Metallurgical wastes landfills in Poland significantly grew during last four decades. Landfilled wastes are characterised by iron content at range 30-50% and zinc content about 2-3%. Therefore wastes are not interesting for the zinc smelter, on the other hand, even such low zinc content in ironmaking burden causes problem with a shaft furnace operation. So, the wastes are valuable for ironmaking due to the high iron content, provided that zinc will be removed from them. The article describes the general ways of dealing with zinc containing metallurgical wastes. In detail, the semi-industrial research conducted on sinter pot set of Stanislaw Staszic Institute for Ferrous Metallurgy is presented. The study determined the conditions under which obtained three benefits: landfilled sludge utilisation, raw materials substitution and zinc recovery.
The paper shows the use of novel modelling techniques adapted from ironmaking in the pyrometallurgical process of zinc production. Firstly, regarding the purpose to determine the boundary conditions of reduction processes taking part in the working volume of an Imperial Smelting Furnace (ISF), a deep thermochemical analysis was conducted. On this basis and using Ramm’s principles of direct and indirect reduction optimal share, the fuel rate minimization model was built. The model’s leading role is minimizing coke consumption in the ISF while maintaining the thermal state of the furnace at the correct level. In addition, the proposed presentation of the ISF thermal state shows in a unified way all the shortcomings in the correct process operation. Verification in real conditions on the ISF in Miasteczko Śląskie shows that model implementation can bring tangible benefits. Coke savings can reach over 30 kg per tonne of raw zinc.
Coke is the only batch component that does not soften in blast furnace thermal conditions. It is especially important at the temperatures of the cohesive zone forming because coke layers are the only gas-permeable charge. The aim of the work described in this article is the identification of individual coke layers situation in the cohesive zone. Numerical calculations of the cohesive zone situation are based on the horizontal below burden probe measures, however, coke layers are calculated using analytical geometry. The results can be presented as a bitmap; the individual and total area of the coke layers passing gases through the cohesive zone is also calculated. This form of results allows for subjective but quick assessment of the blast furnace operation by its crew.
Fuel consumption in blast furnaces depends on many factors that are mainly conditioned by the technological level of a given blast furnace, the steel mill in which it operates, and the type and quality of ferrous feed, coke, and additional reducing agents. These are global factors which a furnace crew cannot control during operation. On the other hand, using their own experience and decision-making software, a crew can run a blast furnace with minimal fuel consumption under current batch and process conditions. The paper presents a model-based algorithm for optimizing the operation of blast furnaces to achieve the lowest fuel consumption. The algorithm allows the heat demands to be continuously calculated and highlights any wastage that could be reduced without affecting the stable operation of the blast furnace.
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