experimental system can provide accurate measurements on gas production, water influx, pressure and so on. The results showed that the original material balance equations are not consistent with experimental data when water invasion happens. With water influx increasing, the errors become more obvious. This phenomenon has been repeated for many times in our lab. On basis of this phenomenon and with the analysis of many experimental data, we observed that water influx causes some high pressure trapped gas which is not considered in original material balance equation. By regression analysis, we proposed a correction term which can be added to the original material balance equation to effectively eliminate the disagreements between the results of original equation and the experiments. The modified material balance equation was also verified by field cases. The correction term can be applied to quantify the degree of trapped gas, which is significant to calculate the water influx and to predict production and improves the original material balance equation so that the trapped gas in water-drive gas reservoir can be fully considered. The correction term is proposed through statistical regression analysis based on a large number of experimental data. The modified material balance equation with the correction term can quantify the trapped gas and have a great significant impact on the development of water-drive gas reservoir, especially on the water influx calculation and production prediction.

Application of dynamic material balance to evaluate oil wells in Buzurgan oil field

The Material Balance Equation is a crucial tool utilized in reservoir studies to evaluate fluids and rock properties at static pressures. The Flowing and Dynamic Material Balance methods offer a significant advantage by avoiding the requirement to shut down wells, as they use flowing pressure instead of static pressure under constant or variable flow rates. The concept of "Dynamic Material Balance" involves converting the bottom hole flowing pressure at any point at any given time to the average reservoir pressure at that point. This allows for the use of classical material balance calculations and the development of classical material balance plots. In this study, the Dynamic Material Balance and Agrawal Type Curve techniques were used to estimate average reservoir pressures, initial hydrocarbon in place, and ultimate oil recovery for a well in the Mishrif reservoir, the main reservoir in the Buzurgan oil field. Many wells in this field experience problems such as high-pressure decline or continuous water production, necessitating ongoing evaluation. While the Dynamic Material Balance method focuses on boundary-dominated flow data, the Agrawal-type curve technique analyzes data from both transient and boundary flow periods. Agarwal decline curves were constructed using relationships of pseudo pressure normalized production, material balance pseudo time, and dimensionless variables in well-test analysis. The results from both methods showed comparable results with an absolute percentage error of (0.738) %, (3.07) %, and 5.7% for oil-in-place, drainage area, and average reservoir pressure, respectively. This strong correlation between the Dynamic Material Balance and Type Curve results indicates their accuracy and reliability.

Estimating the natural gas compressibility factor using a statistical correlations and machine learning approaches

Gas compressibility factor plays an critical role in petroleum engineering applications such as gas metering, pipeline design, reserve estimation, gas flow rate, material balance calculations, and many other significant tasks. Therefore, it is crucial to accurately estimate the gas compressibility factor. There have been a lot of studies on calculating the gas compressibility factor from laboratory data, which can be summarized into two main approaches: statistical correlations and machine learning algorithms. In this study, on statistical correlations the authors implement explicit and implicit method while on machine learning algorithms, we use Artificial Neural Network (ANN) and Least-Squares Support Vector Machine (LS-SVM). The data was collected from open literature. Implementing the two approaches mentioned above and comparing statistical parameters such as Mean Squared Error (MSE), Root Mean Squared Error (RMSE), and Coefficient of Determination (R2 ) found that machine learning algorithms give much more accurate estimation results than statistical correlations, and besides, the ANN algorithm has the most accurate prediction results with the lowest MSE and RMSE (0.000002 and 0.0016) and the highest R2 (0.9999). The high-precision calculation results show that the ANN algorithm mentioned above can be applied to estimate other real gas compressibility factor data sets. On the other hand, this study can be extended to another subset of machine learning algorithms, such as deep learning and ensemble learning.

