Process In Steel Industry Research Articles

The production of large blast furnaces during 2016 and future development of ironmaking in China

The production and development of the ironmaking process in China are crucial for energy saving, emission reduction and transformation and promotion processes of iron and steel industry. In order to fully understand the production and techniques of ironmaking blast furnace in China, the production and operation indexes of large blast furnaces were analysed in this paper. Then challenges of the ironmaking in China were discussed. On this basis, the future development of ironmaking in China was further analysed. The study will contribute to understanding the state of ironmaking process of China.

Statistical Analysis between Output and Energy Consumption of Production Process in Iron and Steel Industry

On the basis of E-P theory of cleaner production, this paper verifies its reliability in terms of prediction of energy consumption using actual production data of output and energy consumption. And then the parameters of the E-P model are determinate by means of least square linear programming method. In addition, we use the actual data to further modify the E-P model in order to improve accuracy of model. It is proved that this model can forecast energy consumption kindly.

Optimizing Production Scheduling of Steel Plate Hot Rolling for Economic Load Dispatch under Time-of-Use Electricity Pricing

Time-of-Use (TOU) electricity pricing provides an opportunity for industrial users to cut electricity costs. Although many methods for Economic Load Dispatch (ELD) under TOU pricing in continuous industrial processing have been proposed, there are still difficulties in batch-type processing, since power load units are not directly adjustable and nonlinearly depend on production planning and scheduling. In this paper, for hot rolling, a typical batch-type and energy intensive process in steel industry, a production scheduling optimization model for ELD is proposed under TOU pricing, in which the objective is to minimize electricity costs while considering penalties caused by jumps between adjacent slabs. A NSGA-II based multiobjective production scheduling algorithm is developed to obtain Pareto optimal solutions, and then TOPSIS based multicriteria decision-making is performed to recommend an optimal solution to facilitate field operation. Experimental results and analyses show that the proposed method cuts electricity costs in production, especially in case of allowance for penalty score increase in a certain range. Further analyses show that the proposed method has effect on peak load regulation of power grid.

Novel technology of reducing SO2 emission in the iron ore sintering

Iron ore sintering is the main SO2 emission process in iron and steel industry. The flue gas of iron ore sintering has been cleaned by desulfurization equipment, which causes high capital and operation cost. A novel technology of reducing SO2 emission of flue gas during iron ore sintering process by adding urea into granules bed was investigated in this paper. The results show that the emission concentration of SO2 in flue gas decreased significantly by adding urea loaded in the bed. The desulfurization rate higher than 85% was obtained when 0.05% urea was added in the bed at the height of 70–150mm from the bed bottom, and there is no adverse influence on sintering indexes and final sinter quality.

Utilization of Steel Slag in Concrete as a Partial Replacement to Fine Aggregate

Concrete is largest produced material in the construction industry and as per WHO concrete is the largest consumed material by human beings after food and water. About 75% of the concrete is composed of aggregates and because of huge demand of concrete all over the world, availability of natural aggregates is becoming scarce. Civil engineers have always been looking for an alternative for the use of more eco-friendly and easily available materials as a replacement to conventional constituents in concrete. Concrete industry has always welcomed the use of various industrial waste materials as a replacement to these constituents since, otherwise such industrial waste need to be disposed in the form of landfills causing enormous amount of land pollution. This project presents the experimental investigation carried out to evaluate the effect of partial replacement of fine aggregate in concrete by steel slag which is waste product generated during the production of steel. The use of steel slag reduces the need of natural rock as constructional material, hence preserving our natural rock resources besides provides an environmental friendly option of concrete production. Steel slag mainly consists of calcium carbonate and is produced as a by-product of oxidation process in steel industry. The primary aim of this study is to evaluate the various properties of a concrete, obtained by partial replacement of fine aggregate by steel slag. In this research, apart from cement, fly ash and metakoalin (as a partial replacement to cement) were used as binding material. Five sample mixes were taken whose compression tests, tensile tests, sorptivity and water absorption tests were conducted. The mixes were obtained with 0, 30 and 40 percent replacement of fine aggregate by steel slag besides using different percentage replacements (25% of cement by fly ash in three trials, 15% and 10% cement by fly ash and metakoalin respectively in other two trials) of cement by pozzalonas. The experimental results were plotted and compared. It was observed that compressive and tensile strength increased with the increase in steel slag percentage upto to certain limit (30%). Increasing the percentage to 40% there was a sharp decline in magnitude of strength parameters and furthermore increasing metakoalin content had an effect of increasing strength. Capillary rise and water absorption increased with addition of steel slag and decreased with increase in metaloalin content.