Computational substantiation of technological characteristics of the closure stage of nuclear fuel cycle using code VIZART

There exist different variants of organizing the closure of nuclear fuel cycle (CNFC) depending on fast reactor type, fuel types, station or centralized allocation of closed nuclear fuel cycle stages. One of the ways to verify and estimate engineering solution is mathematical modeling of radiochemical technology which in the end will allow to optimize composite technological process in order to increase effectiveness and reduce cost. In order to calculate the balance of material flows of process circuits and individual production sections in the stationary and dynamic modes, with taking into account the isotopic composition evolution, a software package VIZART (Virtual Plant of Radiochemical Technologies) was developed, allowing the user to assemble the required sequence of operations for any part of the process scheme and perform the calculation of material balance for all flows of the circuit, as well as to optimize the equipment operating modes and provide the necessary data to justify the safety of certain limits and the entire process circuit. The following capabilities of code VIZART for computational substantiation of CNFC technology design and characteristics are considered: material balance calculation, cyclogram creation, determination of the most loaded parts of processing lines, estimation of fissile materials accumulating in devices and intermediate vessels, optimization of productivity of nodes and devices.

ESFILES: Intelligent process flowsheet synthesis using process knowledge, symbolic AI, and machine learning

Process flowsheet synthesis, design, and simulation require integrated approaches that combine domain knowledge and data-driven methods for fast, efficient, and reliable solutions. However, due to the recent surge in data and machine learning capabilities, there has been a shift towards building purely data-driven systems for process flowsheet synthesis and related problems. Such approaches have certain drawbacks. Here, we present a hybrid method that combines data-driven approaches with domain knowledge to represent process flowsheets and solve problems related to process synthesis, design, and simulation. We present an extended SFILES (or eSFILES) representation, a multi-level hierarchical flowsheet representation with varying degrees of process knowledge. At level 0, flow diagrams are represented as purely text-based SFILES strings. At level 1, the SFILES grammar, along with inferencing algorithms, is used to construct a flowsheet hypergraph explicitly representing flow diagram connectivity. At level 2, specifications needed for material and energy balance calculations are introduced, and, after simulation, the results are also added using annotated flowsheet hypergraphs. Finally, at level 3, a process ontology is connected with the annotated flowsheet hypergraph to include design and operation parameters as well as the detailed simulation results. We discuss this hierarchical framework using several case studies.

Quantifying the Role of Simultaneous Transformation Pathways in the Fate of the Novel Aquatic Herbicide Florpyrauxifen-Benzyl.

Predicting the fate of organic compounds in the environment is challenging due to the inability of laboratory studies to replicate field conditions. We used the intentionally applied aquatic herbicide florpyrauxifen-benzyl (FPB) as a model compound to investigate the contribution of multiple transformation pathways to organic compound fate in lakes. FPB persisted in five Wisconsin lakes for 5-7 days with an in-lake half-life of <2 days. FPB formed four transformation products, with the bioactive product florpyrauxifen persisting up to 30 days post-treatment. Parallel laboratory experiments showed that FPB degrades to florpyrauxifen via base-promoted hydrolysis. Hydroxy-FPB and hydroxy-florpyrauxifen were identified as biodegradation products, while dechloro-FPB was identified as a photoproduct. Material balance calculations using both laboratory rates and field product concentrations demonstrated that hydrolysis (∼47% of loss), biodegradation (∼20%), sorption (∼13%), and photodegradation (∼4%) occurred on similar timescales. Furthermore, the combined results demonstrated that abiotic and plant-catalyzed hydrolysis of FPB to florpyrauxifen, followed by biodegradation of florpyrauxifen to hydroxy-florpyrauxifen, was the dominant transformation pathway in lakes. This study demonstrates how combined field and laboratory studies can be used to elucidate the role of simultaneous and interacting pathways in the fate of organic compounds in aquatic environments.

The precipitation process for a rare earth leach solution with calcium oxide in the presence of ascorbate and calcination to oxide of high purity

Sulfate ions coprecipitate with rare earth metal ions to form alkaline rare earth sulfate (RE2(OH)4SO4) in the CaO precipitation process, leading to excessive content of sulfate in the mixed rare earth oxide. Due to the difference of coordination ability between ascorbate, sulfate, hydroxyl and rare earth metal ions, ascorbate is introduced into the pregnant leach solution (PLS) during the CaO precipitation process. It realizes the coprecipitation between ascorbate (C6H7O6−) and rare earth metal ions, reducing the formation of RE2(OH)4SO4 and improving the purity of mixed rare earth oxide. In this paper, the standard reaction Gibbs free energy changes of the possible reactions in the precipitation process were calculated using the group contribution method, to draw the species distribution equilibrium diagram with Newton's iteration method. When ascorbate exists, rare earth metal ions in the PLS tend to form the alkaline rare earth ascorbate (RE2(OH)4(C6H7O6)2) instead of RE2(OH)4SO4. Furthermore, the effect of the reaction conditions on the precipitation process were studied. When the molar ratio of rare earth metal ions to ascorbate was 1.17, the purity of the mixed rare earth oxide was 96.2 wt% and the sulfate content was 2.2 wt%. Finally, based on the results of the material balance calculation, FTIR, XRD and TG-DSC tests, it was further confirmed that ascorbate participated in the form of RE2(OH)4(C6H7O6)2, and effectively suppressed the generation of RE2(OH)4SO4. Consequently, the results facilitate the green and efficient extraction of rare earths from the ion-adsorption type ore.

New Correlation for Predicting Undersaturated Oil Compressibility for Mishrif Reservoir in the Southern Iraqi Oil Fields

Reservoir fluids properties are very important in reservoir engineering computations such as material balance calculations, well testing analyses, reserve estimates, and numerical reservoir simulations. Isothermal oil compressibility is required in fluid flow problems, extension of fluid properties from values at the bubble point pressure to higher pressures of interest and in material balance calculations (Ramey, Spivey, and McCain). Isothermal oil compressibility is a measure of the fractional change in volume as pressure is changed at constant temperature (McCain). The most accurate method for determining the Isothermal oil compressibility is a laboratory PVT analysis; however, the evaluation of exploratory wells often require an estimate of the fluid behavior prior to obtaining a representative reservoir sample. Also, experimental data is often unavailable.Empirical correlations are often used for these purposes.This paper developed a new mathematical model for calculating undersaturated oil compressibility using 129 experimentally obtained data points from the PVT analyses of 52 bottom hole fluid samples from Mishrif reservoirs in the southern Iraqi oil fields. The new undersaturated oil compressibility correlation developed using Statistical Analysis System (SAS) by applying nonlinear multiple regression method. It was found that the new correlation estimates undersaturated oil compressibility of Mishrif reservoir crudes in the southern Iraqi oil fields much better than the published ones. The average absolute relative error for the developed correlation is 7.16%.

Design and calculation of an environmentally friendly carbon-free hybrid plant based on a microgas turbine and a solid oxide fuel cell

This is an overview of a hybrid power plant design and predesign analysis, including a microgas turbine with heat recovery, a high-temperature fuel cell, and a carbon dioxide capture system. A hybrid installation model is presented, taking into account the compatibility and technological limitations of the main components. The material and heat balance calculation of a hybrid power plant is performed depending on the input parameters under partial load conditions. In order to create a decarbonized highly efficient energy production process and in connection with the need to minimize the negative impact of carbon dioxide on the environment, the article presents the developed technologies for carbon dioxide utilization and a carbon adsorption unit as a hybrid power plant part. The hybrid power plant is a carbon-free mini thermal power plant with integrated electricity, steam, and hot water generation and more than 90% total efficiency.