Changes in Korea Steel Industry and Formation Process of Technology-knowledge network

Changes in Korea Steel Industry and Formation Process of Technology-knowledge network

The production and development of large blast furnaces in China during 2015

The development of large blast furnaces in China is crucial for energy saving, emission reduction and transformation and promotion processes of iron and steel industry. However, the development of large blast furnaces in China was affected by the lower stability state and lack of new technology developments. In this article, the operation indexes of large blast furnaces of China in 2015 were introduced. Then the reasons for lower stability state of large blast furnaces were analysed and some improved measures were proposed. In addition, some new technical thoughts on the development of large blast furnaces were also proposed.

Experimental study on heat pipe assisted heat exchanger used for industrial waste heat recovery

Steel industry plays an important role economically in China. A great amount of hot waste liquids and gases are discharged into environment during many steelmaking processes. These waste liquids and gases have crucial energy saving potential, especially for steel slag cooling process. It could be possible to provide energy saving by employing a waste heat recovery system (WHRS). The optimum operation condition was assessed by integrating the first and the second law of thermodynamics for a water–water heat pipe heat exchanger (HPHE) for a slag cooling process in steel industry. The performance characteristics of a HPHE has been investigated experimentally by analyzing heat transfer rate, heat transfer coefficient, effectiveness, exergy efficiency and number of heat transfer units (NTU). A specially designed on-line cleaning device was used to clean the heat exchange tubes and enhance heat transfer. The results indicated that the exergy efficiency increased with the increment of waste water mass flow rate at constant fresh water mass flow rate, while the effectiveness decreased at the same operation condition. As the waste water mass flow rate varied from 0.83m3/h to 1.87m3/h, the effectiveness and exergy efficiency varied from 0.19 to 0.09 and from 34% to 41%, respectively. In the present work, the optimal flow rates of waste water and fresh water were 1.20m3/h and 3.00m3/h, respectively. The on-line cleaning device had an obvious effect on the heat transfer, by performing the device, heat transfer rate, heat transfer coefficient, effectiveness and exergy efficiency were improved by 6.11%, 9.49%, 7.19% and 7.93%, respectively.

Extenuating Whip-Lash Effect in Multi-Echelon SCM in Steel Processing Industry Using Optimization Model

AbstractForecasting of inventory is an enigma to various firms at different echelon levels of supply chain. Abnormality in forecasting an inventory may leads to fluctuations in upstream supply chain. On upswing it can be uneconomical in terms of stock-out cost, while on the down trend it can be expensive in terms of stock holding costs. To amend the firms efficiency, in this paper the model developed by (Akhtar Tanveer et al. An Optimization model for Mitigating Bullwhip-Effect in a Two-Echelon Supply chain. Int conf Traf Transp Stud 2014;138:289-97) is successfully applied to steel processing firm to mitigate the Bull-whip or Whip-lash effect in the supply chain. The objective function is to minimize the variation between the actual order quantity and demand forecast of multiple products at various echelons and the simple exponential smoothing is compiled to forecast the demand of products. The model is furthermore validated by an illustration of seven products and it depicts that the model emanates an optimal set of smoothing parameters to attenuate the whip-lash effect.