Techno-Economic Analysis and Feasibility of Industrial-Scale Activated Carbon Production from Agricultural Pea Waste Using Microwave-Assisted Pyrolysis: A Circular Economy Approach

This paper examines a novel approach to activated carbon (AC) production that uses pea waste (PW) and to what extent it is economically competitive with current production methods. Additionally, the outcome is to provide a detailed economic analysis to understand whether this process is viable. The focus of this production route and the economic analysis will be on a United Kingdom (UK) basis. The plant will be located within the north UK to minimise storage and transportation costs. It also has extensive links to other clusters of nearby industries that would produce from this process in air pollution control or wastewater treatments. The overall production process is detailed, and detailed equipment specifications, including the sizing of equipment and utility requirements, were also given. Material balance calculations are carried out to assess the performance and improve process design. An economic analysis is performed to study the potential of biomass-to-AC conversion costs and commercialisation viability. The project’s investment is about £100 million. The cost of the plant can be recovered from year 3 (mid) for the 20-year life of the plant. The Net Present Value (NPV) is based on cumulative cash flow. The NPV is calculated as GBP 4,476,137,297.79 for 2020, and the associated internal rate of return (IRR) and the return on investment (ROI) for the project are 55% and 52%, respectively.

Using the Flowing Material Balance Model to Determine Which Wells Out of a Group of Wells belong to the Same Common Pool

Summary In order to properly conduct material balance calculations, the wells must be producing from the same reservoir. Identification and grouping of wells in a common reservoir can be a challenging task. Based on the flowing material balance (FMB), a methodology was developed that utilizes a well’s flow rate and flowing pressure history to identify which wells belong in the same reservoir, and which do not. This methodology, called the FMB model, continuously converts the flowing pressures and rates of each well into the average reservoir pressure. If these average reservoir pressure trends overlap, it indicates that the wells are in the same reservoir. If any of the trends are different, then those wells belong to different reservoirs. The average reservoir pressure is determined in two ways. The first is from the productivity index (PI) and the flowing rates and pressures of that well. The second is from the material balance equation for the total production of the group of wells. These two average reservoir pressure trends will track over time if the well grouping is properly defined (i.e., all the wells in that grouping belong to the same reservoir), and if the correct hydrocarbon in place is used. The FMB model can additionally be used to history match the flowing pressure of each well (using the flow rate as a control) or to match the flow rate of each well (using the flowing pressure as a control). These visual history matches increase our confidence in the interpretation of the FMB and can be used to investigate the sensitivity of magnitude of the hydrocarbons in place. One field study consisting of three adjacent gas wells, coming on production at different times, and some of the wells not having a reliable initial pressure, illustrates clearly which wells are in the same reservoir and which ones are not, and yields the correct values of original gas in place.

Реалізація математичних моделей матеріального та теплового балансів доменної плавки в складі АСУ ТП ПРАТ "МК "Азовсталь"

On the basis of blast furnace operation data of PJSC "MK "Azovstal", an information system has been developed, which is based on mathematical models of material and heat balances of blast furnace smelting developed at the Institute of Ferrous Metallurgy of the National Academy of Sciences of Ukraine. The calculation of the material balance is carried out according to the "accounting system" of V. P. Izhevskii. The thermal energy model of I. D. Semikin is used to calculate the heat balance, which was developed for use in blast furnace production by O. V. Borodulin. The article describes the information system of calculating mathematical models. The information system allows you to calculate balances in automatic mode (collection of data from automatic control system of technological process (ACS TP) and calculation of material and heat balances for the selected period) and in manual mode (calculation of forecast periods to determine reserves for increasing the energy efficiency of blast furnace smelting). The models were adapted by calculating the material and heat balances of blast furnace melting and determining the inconsistencies. Monthly calculations of the material and heat balances of the blast furnaces were performed to adapt the models installed in the ACS TP of the blast furnace workshop of PJSC "MK "Azovstal". Inconsistencies in the overall material balances of the furnaces (the difference between the total input of materials into the furnace and smelting products) and by components (iron, carbon, etc.) were determined. It was established that when using the estimated amount of blast furnace dust at all blast furnaces of PJSC "MK "Azovstal", the amount of discrepancy between the arrival and consumption of materials lies within the credible range of error (&lt;1,5%). Using the results of the calculation of heat balances, a comparison of the Inconsistencies of the blast furnaces was made (the ratio of the calculated indicators to the actual ones). Mathematical models of balances were implemented as part of the ACS TP of the blast furnace workshop of PJSC "MK "Azovstal" and were used to assess deviations from production norms, consumption of coke and conventional fuel, as well as forecast the possibility of improving the technical and economic indicators of smelting.