COMPARATIVE EMISSION OF GREENHOUSE GAS CO2 IN THE PROCESSING OF FERROUS METALLURGY

Carbon dioxide – a greenhouse gas – is formed in all industrial processes of iron and steel industry. We can identify three types of emissions of carbon dioxide of ferrous metallurgy processing: process, transit and through. Through emission of carbon dioxide of different processing is the sum of the integral emission of carbon dioxide of the process and transit. A classification of the processing in the iron industry on the mechanism of formation of carbon dioxide emissions is proposed. The authors have identified five types of processing, which include redistributions, respectively, heating furnace, converters, open-hearth furnaces, blast furnaces and coke batteries. The values of cross-cutting carbon dioxide emissions for the six combinations of steel production stages are presented.

Calcium alginate matrix increases the stability and recycling capability of immobilized endo-β-1,4-xylanase from Geobacillus stearothermophilus KIBGE-IB29.

Exploration of microbial pool from extremely diversified ecosystem is significantly important for various industrial applications. Bacterial communities from extreme habitats including volcanic vents, hot springs, and industrial sectors are eagerly explored for the isolation of thermophiles. Geobacillus stearothermophilus KIBGE-IB29, isolated from blast furnace site of a steel processing industry, is capable of producing thermostable endo-β-1,4-xylanase. In the current study, this enzyme was immobilized within calcium alginate beads using entrapment technique. Amalgamation of sodium alginate (40.0 gL(-1)) and calcium chloride (0.4 M) was used for the formation of immobilized beads. It was observed that temperature (50 °C) and pH (7.0) optima of immobilized enzyme remained same, but enzyme-substrate reaction time increased from 5.0 to 30.0 min as compared to free enzyme. Diffusion limit of high molecular weight xylan (corncob) caused a decline in V max of immobilized enzyme from 4773 to 203.7 U min(-1), whereas K m value increased from 0.5074 to 0.5722 mg ml(-1) with reference to free enzyme. Immobilized endo-β-1,4-xylanase showed its stability even at high temperatures as compared to free enzyme and retained 18 and 9 % residual activity at 70 and 80 °C, respectively. Immobilized enzyme also exhibited sufficient recycling efficiency up to five reaction cycles which indicated that this enzyme can be a plausible candidate in paper and pulp industry.

Surfactant-Based Cu–Water Nanofluid Spray for Heat Transfer Enhancement of High Temperature Steel Surface

Spray cooling is critical in many industrial applications to extract large heat fluxes from metal parts, such as hypervapotron in nuclear fusion reactors, heat treatment of steel plates in run-out table (ROT), electronic parts, and many more. The objective of the present study is to enhance the heat dissipation in transition and nucleate boiling regimes using an air-atomized water spray with water-based copper nanofluid as a coolant. The nanoparticle used in this study is energetic metal Cu, which has been prepared by mechanical milling (MM) process. The nanofluid has been prepared by suspending 0.1 vol. % Cu nanoparticles in water, with or without a dispersing agent (surfactant). The effect of type of dispersing agent on augmentation of boiling heat transfer has also been studied. The spray cooling experiments are conducted on a 6 mm thick stainless steel plate of initial temperature above 900 °C. The transient surface heat flux and temperatures are estimated using commercial inverse heat conduction software named intemp. The experimental results illustrated that transition and nucleate boiling heat flux as well as critical heat flux (CHF) increased significantly using nanofluid spray. A maximum ultrafast cooling (UFC) rate of 267 °C/s is achieved using surfactant-based nanofluid spray, which is 31.53% and 59.88% higher as compared to the nanofluid without any dispersant and pure water sprays, respectively. Overall, the surfactant-based copper nanofluid spray can serve as a better coolant on the ROT of steel processing industry.