Small-Scaled Production of Blue Hydrogen with Reduced Carbon Footprint

This article reviews a method of hydrogen production based on partial non-catalytic oxidation of natural gas in an original synthesis gas generator. The working principles of the unit are similar to those of liquid-propellant rocket engines. This paper presents a description of the operation and technical characteristics of the synthesis gas generator. Its application in the creation of small-scaled plants with a capacity of up to 5–7 thousand m3/h of hydrogen is justified. Hydrogen production in the developed installation requires a two-stage method and includes a technological unit for producing a hydrogen-containing gas. Typical balance compositions of hydrogen-containing gas at the synthesis gas generator’s outlet are given. To increase the hydrogen concentration, it is proposed to carry out a two-stage steam catalytic conversion of carbon monoxide contained in the hydrogen-containing gas at the synthesis gas generator’s outlet using a single Cu–Zn–cement-containing composition. Based on thermodynamic calculations, quasi-optimal modes of natural gas partial oxidation with oxygen are formulated and the results of material balance calculation for the installation are presented. In order to produce “blue” hydrogen, the scheme of carbon dioxide separation and liquefaction is developed. The conclusion section of the paper contains the test results of a pilot demonstration unit and the recommendations for improving the technology and preventing soot formation.

Ruthenium-Exsolution Catalyst for Dry Reforming of Biogas

Solid oxide fuel cells have a proven efficiency for the direct conversion of biogas into electricity, and their full potential from European agricultural and waste-water sites still has to be fully evaluated and harnessed. Biogases are methane-rich mixtures whose composition and trace contaminants, especially of sulfur compounds, can vary greatly.To avoid carbon deposition from the carbon-rich CH4-CO2 mixtures, some amount of steam and/or extra CO2 needs to be added to process the biogas. Ideally this can be recovered from the SOFC exhaust. In a preparatory work, biogas/SOFC integrated systems were studied and compared using Aspen Plus[1]. Best performances are reached with a catalytic methane pre-reformer when a fraction of the anode off-gas is recirculated for mixing with the biogas feed. This work provided the guidelines for the present catalytic study and predicted thermodynamic equilibria of gas mixtures.Here, the overall performance of a ruthenium exsolution catalyst[2] for the reforming of methane was evaluated for these different biogas compositions at various gas hourly space velocities. Gas chromatography and material balance calculations enabled the full measurement of inlet and outlet gas compositions which, in turn, permitted to calculate precise conversion rates, reforming ratio, and the deviation from thermodynamic equilibrium. Methane conversion reached >95 % for a dry-dominant reforming mixture, which simplifies the overall system. The longer-term stability of the catalyst as well as its tolerance towards different sulfur traces that occur in biogas was then evaluated and analyzed. [1] Shuai Ma, Gabriele Loreti, Ligang Wang, Andrea L. Facci, Stefano Ubertini, Changqing Dong, François Maréchal, and Jan Van herle, E3S Web of Conferences 2021 238:04002DOI: 10.1051/e3sconf/202123804002 [2] Muhammad A. Naeem, Paula M. Abdala, Andac Armutlulu, Sung Min Kim, Alexey Fedorov, and Christoph R. Müller, ACS Catalysis 2020 10 (3), 1923-1937DOI: 10.1021/acscatal.9b04555

Impact of physical properties on material balance calculations: case study AL-Nasr oil field, Shabwah Governorate

The accuracy of many petroleum engineering calculations (e.g., material balance calculations, reserve estimation, well test analysis, advanced production data analysis, nodal analysis, surface network modeling, surface separation, and numerical reservoir simulations) largely depends on the accuracy of the data on pressure, volume, and temperature (PVT). An approach to improve the material balance calculation method is presented in this study. To achieve the objective, PVTP and MBAL Software programs were applied. PVT model was built by different methods. Software was implemented to calculate stock-tank oil, initially in place (STOIIP), using different approaches. Sensitive analysis was performed to investigate the effect of different parameters on material balance calculation. Illustration of the proposed approach was done on the data obtained from AL-Nasr oil field. The Average absolute error of PVT properties such as bubble-point pressure, relative volume, oil formation volume factor, Solution gas oil ratio and oil density is used to compare between actual and calculated values. Results showed a good agreement. History production (cumulative oil production, cumulative gas production, cumulative water production) were also calculated to investigate the match between history parameters and calculated parameters. Results indicated that the impact of PVT errors on material balance calculations can be significant.

Emulsion Characterization of the Heavy Oil-Alkaline Water System in Alkaline Flooding Mechanism Investigation Using a Combination of Modified Bottle Test and Sandpack Flooding

Due to the diversity of alkali categories and reservoir conditions, the varied oil recovery driving mechanism of alkaline flooding is subjected to different types of emulsion generation. In this study, a modified bottle test method that assesses major emulsion type formation for preliminary prediction of alkaline flooding performance in oil recovery is introduced. The modified method considers the necessary energy input required for mixing immiscible bulk phases at low interfacial tension (IFT) regions to improve the representativity of emulsion formation in the bottle test to that of in porous media. To accurately evaluate the emulsion type and phase volume distribution from the bottle test, each emulsion phase after aging in the test bottle was sampled and its water content was measured through Karl Fischer titration. Afterward, material balance calculations other than pure volume observation were applied to quantify the emulsion volume and determine the major emulsion type formation. It is found that the majority of emulsion effluent type from the sandpack flooding test were in agreement with the bottle test forecast which proved the feasibility of the modified bottle test method. The statistically optimized experimental designs were implemented due to the simplicity of the new bottle test method and it considerably cut the time expense regarding the alkaline flooding performance prediction. The high versatility of the modified bottle test ensures that the alkali usage is not limited to the inorganic alkalis mentioned in this study; other type of alkaline solutions can also be used for further expanding the scope of its application.

Application of the Modified Method of Material Balance in Combination with Pyrolysis in Estimating the Hydrocarbon Generation Properties of the Bazhenov Formation, Western Siberia

The paper analyzes methods currently used to evaluate the generation parameters of source rocks and suggests a new modified variant of the van Krevelen diagram and an original algorithm for evaluating the hydrocarbon generation properties of bitumen-bearing rocks of the Bazhenov Formation and its analogues. This is done with the application of an integrated approach that employs pyrolitic data on core samples and material-balance calculations. Data on the most probable values of the hydrogen index and the degree of transformations of the original organic matter into naphtides are suggested to use to formally subdivide the possible types of the organic matter into five groups. The paper presents processed analytical data on 340 samples from wells at 13 hydrocarbon fields and three areas in the Khanty–Mansi Autonomous Area and calculated original contents of organic matter in the rocks before naphtide generation was initiated in them, the original and current generation potential values, and the amounts of generated and migrated naphtides. The generation properties of the samples taken at minimum distances from one another (sampling sites spaced 1–3 cm apart) are demonstrated to broadly vary. The broad scatter of the generation properties of the samples cannot be explained only by that they contained organic matter of two types: terra- and aquagenetic. The broad variations in the generation characteristics of the rocks are thought to be likely explained by specifics of their microbial processing and variations in the redox parameters of sedimentation and diagenesis. The two probable reasons for the high S1/S2 ratios of the bitumen-bearing rocks are (1) the open porosity of the rocks and (2) active generation and sluggish migration of naphtides generated in these rocks. The very high contents of organic matter of the rocks (up to 40–50% and more) are explained by that they contain epigenetic thiobitumen, which were produced when these rocks were affected by high-enthalpy hydrothermal fluids. The minimum and maximum specific generation of naphtides in rocks of the Bazhenov Formation and its analogues are evaluated (per 1 km2, per 25 m rock thickness). The specific migration of naphtides generated in the Bazhenov Formation and its analogues are compared with the specific (per 1 km2) geological hydrocarbon reserves in the Khanty-Mansi Autonomous Area.