Heat transfer of spent ion exchange resin in iron ore sintering process

Spent ion exchange resin (SIER) is a kind of solid waste which derived from water treatment process in iron and steel industry. Utilization of SIER as a replacement of fuel in sintering process is a promising method of SIER treatment. In order to investigate the feasibility of this method, heat transfer effects of SIER in iron ore sintering process were studied in this paper via numerical simulation. A 3D unsteady numerical reference model was developed on the basis of the porous media model and local non-equilibrium thermodynamics model and verified by the data form measurement. Heat transfer effects of different SIER mass fractions (0–8%) in sintering material during the sintering process were studied on the numerical model established in this paper. The results showed that with the increasing mass fraction of SIER, the maximum combustion zone thickness and flame front speed are both increased, the heating-up point, the moment when solid temperature reached the top and the maximum temperatures were all became earlier in different location of sintering bed. When SIER content is 8%, the maximum sintering temperature exceeds the maximum limit of best sintering temperature.

EFFECT OF USING STEEL SLAG AGGREGATE ON MECHANICAL PROPERTIES OF CONCRETE

This study presents an evaluation of the physical and mechanical properties and characteristics of steel slag aggregate concrete in comparison with the typical crushed limestone stone aggregate concrete. Hardened concrete consist of more than 70% aggregate due to the high demand in building construction and the increase of the amount of disposed waste material, suppliers and researchers are exploring the use of alternative materials which could preserve natural sources and save the environment. In this study, steel slag was used as an aggregate replacement in conventional concrete mixes. Steel slag which is mainly consists of calcium carbonate is produced as a by-product during the oxidation process in steel industry. Steel slag was selected due to its characteristics, which are almost similar to conventional aggregates and the fact that it is easily obtainable as a by-product of the steel industry. As a result, utilization of steel slag will save natural resources and clean environment. Furthermore, results have shown that slag aggregate has better abrasion factor and impact value than conventional aggregate. Thorough investigation of the results have indicated that the amount of increase in compressive strength at age of 7 days are much more than that of age 28 days for all types of aggregate replacement. This indicates that the added slag could work as accelerator at early age while at 28 days age, the effect is reduced. The fine slag replacement scores the highest effect.

Modeling and Branch-and-price Algorithm for Logistics Optimization Problem of Plant-wide Production Processes in Steel Industry

Modeling and Branch-and-price Algorithm for Logistics Optimization Problem of Plant-wide Production Processes in Steel Industry

PM2.5 Chemical Source Profiles of Emissions Resulting from Industrial and Domestic Burning Activities in India

A study has been performed to develop PM_(2.5) (particles with aerodynamic diameters≦2.5) chemically speciated source profiles of different industrial and domestic burning practices in India. A total of fifty-five PM_(2.5) samples have been collected in emissions resulting from (1) industrial furnaces, (2) household fuels, (3) municipal solid waste burning, and (4) welding workshop burning practices, and categorized for eleven subtypes of sources. The collected samples were subjected to chemical analysis for twenty-one elemental (AI, As, Ca, Cd, Co, Cr, Cu, Fe, Hg, K, Mg, Mn, Mo, Na, Ni, Pb, S, Sb, Se, V, Zn), nine ionic (Na^+, K^+, Mg^(2+), Ca^(2+), NH_4^+, CI^-, F, NO_3^(-), SO_4^(2-)), OC, and EC source indicator species using atomic absorption spectrometry , ion chromatography and carbon analysis (thermal/optical transmittance method), respectively. The carbonaceous fraction was most abundant in household fuel burning emissions (47.6±7.45% to 65.92±13.13%). The ionic/elemental ratios of major inorganic constituents (Ca^(2+)/Ca, Mg^(2+)/Mg and Na+/Na) have been identified to describe the PM_(2.5) emissions from combustion or re-suspension dusts during industrial activities. Brick Kiln processes (BKP) have been identified as the major emitter of the highest number oftoxic species (Cd, Co, Mo, Sb and V), followed by steel rerolling mills (Hg and Pb) and steel processing industries (As, Ni). The source marker calculations also confirmed that K^+, Mn, and As are good markers for biomass burning, metallurgical industrial emission, and coal burning, respectively, similar to the findings in previous studies.