Extent of Ore Prereduction in Pilot-scale Production of High Carbon Ferromanganese

Three pilot-scale experiments have been conducted at SINTEF/NTNU in a 440 kVA AC electric furnace to demonstrate the process operation, energy requirements and CO2 emissions in the production of high carbon ferromanganese alloys. Comilog, UMK and Nchwaning (Assmang) ores blended with other materials, such as sinter and flux, thus achieving different charge mixtures have been utilized in the experiments. In the prereduction zone, higher manganese oxides in the ore are reduced to MnO through solid-gas exothermic reactions and at a temperature around 800oC, the unwanted endothermic Boudouard reaction is also active. As such, the total coke and energy consumption is highly dependent on if the prereduction occurs by CO gas or solid C. The pilot furnace has been excavated after each experiment and the extent of prereduction of the ore has been investigated by collecting samples from specific regions in the prereduction zone. In addition, material, and energy balance calculations for the three pilot experiments have been calculated using HSC Chemistry software. The HSC material and energy balance calculations have shown that the slag/alloy ratios, metal analyses, carbon consumption and the overall energy consumption are mainly affected by the composition of the charge mixtures. The relationship between the specific carbon consumption, the off-gas CO2/(CO2+CO) ratio and energy consumption to produce 1 tonne of HCFeMn alloy is discussed for the three different pilot-scale scenarios.

ПРИНЦИПОВА СХЕМА МОДЕЛІ НАСКРШЗНОЇ ТЕХНОЛОГІЇ ВИРОБНИЦТВА КОНКУРЕНТОЗДАТНОЇ МЕТАЛОПРОДУКЦІЇ ПІДПРИЄМСТВАМИ УКРАЇНИ, ЩО ПРАЦЮЮТЬ В НЕСТАБІЛЬНИХ СИРОВИННИХ ТА ЕНЕРГЕТИЧНИХ УМОВАХ

Detailed calculation-analytical, laboratory and industrial researches of influence of sinter composition on features of technology of production of an agglomerate, and also use of such agglomerate in a complex with application of pulverized coal on results of technology and parameters of the made pig-iron are executed. The influence of the introduction of secondary materials into the sintering charge on the indicators of experimental sintering of the sinter on the example of the introduction of the use of sludge and fine dust was studied. It is established that the use of sludge blast furnace production has a greater impact on the productivity of sintering machines, to a lesser extent on the yield and cold strength. The use in the charge of fine dust electrostatic precipitators in the amount of ~ 20.5 kg/t leads to a significant reduction in productivity and strength characteristics of the sinter. Based on the results of experimental studies, the influence of the introduction of different amounts of secondary resources into the sinter charge on some characteristics of the sinter some indicators of the blast furnace operation. The balance calculations showed that with the partial replacement of pulverized coal with natural gas in the amount of 35 m3/t of cast iron, coke consumption decreased by 35 kg/t of cast iron, which led to a decrease in the cost of cast iron by 2.1%. Mathematical models created using the results of experimental data, as well as graphical dependences of reagent consumption (Mg and Mg + CaO mixture) allowed to determine the required values of specific mass consumption of reagents and on this basis to determine the cost of production of low-sulfur iron. Mathematical modeling of oxygen-converter smelting on the basis of calculation of material and heat balances and taking into account thermodynamic and physicochemical features of chemical transformations is performed. Using mathematical modeling, a comprehensive comparative analysis of the impact of the design of blast devices and the type of liquid cast iron on the technical and economic performance of steel production OS in the oxygen-converter shop of PJSC "DMK".