品質制御や製造プロセス管理を支えるICP・MIP分析

品質制御や製造プロセス管理を支えるICP・MIP分析

Characterisation of trace metals in atmospheric particles in the vicinity of iron and steelmaking industries in Australia

The aims of this work are to provide a detailed physicochemical assessment of atmospheric particles collected in the vicinity of three iron and steelmaking plants and to indicate the importance of chemical characterisation of the particles, in addition to the assessment of the particle size and concentrations. In this study, atmospheric sampling sites were selected downstream of three iron and steel processing operations in Australia and one background site in an urban area with little industrial activity. The collected particles were analysed for a range of particle size mass concentrations and detailed chemical analysis of the trace metals Ti, V, Cr, Mn, Fe, Co, Ni, Cu and Zn in the corresponding particle size ranges was carried out. The PM2.5 fractions in the PM10 particles at all sampling sites ranged from 35 to 62% indicating fine particles made a significant contribution to this size fraction at these sampling sites. Similarly, PM1 to the total PM10 at all sites varied from 20 to 46% and contributed significantly to the PM10 mass loading. When compared to the background sampling site, all detected metals in the particles collected near the iron and steelmaking operations had 3.4–14 times higher concentrations of PM10, PM2.5 and PM1. Iron (Fe) was found to be the dominant metal in the particles collected in vicinity of the iron and steel processing industries contributing up to 12% of the total particle mass loading. This study suggests that the metal composition of PM10, PM2.5 and PM1 varies significantly between sites and the associated metal exposure value is considerably higher in the vicinity of iron and steel processing industries than in the urban area for the same particle concentration level.

Air toxics concentrations, source identification, and health risks: An air pollution hot spot in southwest Memphis, TN

Southwest Memphis is a residential region surrounded by fossil fuel burning, steel, refining, and food processing industries, and considerable mobile sources whose emissions may pose adverse health risks to local residents. This study characterizes cancer and non-cancer risks resulting from exposure to ambient air toxics in southwest Memphis. Air toxics samples were collected at a central location every 6 days from June 5, 2008 to January 8, 2010. Volatile organic compounds (VOCs) were collected in evacuated stainless-steel canisters and aldehydes by DNPH cartridges, and samples were analyzed for 73 target compounds. A total of 60 compounds were detected and 39 were found in over 86% of the samples. Mean concentrations of many compounds were higher than those measured in many industrial communities throughout the U.S. The cumulative cancer risk associated with exposure to 13 carcinogens found in southwest Memphis air was 2.3 × 10−4, four times higher than the national average of 5.0 × 10−5. Three risk drivers were identified: benzene, formaldehyde, and acrylonitrile, which contributed 43%, 19%, and 14% to the cumulative risk, respectively. This is the first field study to confirm acrylonitrile as a potential risk driver. Mobile, secondary, industrial, and background sources contributed 57%, 24%, 14%, and 5% of the risk, respectively. The results of this study indicate that southwest Memphis, a region of significant income, racial, and social disparities, is also a region under significant environmental stress compared with surrounding areas and communities.

Optimization of Primary Steelmaking Purchasing and Operation under Raw Material Uncertainty

A centralized optimization strategy is proposed to determine optimal raw material purchasing and plant operation practices as applied to primary steelmaking in the steel processing industry. Raw materials are purchased on the open market and include coal, iron ore pellets, and scrap steel. There are many raw material vendors, providing products varying in quality and price. It is desired to determine the least costly method of both purchasing and processing the raw materials to make steel of acceptable quality. A model for primary steelmaking is developed using a combination of mass balances and empirical relationships. The model, in addition to process constraints, is combined with an economic objective function and the resulting optimization problem solved using a mixed-integer nonlinear programming (MINLP) solver. Case studies illustrate the strong connection between plant sections, and the significant impact that the carbon, volatile matter, and phosphorus content of the coals and pellets have on raw ...